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NASA NTRSDate not supplied

Advanced Environmental Barrier Coating Testing and Development for Gas Turbine Engines

Environmental barrier coatings (EBCs) are an enabling technology for the use of SiC-based ceramic matrix composites (CMCs) in next generation gas turbine engines. SiC-based CMCs are lightweight and have higher temperature stability than traditional nickel based superalloys. However, SiC is susceptible to rapid oxidation and recession due to high temperature reactions with water vapor and other combustion species. Thus, EBCs were developed to protect these components and extend operating lifetime. In the extreme engine environment, EBCs must be able to withstand a variety of damage mechanisms and the synergies of degradation between them. This presentation will provide an overview of NASA Glenn Research Center, current aeronautics research, and an introduction to EBC failure modes and environmental durability test methods.

Jamesa L Stokes↗
NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗
NASA NTRS2016

Heatshield for Extreme Entry Environment Technology (HEEET) Development Status

The Heat shield for Extreme Entry Environment Technology (HEEET) Project is a NASA STMD and SMD co-funded effort. The goal is to develop and mission infuse a new ablative Thermal Protection System that can withstand extreme entry. It is targeted to support NASAs high priority missions, as defined in the latest decadal survey, to destinations such as Venus and Saturn in-situ robotic science missions. Entry into these planetary atmospheres results in extreme heating. The entry peak heat-flux and associated pressure are estimated to be between one and two orders of magnitude higher than those experienced by Mars Science Laboratory or Lunar return missions. In the recent New Frontiers community announcement NASA has indicated that it is considering providing an increase to the PI managed mission cost (PIMMC) for investigations utilizing the Heat Shield for Extreme Entry Environment Technology (HEEET) and in addition, NASA is considering limiting the risk assessment to only their accommodation on the spacecraft and the mission environment. The HEEET ablative TPS utilizes 3D weaving technology to manufacture a dual layer material architecture. The 3-D weaving allows for flat panels to be woven. The dual layer consists of a top layer designed to withstand the extreme external environment while the inner or insulating layer by design, is designed to achieve low thermal conductivity, and it keeps the heat from conducting towards the structure underneath. Both arc jet testing combined with material properties have been used to develop thermal response models that allows for comparison of performance with heritage carbon phenolic. A 50 mass efficiency is achieved by the dual layer construct compared to carbon phenolic for a broad range of missions both to Saturn and Venus. The 3-D woven flat preforms are molded to achieve the shape as they are compliant and then resin infusion with curing forms a rigid panels. These panels are then bonded on to the aeroshell structure. Gaps exist between the panels and these gaps have to be filled with seams. The seam material then has to be bonded on to adjacent panels and also to the structure. The heat-shield assembly is shown in Figure 1. One of the significant challenges we have overcome recently is the design, development and testing of the seam. HEEET material development and the seam concept development have utilized some of the unique test capabilities available in the US. The various test facilities utilized in thermal testing along with the entry environment for Saturn and Venus missions are shown in Figure 2. The HEEET project is currently in its 3rd year of a four-year development. Figure 3 illustrates the key accomplishments to date and the challenges yet to be overcome before the technology is ready for mission infusion. This proposed presentation will cover both progress that has been made in the HEEET project and also the challenges to be overcome that is highlighted in Figure 3. Objective of the HEEET project is to mature the system in time to support the next New Frontiers opportunity and we believe we are well along the way to mission infuse HEEET.

Thermal Protection System↗
NASA NTRSDate not supplied

Recent Advances in the U.S. in Ablative TPS for In-situ Exploration of Giant Planets

The Decadal Survey report released [1] prioritizes Uranus as the highest priority Flagship class mission to be explored with an orbiter and a probe and it also recommended Saturn Probe under New Frontiers mission class. Thermal protection system (TPS) is essential for Uranus and Saturn probe missions. The two cardinal requirements are that it must be fail-safe and yet be mass efficient. The Decadal Survey report also pointed out the readiness of heatshield for extreme entry environment technology (HEEET) at TRL 6 for probe missions at Gas Giants. HEEET relies on 3-D weaving and is shown to be a robust and mass efficient TPS through ground testing and analysis. HEEET was matured to TRL 6 in 2019. HEEET was reported at the Ice Giant Workshop in 2019 at Marseille. Since 2019, significant advances have been made primarily because of Mars Sample Return (MSR) mission. MSR baselined 3-D Woven TPS as its heatshield for the earth entry system. MSR earth entry system (EES) requirements and the resulting heatshield/TPS requirements are most stringent of all entry missions. This is a result of backward contamination protection which classifies MSR as a “restricted class 5” mission to safeguard the accidental release of potentially hazardous Mars Sample into Earth’s atmosphere. Complex requirements for the heatshield start with micro-meteor impact tolerance followed by the requirement for steep entry to minimize the size of the impact footprint which results in extreme heating. The heatshield is part of the impact attenuation system. The EES architecture does not use a parachute and is designed to tolerate impact loads. Hence heatshield TPS selection and design becomes one of the key challenges. After completion of the HEEET technology maturation in 2019, IRAD efforts focused on assessing the 3-D Woven family of TPS to MSR EES. After nearly two years of evaluation of alternate TPS such as carbon phenolic, C-C hot structure, PICA, and 3-D woven family of TPS, a single layer 3-D woven TPS derived from the dual-layer HEEET was down selected and is currently the baseline. A new loom capable of weaving the single-layer 3-D woven preform at 80” wide has been designed, assembled and is currently on the verge of weaving the MSR EES TPS. During the HEEET maturation and the follow-on development, the single-layer TPS has been tested at extreme heating conditions. As a result, single layer TPS was recommended and evaluated during the Planetary Mission Concept Studies funded by NASA in preparation for the Decadal committee. In addition, in anticipation of Saturn mission proposals, single layer was evaluated as well. Aerocapture can reduce the trip time, also allow bigger payload fraction and in addition, it allows for the possibility of probe delivery once the spacecraft is in orbit. This can lead to obtaining both in-situ data as well as data from orbit simultaneously. Since Aerocapture depletes energy/velocity, probe delivery from orbit reduces the demand on TPS. Aerocapture was mentioned in the Decadal Study report as ready for implementation, but due to perceived risk it is not adopted by the mission designers. Establishing TPS readiness for aerocapture missions will be addressed. Going one step beyond aerocapture is aerogravity assist if fast return is the goal. Recent studies [4] looked at aerogravity assist and the TPS readiness. This talk will highlight both aerocapture and aerogravity assist from a TPS perspective. The main objective of this proposed talk is to present a comprehensive picture of the SOA TPS technology including recent developments. The talk will highlight advances in manufacturing, results from the Decadal White Papers, PMCS and other studies, and aerocapture and aerogravity assist that could play a role in the near or far term in-situ exploration.

E. Venkatapathy↗
NASA NTRS2018

Channel Wall Nozzle Manufacturing and Hot-Fire Testing using a Laser Wire Deposition Closeout Technique for Liquid Rocket Engines

A regeneratively-cooled nozzle for liquid rocket engine applications is a significant cost of the overall engine due to the complexities of manufacturing a large thin-walled structure that must operate in extreme temperature and pressure environments. NASA has been investigating and advancing methods for fabrication of liquid rocket engine channel wall nozzles to realize further cost and schedule improvements. The methods being evaluated are targeting increased scale required for current NASA and commercial space programs. Several advanced rapid fabrication methods are being investigated for forming of the inner liner, producing the coolant channels, closeout of the coolant channels, and fabrication of the manifolds. NASA Marshall Space Flight Center (MSFC) completed process development and subscale hot-fire testing of a series of these advanced fabrication channel wall nozzle technologies to gather performance data in a relevant environment. The primary fabrication technique being discussed in this paper is Laser Wire Deposition Closeout (LWDC). This process has been developed to significantly reduce time required for closeouts of regeneratively-cooled slotted liners. It allows for channel closeout to be formed in place in addition to the structural jacket without the need for channel fillers or complex tooling. Additional technologies were also tested as part of this program including water jet milling and arc-based additive manufacturing deposition. Each nozzle included different fabrication features, materials, and methods to demonstrate durability in a hot-fire environment. The results of design, fabrication and hot-fire testing performance is discussed in this paper.

Gradl, Paul R.↗
NASA NTRS1983

Experimental modal analysis

Experimental modal analysis is extremely important with regard to verification of analytical models, identification of vibration and acoustic problems, and structural modification and sensitivity analysis. With the expanding access of the testing environment to computational power, the complexity of existing approaches, as well as the development of new approaches, to the estimation of modal parameters has grown tremendously. Currently, the state of the art in experimental modal analysis involves methods that can be grouped in four categories: forced normal mode excitation method, frequency response function method, damped complex exponential function method, and mathematical input-output model methods. The theoretical basis of each of these general approaches, with appropriate references, is reviewed briefly.

Allemang, R. J.↗
NASA NTRS2022

Single-Event Effect Testing of the PNI RM3100 Magnetometer for Space Applications

The results of a destructive single-event effect susceptibility radiation test of the PNI RM3100 magnetometer sensor, specifically the MagI 2 C ASIC (application-specific integrated circuit) on the sensor board are presented. The sensor is a low-resource commercial off-the-shelf (COTS) magneto-inductive magnetometer. The device was monitored for destructive events and functional interruptions during exposure to a heavy ion beam at the Lawrence Berkeley National Laboratory's 88′′ Cyclotron. The RM3100 did not experience any destructive single-event effects when irradiated to a total fluence of 1.4 × 10 7 cm −2 at an effective linear energy transfer (LET) of 76.7 MeV cm 2 mg −1 while operated at nominal voltage (3.3 V) and elevated temperature (85 ∘C). When these results are combined with previous total ionizing dose tests showing no failures up to 150 kRad (Si), we conclude that the PNI RM3100 is extremely radiation tolerant and can be used in a variety of space environments.

Mark B. Moldwin↗
NASA NTRS2001

Laser High-Cycle Thermal Fatigue of Pulse Detonation Engine Combustor Materials Tested

Pulse detonation engines (PDE's) have received increasing attention for future aerospace propulsion applications. Because the PDE is designed for a high-frequency, intermittent detonation combustion process, extremely high gas temperatures and pressures can be realized under the nearly constant-volume combustion environment. The PDE's can potentially achieve higher thermodynamic cycle efficiency and thrust density in comparison to traditional constant-pressure combustion gas turbine engines (ref. 1). However, the development of these engines requires robust design of the engine components that must endure harsh detonation environments. In particular, the detonation combustor chamber, which is designed to sustain and confine the detonation combustion process, will experience high pressure and temperature pulses with very short durations (refs. 2 and 3). Therefore, it is of great importance to evaluate PDE combustor materials and components under simulated engine temperatures and stress conditions in the laboratory. In this study, a high-cycle thermal fatigue test rig was established at the NASA Glenn Research Center using a 1.5-kW CO2 laser. The high-power laser, operating in the pulsed mode, can be controlled at various pulse energy levels and waveform distributions. The enhanced laser pulses can be used to mimic the time-dependent temperature and pressure waves encountered in a pulsed detonation engine. Under the enhanced laser pulse condition, a maximum 7.5-kW peak power with a duration of approximately 0.1 to 0.2 msec (a spike) can be achieved, followed by a plateau region that has about one-fifth of the maximum power level with several milliseconds duration. The laser thermal fatigue rig has also been developed to adopt flat and rotating tubular specimen configurations for the simulated engine tests. More sophisticated laser optic systems can be used to simulate the spatial distributions of the temperature and shock waves in the engine. Pulse laser high-cycle thermal fatigue behavior has been investigated on a flat Haynes 188 alloy specimen, under the test condition of 30-Hz cycle frequency (33-msec pulse period and 10-msec pulse width including a 0.2-msec pulse spike; ref. 4). Temperature distributions were calculated with one-dimensional finite difference models. The calculations show that that the 0.2-msec pulse spike can cause an additional 40 C temperature fluctuation with an interaction depth of 0.08 mm near the specimen surface region. This temperature swing will be superimposed onto the temperature swing of 80 C that is induced by the 10-msec laser pulse near the 0.53-mm-deep surface interaction region.

Zhu, Dong-Ming↗
NASA NTRS2005

Re-Configurable Electronics Characterization under Extreme Thermal Environment

The need for reconfigurable electronics is driven by requirements to survive longer missions and harsher environments. It is possible to compensate for degradations in Extreme Environments (EE). EE has effect on electronics: circuits are designed to exploit device characteristics and when a certain temperature or radiation range is exceeded the circuit function gradually degrades. It is possible to employ Hardening by reconfiguration (HBR) to mitigate drifts, degradation, or damage on electronic devices in EE by using reconfigurable devices and an adaptive self-reconfiguration of circuit topology. In this manner degraded components can be salvaged, and completely damaged components can be bypassed. The challenge of conventional design is replaced with that of designing a recover process that automatically performs the (re) design in place of the designer. The objective of testing a Digital Signal Processor (DSP) under the extreme temperatures was to determine the lowest temperature at which the DAP can operate. The objective of testing a Xilinx VirtexII Pro FPGA board was to initially find our whether the evaluation board and the FPGA would survive and continue at temperature ranges from -180 C, and 120 C. The Virtex II functioned correctly at the temperatures tested. The next test was done on the GM-C filter building block using the same temperature range as the Virtex II. The current lower and upper limits were shown to be reduced as the temperature gets lower. The device function can be recovered by increasing the Vb from .08V to .85V. The negative and positive saturation voltages increases as the temperature gets higher. The function of the device can be recovered by decreasing the Vb from .8V to around .75V. The next test was performed to test the recovery of the GmC low pass filter through Vb in a filter circuit. The test indicate that bias voltage control adjustment is an efficient mechanism for circuit recovery at extreme temperatures.

reliability↗
NASA NTRS2018

Channel Wall Nozzle Manufacturing and Hot-Fire Testing Using a Laser Wire Direct Closeout Technique for Liquid Rocket Engines

A regeneratively-cooled nozzle for liquid rocket engine applications is a significant cost of the overall engine due to the complexities of manufacturing a large thin-walled structure that must operate in extreme temperature and pressure environments. The National Aeronautics and Space Administration (NASA) has been investigating and advancing methods for fabrication of liquid rocket engine channel wall nozzles to realize further cost and schedule improvements over traditional techniques. The methods being evaluated are targeting increased scale required for current NASA and commercial space programs. Several advanced rapid fabrication methods are being investigated for forming of the inner liner, producing the coolant channels, closeout of the coolant channels, and fabrication of the manifolds. NASA's Marshall Space Flight Center (MSFC) has completed process development and subscale hot-fire testing of a series of these advanced fabrication channel wall nozzle technologies to gather performance data in a relevant environment. The primary fabrication technique being discussed in this paper is Laser Wire Direct Closeout (LWDC). This process has been developed to significantly reduce the time required for closeouts of regeneratively-cooled slotted liners. It allows for channel closeout to be formed in place in addition to the structural jacket without the need for channel fillers or complex tooling. Additional technologies were also tested as part of this program including water jet milling and arc-based additive manufacturing deposition. Each nozzle included different fabrication features, materials, and methods to demonstrate durability in a hot-fire environment. The results of design, fabrication, and hot-fire testing are discussed in this paper.

Gradl, Paul R.↗
NASA NTRS2008

Predicting Material Performance in the Space Environment from Laboratory Test Data, Static Design Environments, and Space Weather Models

Qualifying materials for use in the space environment is typically accomplished with laboratory exposures to simulated UV/EUV, atomic oxygen, and charged particle radiation environments with in-situ or subsequent measurements of material properties of interest to the particular application. Choice of environment exposure levels are derived from static design environments intended to represent either mean or extreme conditions that are anticipated to be encountered during a mission. The real space environment however is quite variable. Predictions of the on orbit performance of a material qualified to laboratory environments can be done using information on 'space weather' variations in the real environment. This presentation will first review the variability of space environments of concern for material degradation and then demonstrate techniques for using test data to predict material performance in a variety of space environments from low Earth orbit to interplanetary space using historical measurements and space weather models.

Minow, Josep I.↗
NASA NTRS1992

Demonstrated survivability of a high temperature optical fiber cable on a 1500 pound thrust rocket chamber

A demonstration of the ability of an existing optical fiber cable to survive the harsh environment of a rocket engine was performed at the NASA Lewis Research Center. The intent of this demonstration was to prove the feasibility of applying fiber optic technology to rocket engine instrumentation systems. Extreme thermal transient tests were achieved by wrapping a high temperature optical fiber, which was cablized for mechanical robustness, around the combustion chamber outside wall of a 1500 lb Hydrogen-Oxygen rocket engine. Additionally, the fiber was wrapped around coolant inlet pipes which were subject to near liquid hydrogen temperatures. Light from an LED was sent through the multimode fiber, and output power was monitored as a function of time while the engine was fired. The fiber showed no mechanical damage after 419 firings during which it was subject to transients from 30 K to 350 K, and total exposure time to near liquid hydrogen temperatures in excess of 990 seconds. These extreme temperatures did cause attenuation greater than 3 dB, but the signal was fully recovered at room temperature. This experiment demonstrates that commercially available optical fiber cables can survive the environment seen by a typical rocket engine instrumentation system, and disclose a temperature-dependent attenuation observed during exposure to near liquid hydrogen temperatures.

Sovie, Amy L.↗
NASA NTRS1989

Ventilation loss and pressurization in the NASA launch/entry suit: Potential for heat stress

The potential of the NASA Launch/Entry Suit (LES) for producing heat stress in a simulated Space Shuttle cabin environment was studied. The testing was designed to identify potential heat stress hazards if the LES were pressurized or if ventilation were lost. Conditions were designed to simulate an extreme pre-launch situation with chamber temperatures maintained at dry bulb temperature = 27.2 +/- 0.1 C, globe temperature = 27.3 +/- 0.1 C, and wet bulb temperature = 21.1 +/- 0.3 C. Two females and two males, 23 to 34 years of age, were employed in this study, with two subjects having exposures in all 3 conditions. Test durations in the ventilated (V) and unventilated (UV) conditions were designed for 480 minutes, which all subjects achieved. Pressurized runs (Pr) were designed for 45 minutes, which all subjects also achieved. While some significant differences related to experimental conditions were noted in rectal and mean skin temperatures, evaporation rates, sweat rates, and heart rate, these differences were not thought to be physiologically significant. The results indicate that the LES garment, in either the Pr or UV state, poses no danger of inducing unacceptable heat stress under the conditions expected within the Space Shuttle cabin during launch or reentry.

Kaufman, Jonathan W.↗
NASA NTRS1999

On the Use of Accelerated Aging Methods for Screening High Temperature Polymeric Composite Materials

A rational approach to the problem of accelerated testing of high temperature polymeric composites is discussed. The methods provided are considered tools useful in the screening of new materials systems for long-term application to extreme environments that include elevated temperature, moisture, oxygen, and mechanical load. The need for reproducible mechanisms, indicator properties, and real-time data are outlined as well as the methodologies for specific aging mechanisms.

Gates, Thomas S.↗
NASA NTRS2016

High Temperature Boost (HTB) Anode Power Supply for a Modular and Scalable Power Processing Unit

A concept of a modular and scalable 10kW to 80kW High Temperature Boost (HTB) Power Processing Unit (PPU) capable of operating at temperatures beyond the standard military temperature range was proposed for solar electric in-space propulsion. Within the PPU, the Anode Power Supply (APS) module is a 10kW modular power stage and is the key to the HTB PPU. This paper is to present the design, development, fabrication, testing and thermal demonstration of the 10kW HTB APS. The system architecture and the paradigm shift of the HTB PPU is also to be described. In addition, the extreme environments electronic and packaging technologies are addressed as the fundamental technology path. The HTB PPU is intended for power processing in the area of space solar electric propulsion, where reduction of in-space mass and volume are desired, and sometimes even critical, to achieve the goals of future space flight missions. The concept of the HTB PPU can also be applied to other extreme environment applications, such as geothermal and petroleum deep-well drilling, where higher temperature operation is required.

Carr, Gregory A.↗
NASA NTRS2021

Matrix Microcracking Effect on the Structural Response of a Thermal Protection System

The effect of microcracking in the phenolic matrix of a three-dimensional woven thermal protection system (TPS) and resulting material stiffness reduction was studied via a comparison of finite element results from linear and iterative linear analyses. A dual-layer continuous dry weave material with a low-density phenolic resin matrix has been developed for use in extreme environments. Due to high stresses in the through-the-thickness direction, microcracks may form in the matrix. The matrix does not have structural load transfer requirements, and testing has shown that microcracked phenolic resin satisfies thermal requirements. Microcracks in the matrix would result in a reduction of stiffness, which could alter the structural performance. A study was conducted to determine if reduction in material stiffness would change the load paths or structural margins. A linear finite element analysis that did not account for microcracking and an iterative linear finite element analysis that accounted for propagation microcracks were compared. Four subcases were analyzed with results indicating that the assumed propagation strength for the microcracking is the critical parameter for determining the extent of microcracking. Phenolic microcracking does not appear to have an adverse effect on the structural response and is not a critical failure for the modeled TPS.

Thermal Protection System↗
NASA NTRSDate not supplied

Artemis Lunar Surface VR/ARGOS Trainer

This proposal aims to provide insight by identifying potential risks and unknowns of lander egress and surface operations through a Mixed Reality (MR) planning, training, and analysis capability that integrates Virtual Reality (VR) simulations and the Active Response Gravity Offload System (ARGOS) in support of Artemis missions to the moon. The VR simulation will incorporate lunar digital elevation map data and imagery to provide accurate terrain of the south pole and Shackleton Crater. Date specific ephemerides will used to simulate the extreme lighting environment. Virtual representations of a lunar lander vehicle will be represented with a physical mockup of the porch and ladder assembly. Human-in-the-loop engineering test runs within ARGOS will be used to refine performance of the Mixed Reality interface with the mockup platform and define procedures for training.

Lee K Bingham↗
NASA NTRSDate not supplied

Macro-scale Testing and Micromechanics Modeling of Fracture Behaviors for Boron Carbide Composites with Hierarchical Microstructures

With a unique combination of properties including high hardness, low density, wear and corrosion resistance, thermal stability, high neutron absorption, and semi-conductivity, boron carbide (B4C) is a candidate material for various engineering applications that involve extreme environment. The current applications of boron carbide, however, are limited by its intrinsic brittleness due to its strong covalent bonding. To toughen boron carbide, in this work hierarchical microstructure designs was used to provide multiple toughening mechanisms including crack deflection/bridging, micro-crack toughening, etc. Using field assisted sintering, B4C composites with hierarchical microstructure features including graphite platelets, micron and sub-micron sized TiB2 reinforcements were fabricated. The fracture toughness of fabricated B4C composites were previously measured at micro-scale using micro-indentation followed by post-testing microstructure inspection. However, questions including whether the fracture toughness enhancement measured at micro-scale can translate to macro-scale mechanical properties, and what are the fundamental mechanisms behind observed fracture toughness enhancement, remain to be answered. In this study, the fabricated B4C composites were tested using standardized four-point bending method to obtain fracture toughness at macro-scale. In addition, micromechanics modeling was conducted using MAC/GMC code and crack-band model to study the effect of residual stress and weak interphases on fracture behaviors of B4C composites reinforced with TiB2 particles. Through standardized four-point bending tests, fracture toughness enhancements up to 2.85, 3.32, and 3.65 MPa∙m(exp 1/2) (from 2.38 MPa∙m(exp 1/2)) were achieved for B4C composites with graphite platelets addition (micro/nano B4C), with TiB2 formation (micro B4C-TiB2), and with both graphite and TiB2 addition (micro/nano B4C-TiB2) respectively. Micromechanics modeling indicated that introduction of thermal residual stress and weak interphases caused enhanced micro-cracking behavior and resulted in the observed fracture toughness enhancement. These results furthered understanding about the mechanical behaviors at macro-scale and the mechanisms behind observed fracture toughness enhancement for B4C composites with hierarchical microstructures and can provide reference data for the future design of B4C composites with optimized microstructures for further fracture toughness enhancement.

Boron Carbide↗