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At least 325 records · Page 18

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NASA NTRS1988

Fiber reinforced superalloys for rocket engines

High-pressure turbopumps for advanced reusable liquid-propellant rocket engines such as that for the Space Shuttle Main Engine (SSME) require turbine blade materials that operate under extreme conditions of temperature, hydrogen environment, high-cycle fatigue loading, thermal fatigue and thermal shock. Such requirements tax the capabilities of current blade materials. Based on projections of properties for tungsten fiber reinforced superalloy (FRS) composites, it was concluded that FRS turbine blades offer the potential of a several-fold increase in life and over a 200C increase in temperature capability over current SSME blade material. FRS composites were evaluated with respect to mechanical property requirements for SSME blade applications. Compared to the current blade material, the thermal shock resistance of FRS materials is excellent, two to nine times better, and their thermal fatigue resistance is equal to or higher than the current blade material. FRS materials had excellent low and high-cycle fatigue strengths, and thermal shock-induced surface microcracks had no influence on their fatigue strength. The material also exhibited negligible embrittlement when exposed to a hydrogen environment.

Petrasek, Donald W.↗

NASA NTRS1989

The effects of simulated space environmental parameters on six commercially available composite materials

The effects of simulated space environmental parameters on microdamage induced by the environment in a series of commercially available graphite-fiber-reinforced composite materials were determined. Composites with both thermoset and thermoplastic resin systems were studied. Low-Earth-Orbit (LEO) exposures were simulated by thermal cycling; geosynchronous-orbit (GEO) exposures were simulated by electron irradiation plus thermal cycling. The thermal cycling temperature range was -250 F to either 200 F or 150 F. The upper limits of the thermal cycles were different to ensure that an individual composite material was not cycled above its glass transition temperature. Material response was characterized through assessment of the induced microcracking and its influence on mechanical property changes at both room temperature and -250 F. Microdamage was induced in both thermoset and thermoplastic advanced composite materials exposed to the simulated LEO environment. However, a 350 F cure single-phase toughened epoxy composite was not damaged during exposure to the LEO environment. The simuated GEO environment produced microdamage in all materials tested.

Funk, Joan G.↗

NASA NTRS1989

Fiber reinforced superalloys for rocket engines

High pressure turbopumps for advanced reusable liquid propellant rocket engines such as that for the Space Shuttle Main Engine (SSME) require turbine blade materials that operate under extreme conditions of temperature, hydrogen environment, high-cycle fatigue loading, thermal fatigue and thermal shock. Such requirements tax the capabilities of current blade materials. Based on projections of properties for tungsten fiber reinforced superalloy (FRS) composites, it was concluded that FRS turbine blades offer the potential of a several fold increase in life and over a 200 C increase in temperature capability over the current SSME blade material. FRS composites were evaluated with respect to mechanical property requirements for SSME blade applications. Compared to the current blade material, the thermal shock resistance of FRS materials is excellent, two to nine times better, and their thermal fatigue resistance is equal to or higher than the current blade material. FRS materials had excellent low and high-cycle fatigue strengths, and thermal shock-induced surface microcracks had no influence on their fatigue strength. The material also exhibited negligible embrittlement when exposed to a hydrogen environment.

Petrasek, Donald W.↗

NASA NTRS1988

Growth and characterization of large YBa2Cu3O(7-x) single crystals

Centimeter-sized crystal plates of YBa2Cu3O(7-x) have been obtained using a bulk composition and method described by Schneemeyer at al. (1987) modified for growth in a pure oxygen atmosphere. A porous MgO crucible and long soak time promote large crystals. Mg was not detectable in the crystals. Electron microbeam analysis using a 60 A monochromator crystal for the oxygen determination gave the composition Y(1.05)Ba(2.02)Cu(2.94)O(6.52 + or - 0.06). As-grown crystals from the melt surface exhibit a fairly sharp Tc with zero resistance at 80 K, and show complex twinning and crack patterns. Optical micrographs of a lightly polished surface normal to the c-axis of a 3-mm crystal delineate twinning and fine scale microcracking; this crystal surface now has a zero resistance at 68 K. Microhardness measurements and microfracture observations indicate intrinsic properties that may inhibit or impede large scale manufacture of electronic ceramics.

Keester, Kenneth L.↗

NASA NTRS1988

Prediction of the microyield strength of polymer matrix composites

A theory for the prediction of the creep and the microyield strength of composite laminates with viscoelastic matrices has been developed and tested. Precise creep curves from three laminates with arbitrary orientations provide the necessary input data. The time-dependent lamina properties are derived for subsequent use with standard laminate codes. Both the level and the shape of creep and strain recovery curves can be predicted. Extensions of the theory to include the effects of microcracking are outlined.

Wolff, Ernest G.↗

NASA NTRS1988

Water intrusion in thin-skinned composite honeycomb sandwich structures

Thin-skinned composite honeycomb sandwich structures from the trailing edge of the U.S. Army's Apache and Chinook helicopters have been tested to ascertain their susceptibility to water intrusion as well as such intrusions' effects on impact damage and cyclic loading. Minimum-impact and fatigue conditions were determined which would create microcracks sufficiently large to allow the passage of water through the skins; damage sufficient for this to occur was for some skins undetectable under a 40X-magnification optical microscope. Flow rate was a function of moisture content, damage, applied strain, and pressure differences.

Jackson, Wade C.↗

NASA NTRS1988

Effect of microstructural damage on ply stresses in laminated composites

The mechanisms involved in damage and failure of laminated orthotropic composites are investigated theoretically. The continuum model developed accounts for both matrix cracks and interply delamination using second-order tensor-valued internal-state variables based on the locally averaged microcrack dynamics. The derivation of the model is given in detail, and numerical results for sample problems are presented in extensive graphs and tables. The model is shown to be effective in predicting stresses at the ply level, and significant damage-induced decreases in laminate stress states are found.

Allen, D. H.↗

NASA NTRS1989

Space radiation effects on dimensional stability of composites

The long-term space environment at GEO, consisting of high doses (less than 10 to the 9th rads) of electron radiation and large cyclic (-157 C to +121 C) temperature changes, can significantly affect the dimensional stability of polymer matrix composites. Radiation alters the chemical structure of epoxies by both chain scission and cross-linking. In this paper, an attempt is made to summarize and examine the effects of electron radiation damage on dimensional stability of composites. Microcracking measurements were made for standard 177 C cure Gr/Ep, rubber toughened Gr/Ep, Gr/Polymide, and GR/Thermoplastic composites. Results show that radiation damage can significantly change matrix-dependent mechanical and physical properties of composites, with data explaining how these changes can affect their dimensional stability.

Tenney, Darrel R.↗

NASA NTRS1989

Thermal barrier coating life prediction model development, phase 1

The objective of this program was to establish a methodology to predict thermal barrier coating (TBC) life on gas turbine engine components. The approach involved experimental life measurement coupled with analytical modeling of relevant degradation modes. Evaluation of experimental and flight service components indicate the predominant failure mode to be thermomechanical spallation of the ceramic coating layer resulting from propagation of a dominant near interface crack. Examination of fractionally exposed specimens indicated that dominant crack formation results from progressive structural damage in the form of subcritical microcrack link-up. Tests conducted to isolate important life drivers have shown MCrAlY oxidation to significantly affect the rate of damage accumulation. Mechanical property testing has shown the plasma deposited ceramic to exhibit a non-linear stress-strain response, creep and fatigue. The fatigue based life prediction model developed accounts for the unusual ceramic behavior and also incorporates an experimentally determined oxide rate model. The model predicts the growth of this oxide scale to influence the intensity of the mechanic driving force, resulting from cyclic strains and stresses caused by thermally induced and externally imposed mechanical loads.

Demasi, Jeanine T.↗

NASA NTRS1988

Advanced composite materials for precision segmented reflectors

The objective in the NASA Precision Segmented Reflector (PSR) project is to develop new composite material concepts for highly stable and durable reflectors with precision surfaces. The project focuses on alternate material concepts such as the development of new low coefficient of thermal expansion resins as matrices for graphite fiber reinforced composites, quartz fiber reinforced epoxies, and graphite reinforced glass. Low residual stress fabrication methods will be developed. When coupon specimens of these new material concepts have demonstrated the required surface accuracies and resistance to thermal distortion and microcracking, reflector panels will be fabricated and tested in simulated space environments. An important part of the program is the analytical modeling of environmental stability of these new composite materials concepts through constitutive equation development, modeling of microdamage in the composite matrix, and prediction of long term stability (including viscoelasticity). These analyses include both closed form and finite element solutions at the micro and macro levels.

Stein, Bland A.↗

NASA NTRS1990

Probabilistic simulation of uncertainties in composite uniaxial strengths

Probabilistic composite micromechanics methods are developed that simulate uncertainties in unidirectional fiber composite strengths. These methods are in the form of computational procedures using composite mechanics with Monte Carlo simulation. The variables for which uncertainties are accounted include constituent strengths and their respective scatter. A graphite/epoxy unidirectional composite (ply) is studied to illustrate the procedure and its effectiveness to formally estimate the probable scatter in the composite uniaxial strengths. The results show that ply longitudinal tensile and compressive, transverse compressive and intralaminar shear strengths are not sensitive to single fiber anomalies (breaks, intergacial disbonds, matrix microcracks); however, the ply transverse tensile strength is.

Chamis, C. C.↗

NASA NTRS1990

Corrosion fatigue crack propagation in metals

This review assesses fracture mechanics data and mechanistic models for corrosion fatigue crack propagation in structural alloys exposed to ambient temperature gases and electrolytes. Extensive stress intensity-crack growth rate data exist for ferrous, aluminum and nickel based alloys in a variety of environments. Interactive variables (viz., stress intensity range, mean stress, alloy composition and microstructure, loading frequency, temperature, gas pressure and electrode potential) strongly affect crack growth kinetics and complicate fatigue control. Mechanistic models to predict crack growth rates were formulated by coupling crack tip mechanics with occluded crack chemistry, and from both the hydrogen embrittlement and anodic dissolution/film rupture perspectives. Research is required to better define: (1) environmental effects near threshold and on crack closure; (2) damage tolerant life prediction codes and the validity of similitude; (3) the behavior of microcrack; (4) probes and improved models of crack tip damage; and (5) the cracking performance of advanced alloys and composites.

Gangloff, Richard P.↗

NASA NTRS1990

Production of superconductor/carbon bicomponent fibers

Certain materials are unable to be drawn or spun into fiber form due to their improper melting characteristics or brittleness. However, fibrous samples of such materials are often necessary for the fabrication of intricate shapes and composites. In response to this problem, a unique process, referred to as the piggyback process, was developed to prepare fibrous samples of a variety of nonspinnable ceramics. In this technique, specially produced C-shaped carbon fibers serve as micromolds to hold the desired materials prior to sintering. Depending on the sintering atmosphere used, bicomponent or single component fibers result. While much has been demonstrated worldwide concerning the YBa2Cu3O(7-x) superconductor, fabrication into unique forms has proven quite difficult. However, a variety of intricate shapes are necessary for rapid commercialization of the superconducting materials. The potential for producing fibrous samples of the YBa2Cu3O(7-x) compound by the piggyback process is being investigated. Various organic and acrylic materials were investigated to determine suspending ability, reactivity with the YBa2Cu3O(7-x) compound during long term storage, and burn out characteristics. While many questions were answered with respect to the interfacial reactions between YBa2Cu3O(7-x) and carbon, much work is still necessary to improve the quality of the sintered material if the fibers produced are to be incorporated into useful composites or cables. Additional research is necessary to evaluate quality of the barrier layer during long soakings at the peak temperature; adjust the firing schedule to avoid microcracking and improve densification; and increase the solids loading in the superconductive suspension to decrease porosity.

Wise, S. A.↗

NASA NTRS1989

Failure processes within ceramic coatings at high temperatures

Plasma sprayed coatings have a complex structure which is produced by the overlaying of many molten or semi-molten particles in the diameter range of 20 to 120 microns. The failure behavior of coatings has been characterized by using acoustic emission (AE) methodology. Coatings of NiCrAlY bond coat with a zirconia-12 wt pct yttria overlay were applied to disk-shaped specimens of U-700 alloy. A waveguide of 1-mm diameter platinum was TlG welded to the specimen and allowed it to be suspended in a tubular furnace. The specimen was thermally cycled to 1150 C and the AE monitored. Analyses have been carried out with the aim of establishing parameters which are related to the crack size population. These studies have been used to postulate types of cracking mechanisms which may occur in plasma sprayed coatings during thermal cycling. It is shown that microcracking gave rise to a large amount of AE. However, this coating still survived more thermal cycles than a coating which exhibited macrocracking events.

Berndt, Christopher↗

NASA NTRS1989

The high temperature creep deformation of Si3N4-6Y2O3-2Al2O3

The creep properties of silicon nitride containing 6 wt percent yttria and 2 wt percent alumina have been determined in the temperature range 1573 to 1673 K. The stress exponent, n, in the equation epsilon dot varies as sigma sup n, was determined to be 2.00 + or - 0.15 and the true activation energy was found to be 692 + or - 25 kJ/mol. Transmission electron microscopy studies showed that deformation occurred in the grain boundary glassy phase accompanied by microcrack formation and cavitation. The steady state creep results are consistent with a diffusion controlled creep mechanism involving nitrogen diffusion through the grain boundary glassy phase.

Todd, J. A.↗

NASA NTRS1991

Improved Metallography Of Thermal-Barrier Coatings

New technique for preparation of metallographic samples makes interpretation of images of pores and microcracks more reliable. Involves use of vacuum epoxy infiltration and interference-film coating to reduce uncertainty. Developed for inspection of plasma-sprayed ceramic thermal-barrier coatings on metals but applicable to other porous, translucent materials, including many important ceramics.

Brindley, William J.↗

NASA NTRS1991

LaRC-RP41: A Tough, High-Performance Composite Matrix

New polymer exhibits increased toughness and resistance to microcracking. Cross-linking PMR-15 and linear LaRC-TPI combined to provide sequential semi-2-IPN designated as LaRC-RP41. Synthesized from PMR-15 imide prepolymer undergoing cross-linking in immediate presence of LaRC-TPI polyamic acid, also undergoing simultaneous imidization and linear chain extension. Potentially high-temperature matrix resin, adhesive, and molding resin. Applications include automobiles, electronics, aircraft, and aerospace structures.

Pater, Ruth H.↗

NASA NTRS1990

Composite materials for space applications

The objectives of the program were to: generate mechanical, thermal, and physical property test data for as-fabricated advanced materials; design and fabricate an accelerated thermal cycling chamber; and determine the effect of thermal cycling on thermomechanical properties and dimensional stability of composites. In the current program, extensive mechanical and thermophysical property tests of various organic matrix, metal matrix, glass matrix, and carbon-carbon composites were conducted, and a reliable database was constructed for spacecraft material selection. Material property results for the majority of the as-fabricated composites were consistent with the predicted values, providing a measure of consolidation integrity attained during fabrication. To determine the effect of thermal cycling on mechanical properties, microcracking, and thermal expansion behavior, approximately 500 composite specimens were exposed to 10,000 cycles between -150 and +150 F. These specimens were placed in a large (18 cu ft work space) thermal cycling chamber that was specially designed and fabricated to simulate one year low earth orbital (LEO) thermal cycling in 20 days. With this rate of thermal cycling, this is the largest thermal cycling unit in the country. Material property measurements of the thermal cycled organic matrix composite laminate specimens exhibited less than 24 percent decrease in strength, whereas, the remaining materials exhibited less than 8 percent decrease in strength. The thermal expansion response of each of the thermal cycled specimens revealed significant reduction in hysteresis and residual strain, and the average CTE values were close to the predicted values.

Rawal, Suraj P.↗