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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

A generic model for creep rupture lifetime estimation on fibrous ceramic composites

Because of their high strength and toughness at elevated temperatures, fiber reinforced ceramic composites such as SiC(f)/SiC and SiC(f)/Si3N4 have become candidates for next-generation turbine engine materials. A generic model is proposed for assessing the lifetime of this class of materials when subjected to long-term creep rupture conditions. This 2D model consists of interfacial cracks growing between square grains and rectangular fibers in the direction normal to the principal tensile stress axis. Neglecting transient effects, the total lifetime is derived based on the criterion that rupture is due to coalescence of adjacent cracks. Lifetime is inversely proportional to crack growth rate, volume fraction, and aspect ratio of the fibers; but extremely sensitive to the applied stress, due to the high power of the V-K(I) law. This lifetime estimation seems to be in fair agreement with the creep rupture data of SiC(w)/Si3N4 composite with 0 and 30 vol percent reinforcement tested at 1250 C in air. TEM performed on the postcrept specimens revealed that creep damage is predominantly in the form of microcracks at matrix/matrix as well as fiber/matrix interfaces, approximately in accord with the model simulation.

Chuang, Tze-Jer↗
NASA NTRS1992

Ceramic matrix composite applications in advanced liquid fuel rocket engine turbomachinery

Fiber-reinforced ceramic matrix composites have been identified with properties suitable for near term applications. Conceptual design studies indicate the feasibility of applying C/SiC, and subelements were manufactured that verify selected fabrication features and key material properties. Tests and inspection of these subelements confirmed their capabilities.

Brockmeyer, Jerry W.↗
NASA NTRS2001

Effect of Load Rate on Ultimate Tensile Strength of Ceramic Matrix Composites at Elevated Temperatures

The strengths of three continuous fiber-reinforced ceramic composites, including SiC/CAS-II, SiC/MAS-5 and SiC/SiC, were determined as a function of test rate in air at 1100 to 1200 C. All three composite materials exhibited a strong dependency of strength on test rate, similar to the behavior observed in many advanced monolithic ceramics at elevated temperatures. The application of the preloading technique as well as the prediction of life from one loading configuration (constant stress-rate) to another (constant stress loading) suggested that the overall macroscopic failure mechanism of the composites would be the one governed by a power-law type of damage evolution/accumulation, analogous to slow crack growth commonly observed in advanced monolithic ceramics. It was further found that constant stress-rate testing could be used as an alternative to life prediction test methodology even for composite materials, at least for short range of lifetimes and when ultimate strength is used as the failure criterion.

Choi, Sung R.↗
NASA NTRS2010

Economical Fabrication of Thick-Section Ceramic Matrix Composites

A method was developed for producing thick-section [>2 in. (approx.5 cm)], continuous fiber-reinforced ceramic matrix composites (CMCs). Ultramet-modified fiber interface coating and melt infiltration processing, developed previously for thin-section components, were used for the fabrication of CMCs that were an order of magnitude greater in thickness [up to 2.5 in. (approx.6.4 cm)]. Melt processing first involves infiltration of a fiber preform with the desired interface coating, and then with carbon to partially densify the preform. A molten refractory metal is then infiltrated and reacts with the excess carbon to form the carbide matrix without damaging the fiber reinforcement. Infiltration occurs from the inside out as the molten metal fills virtually all the available void space. Densification to <5 vol% porosity is a one-step process requiring no intermediate machining steps. The melt infiltration method requires no external pressure. This prevents over-infiltration of the outer surface plies, which can lead to excessive residual porosity in the center of the part. However, processing of thick-section components required modification of the conventional process conditions, and the means by which the large amount of molten metal is introduced into the fiber preform. Modification of the low-temperature, ultraviolet-enhanced chemical vapor deposition process used to apply interface coatings to the fiber preform was also required to accommodate the high preform thickness. The thick-section CMC processing developed in this work proved to be invaluable for component development, fabrication, and testing in two complementary efforts. In a project for the Army, involving SiC/SiC blisk development, nominally 0.8 in. thick x 8 in. diameter (approx. 2 cm thick x 20 cm diameter) components were successfully infiltrated. Blisk hubs were machined using diamond-embedded cutting tools and successfully spin-tested. Good ply uniformity and extremely low residual porosity (<2 percent) were achieved, the latter being far lower than that achieved with SiC matrix composites fabricated via CVI or PIP. The pyrolytic carbon/zirconium nitride interface coating optimized in this work for use on carbon fibers was incorporated in the SiC/SiC composites and yielded a >41 ksi (approx. 283 MPa) flexural strength.

Babcock, Jason↗
NASA NTRS1992

Glasses, ceramics, and composites from lunar materials

A variety of useful silicate materials can be synthesized from lunar rocks and soils. The simplest to manufacture are glasses and glass-ceramics. Glass fibers can be drawn from a variety of basaltic glasses. Glass articles formed from titania-rich basalts are capable of fine-grained internal crystallization, with resulting strength and abrasion resistance allowing their wide application in construction. Specialty glass-ceramics and fiber-reinforced composites would rely on chemical separation of magnesium silicates and aluminosilicates as well as oxides titania and alumina. Polycrystalline enstatite with induced lamellar twinning has high fracture toughness, while cordierite glass-ceramics combine excellent thermal shock resistance with high flexural strengths. If sapphire or rutile whiskers can be made, composites of even better mechanical properties are envisioned.

Beall, George H.↗
NASA NTRS1985

Fibers for structurally reliable metal and ceramic composites

In their current state of development, commercially available reinforcing fibers fail to meet the requirements formulated for metal or ceramic matrix composites of sufficient strength and toughness. Attention is presently given to criteria for high strength and toughness in metal and ceramic matrix composites, as well as the approach adopted in fiber evaluation as a result of studies at the NASA Lewis Research Center. Two areas of special interest have been strength improvement in large diameter boron fibers for tough, impact-resistant boron/aluminum composites, and the evaluation of SiC fibers as reinforcement in tough ceramic-matrix composites with service temperatures of the order of 1400 C.

Dicarlo, J. A.↗
NASA NTRS1990

Ceramic Matrix Composites (CMC) Life Prediction Development

Advanced launch systems will very likely incorporate fiber reinforced ceramic matrix composites (CMC) in critical propulsion and airframe components. The use of CMC will save weight, increase operating margin, safety and performance, and improve reuse capability. For reusable and single mission use, accurate life prediction is critical to success. The tools to accomplish this are immature and not oriented toward the behavior of carbon fiber reinforced silicon carbide (C/SiC), the primary system of interest for many applications. This paper describes an approach and progress made to satisfy the need to develop an integrated life prediction system that addresses mechanical durability and environmental degradation.

Levine, Stanley R.↗
NASA NTRS1993

Push-out tests on a new silicon carbide/reaction-bonded silicon carbide ceramic matrix composite

Fiber push-out tests have been performed on a ceramic matrix composite consisting of carborundum-sintered SiC fibers, with a BN coating, embedded in a reaction-bonded SiC matrix. Analysis of the push-out data, utilizing the most complete theory presently available, shows that one of the fiber/coating/matrix interfaces has a low fracture energy (one-tenth that of the fiber) and a moderate sliding resistance of about 8 MPa. The debonded sliding interface shows some continuous but minor abrasion, which appears to increase the sliding resistance, but overall the system exhibits very clean smooth sliding. The tensile response of a full-scale composite is then modeled using data obtained here and known fiber strengths to demonstrate the good composite behavior predicted for this material.

Curtin, William A.↗
NASA NTRS2002

Ultimate Tensile Strength as a Function of Test Rate for Various Ceramic Matrix Composites at Elevated Temperatures

Ultimate tensile strength of five different continuous fiber-reinforced ceramic composites, including SiC/BSAS (2D 2 types), SiC/MAS-5 (2D), SiC/SiC (2D enhanced), and C/SiC(2D) was determined as a function of test rate at I 100 to 1200 'C in air. All five composite materials exhibited a significant dependency of ultimate strength on test rate such that the ultimate strength decreased with decreasing test rate, similar to the behavior observed in many advanced monolithic ceramics at elevated temperatures. The application of the preloading technique as well as the prediction of life from one loading configuration (constant stress rate) to another (constant stress loading) for SiC/BSAS suggested that the overall macroscopic failure mechanism of the composites would be the one governed by a power-law type of damage evolution/accumulation, analogous to slow crack growth commonly observed in advanced monolithic ceramics.

Choi, Sung R.↗
NASA NTRS1992

Ceramic matrix composites for rocket engine turbine applications

A program to establish the potential for introducing fiber reinforced ceramic matrix composites (FRCMC) in future rocket engine turbopumps was instituted in 1987. A brief summary of the overall program (both contract and in-house research) is presented. Tests at NASA Lewis include thermal upshocks in a hydrogen/oxygen test rig capable of generating heating rates up to 2500 C/sec. Post thermal upshock exposure evaluation includes the measurement of residual strength and failure analysis. Test results for monolithic ceramics and several FRCMC are presented. Hydrogen compatibility was assessed by isothermal exposure of monolithic ceramics in high temperature gaseous hydrogen plus water vapor.

Herbell, Thomas P.↗
NASA NTRS1984

High performance fibers for structurally reliable metal and ceramic composites

Very few of the commercially available high performance fibers with low densities, high Young's moduli, and high tensile strengths possess all the necessary property requirements for providing either metal matrix composites (MMC) or ceramic matrix composites (CMC) with high structural reliability. These requirements are discussed in general and examples are presented of how these property guidelines are influencing fiber evaluation and improvement studies at NASA aimed at developing structurally reliable MMC and CMC for advanced gas turbine engines.

Dicarlo, J. A.↗
NASA NTRS1990

Friction And Wear Of Silicon Ceramics

Report presents results of experimental study of friction and wear in unlubricated sliding of silicon-based ceramics on Inconel(R) 718 nickel-based alloy. Both monolithic and fiber-reinforced ceramics tested at temperatures from 25 to 800 degrees C. Evaluates ceramic materials for potential use as cylinder liners, piston caps, and other engine parts subjected to sliding or rubbing.

Deadmore, Daniel L.↗
NASA NTRS1986

Impact-Resistant Ceramic Coating

Refractory fibers more than double strength of coating. Impact strengths of ceramic coatings increase with increasing whisker content. Silicon carbide whiskers clearly produce largest increase, and improvement grows even more with high-temperature sintering. Coating also improves thermal and mechanical properties of electromagnetic components, mirrors, furnace linings, and ceramic parts of advanced internal-combustion engines.

Wheeler, W. H.↗
NASA NTRS1987

Materials for engine applications above 3000 deg F: An overview

Materials for future generations of aeropropulsion systems will be required to perform at ever-increasing temperatures and have properties superior to the current state of the art. Improved engine efficiency can reduce specific fuel consumption and thus increase range and reduce operating costs. The ultimate payoff gain is expected to come when materials are developed which can perform without cooling at gas temperatures to 2200 C (4000 F). An overview is presented of materials for applications above 1650 C (3000 F), some pertinent physical property data, and the rationale used: (1) to arrive at recommendations of material systems that qualify for further investigation, and (2) to develop a proposed plan of research. From an analysis of available thermochemical data it was included that such materials systems must be composed of oxide ceramics. The required structural integrity will be achieved by developing these materials into fiber-reinforced ceramic composites.

Shaw, Nancy J.↗
NASA NTRS1986

Ceramic matrix composites

An overview is presented covering NASA Lewis research efforts aimed at materials and processing development for structurally reliable fiber-reinforced ceramic matrix composites (FRC). With the primary goal of developing technology for strong, tough Si-based FRC with use-temperatures above 1400 C, guidelines for optimum material properties and current problems in achieving these properties are discussed. Brief descriptions of particular research projects directed toward solving these problems are presented. Particular emphasis is placed on those efforts addressing the critical need of developing high performance SiC fibers with stability above 1400 C and with proper coatings for optimum composite structural performance. Based on current results for fiber and matrix development, concluding remarks are made concerning future directions of FRC studies.

Dicarlo, James A.↗
NASA NTRS1966

Fibers of newly developed refractory ceramics produced by improved process

Rods of refractory ceramic material and glasses having relatively high fusion temperatures and tensile strengths are converted to fiber by subjecting these rods to alternate fusion and gas-jet bursts. The refractory, high tensile strength fibers produced are combined with suitable binder to produce heat-resistant fabrics and rigid structures.

Source record↗
NASA NTRS1990

Influence of interfacial shear strength on the mechanical properties of SiC fiber reinforced reaction-bonded silicon nitride matrix composites

The influence of fiber/matrix interface microstructure and interfacial shear strength on the mechanical properties of a fiber-reinforced ceramic composite was evaluated. The composite consisted of approximately 30 vol percent uniaxially aligned 142 microns diameter SiC fibers (Textron SCS-6) in a reaction-bonded Si3N4 matrix (SiC/RBSN). The interface microstructure was varied by controlling the composite fabrication conditions and by heat treating the composite in an oxidizing environment. Interfacial shear strength was determined by the matrix crack spacing method. The results of microstructural examination indicate that the carbon-rich coating provided with the as-produced SiC fibers was stable in composites fabricated at 1200 C in a nitrogen or in a nitrogen plus 4 percent hydrogen mixture for 40 hr. However this coating degraded in composites fabricated at 1350 C in N2 + 4 percent H2 for 40 and 72 hr and also in composites heat treated in an oxidizing environment at 600 C for 100 hr after fabrication at 1200 C in a nitrogen. It was determined that degradation occurred by carbon removal which in turn had a strong influence on interfacial shear strength and other mechanical properties. Specifically, as the carbon coating was removed, the composite interfacial shear strength, primary elastic modulus, first matrix cracking stress, and ultimate tensile strength decreased, but the first matrix cracking strain remained nearly the same.

Bhatt, Ramakrishna T.↗
NASA NTRS2002

Effect of Environment on Stress-Rupture Behavior of a Carbon Fiber-Reinforced Silicon Carbide (C/SiC) Ceramic Matrix Composite

Stress-rupture tests were conducted in air, vacuum, and steam-containing environments to identify the failure modes and degradation mechanisms of a carbon fiber-reinforced silicon carbide (C/SiC) composite at two temperatures, 600 and 1200 C. Stress-rupture lives in air and steam containing environments (50 - 80% steam with argon) are similar for a composite stress of 69 MPa at 1200 C. Lives of specimens tested in a 20% steam/argon environment were about twice as long. For tests conducted at 600 C, composite life in 20% steam/argon was 20 times longer than life in air. Thermogravimetric analysis of the carbon fibers was conducted under similar conditions to the stress-rupture tests. The oxidation rate of the fibers in the various environments correlated with the composite stress-rupture lives. Examination of the failed specimens indicated that oxidation of the carbon fibers was the primary damage mode for specimens tested in air and steam environments at both temperatures.

Verrilli, Michael J.↗