Wide-Angle Ultrasonic Backscatter: Concept for Enhanced Array-Based Inspection of Composite Materials
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Johnston, Pat↗
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Understanding the Durability of SiC Based Ceramic Matrix Composites (CMCs) for Gas Turbine Engine Hot Section Components
Silicon carbide fiber reinforced silicon carbide ceramic matrix composites (SiCf/SiC-CMCs) are being used in the fabrication of gas turbine engine hot section components due to their light weight and excellent thermal and chemical stabilities at high-temperature. These superior properties enable significant enhancements in engine efficiency and reduced fuel burn, emissions, and cooling requirements. In support of NASA’s Aeronautics Mission under various programs at Glenn Research Center, different types of composites have been developed and assessed for a high temperature (2700 °F) SiCf/SiC CMC system for turbine engine applications. These composites have creep-resistant SiC fibers, advanced 3D weaves, 2700 °F-capable hybrid SiC matrices, and durable environmental barrier coatings (EBCs). These efforts have resulted in improvements in the overall CMC thermomechanical and environmental durability. In order to study the role of different constituents and processing variables, a single fiber tow CVI (chemical vapor infiltration) SiC/SiC mini-composite can be considered the basic architectural feature of woven and laminate SiC/SiC CMCs. Moreover, the mini-composite mechanical and tensile creep damage behavior represents the creep behavior of 0° fiber tows in the axial loading direction of a macro-composite or component. In addition, a large number of mini-composite samples can be fabricated at relatively low cost within a short time, which makes them attractive for obtaining a robust set of experimental data and studying constituent behavior. In this presentation, the mini-composite approach to study damage mechanisms that limit CMC life in extreme environments including exposure to steam will be presented. The effects of constituent type and volume fraction on the CMC durability, which will help influence CMC design, will be discussed.
Ceramic Matrix Composites (CMCs)↗
High-Cycle Fatigue Behavior of SiC-based Ceramic Matrix Composites (CMCs) at High Temperatures
High-cycle fatigue (HCF) behavior of a melt-infiltrated, pre-preg SiC/SiC ceramic matrix composite (CMC) was investigated using dogbone tensile specimens without and with simulated cooling holes at 1500 and 2400 °F. The CMC material used for this study was fabricated by GE Aviation and had a ply configuration of [0/90/0]3. HCF tests were conducted with an R-ratio of 0.6 and a cyclic frequency of 30 Hz. Runout in HCF was defined as 30 million cycles. Monotonic tensile tests were conducted at room temperature (RT) on as-received CMC specimens and on runout HCF specimens to determine residual tensile strengths. Digital image correlation (DIC) and acoustic emission (AE) techniques were used to monitor the initiation and progression of damage in RT tensile tests on specimens with and without holes. Microscopy was performed on the polished edge of specimens without cooling holes and on the polished face of specimens with cooling holes that were tested in HCF and achieved runout. Comparisons were made with baseline specimens. Fractography was performed to examine the fracture surfaces of samples that failed under different loading conditions.
Ceramic Matrix Composites↗
Thermal emittance enhancement of graphite-copper composites for high temperature space based radiators
Graphite-copper composites are candidate materials for space based radiators. The thermal emittance of this material, however, is a factor of two lower than the desired emittance for these systems of greater than or equal to 0.85. Arc texturing was investigated as a surface modification technique for enhancing the emittance of the composite. Since the outer surface of the composite is copper, and samples of the composite could not be readily obtained for testing, copper was used for optimization testing. Samples were exposed to various frequencies and currents of arcs during texturing. Emittances near the desired goal were achieved at frequencies less than 500 Hz. Arc current did not appear to play a major role under 15 amps. Particulate carbon was observed on the surface, and was easily removed by vibration and handling. In order to determine morphology adherence, ultrasonic cleaning was used to remove the loosely adherent material. This reduced the emittance significantly. Emittance was found to increase with increasing frequency for the cleaned samples up to 500 Hz. The highest emittance achieved on these samples over the temperature range of interest was 0.5 to 0.6, which is approximately a factor of 25 increase over the untextured copper emittance.
Rutledge, Sharon K.↗
Thermal emittance enhancement of graphite-copper composites for high temperature space based radiators
Graphite-copper composites are candidate materials for space based radiators. The thermal emittance of this material, however, is a factor of two lower than the desired emittance for these systems of greater than or equal to 0.85. Arc texturing was investigated as a surface modification technique for enhancing the emittance of the composite. Since the outer surface of the composite is copper, and samples of the composite could not be readily obtained for testing, copper was used for optimization testing. Samples were exposed to various frequencies and currents of arcs during texturing. Emittances near the desired goal were achieved at frequencies less than 500 Hz. Arc current did not appear to play a major role under 15 amps. Particulate carbon was observed on the surface, and was easily removed by vibration and handling. In order to determine morphology adherence, ultrasonic cleaning was used to remove the loosely adherent material. This reduced the emittance significantly. Emittance was found to increase with increasing frequency for the cleaned samples up to 500 Hz. The highest emittance achieved on these samples over the temperature range of interest was 0.5 to 0.6, which is approximately a factor of 25 increase over the untextured copper emittance.
Rutledge, Sharon K.↗
Micromechanical modeling of damage growth in titanium based metal-matrix composites
The thermomechanical behavior of continuous-fiber reinforced titanium based metal-matrix composites (MMC) is studied using the finite element method. A thermoviscoplastic unified state variable constitutive theory is employed to capture inelastic and strain-rate sensitive behavior in the Timetal-21s matrix. The SCS-6 fibers are modeled as thermoplastic. The effects of residual stresses generated during the consolidation process on the tensile response of the composites are investigated. Unidirectional and cross-ply geometries are considered. Differences between the tensile responses in composites with perfectly bonded and completely debonded fiber/matrix interfaces are discussed. Model simulations for the completely debonded-interface condition are shown to correlate well with experimental results.
Sherwood, James A.↗
The effect of TiB2 reinforcement on the mechanical properties of an Al-Cu-Li alloy-based metal-matrix composite
The addition of ceramic particles to aluminum based alloys can substantially improve mechanical properties, especially Young's modulus and room and elevated temperature strengths. However, these improvements typically occur at the expense of tensile ductility. The mechanical properties are evaluated to a metal matrix composite (MMC) consisting of an ultrahigh strength aluminum lithium alloy, Weldalite (tm) 049, reinforced with TiB2 particles produced by an in situ precipitation technique called the XD (tm) process. The results are compared to the behavior of a nonreinforced Weldalite 049 variant. It is shown that both 049 and 049-TiB2 show very attractive warm temperature properties e.g., 625 MPa yield strength at 150 C after 100 h at temperature. Weldalite 049 reinforced with a nominal 4 v pct. TiB2 shows an approx. 8 pct. increase in modulus and a good combination of strength (529 MPa UTS) and ductility (6.5 pct.) in the T3 temper. And the high ductility of Weldalite 049 in the naturally aged and underaged tempers makes the alloy a good, high strength matrix for ceramic reinforcement.
Source record↗
Effect of Mechanical and Thermal Loading Histories on Residual Properties of SiCf/SiC Ceramic Matrix Composites
Silicon Carbide based Ceramic Matrix Composites (CMCs) are attractive materials for use in high-temperature structural applications in the aerospace and nuclear industries. Under high stresses and temperatures, creep degradation is the dominant damage mechanism in CMCs. Consequently, chemical vapor infiltration (CVI) SiCf/SiC ceramic matrix composites (CMC) incorporating SylramicTM-iBN SiC fibers coated with boron nitride (BN) interphase and CVI-SiC matrix were tested to examine creep behavior in air at a range of elevated temperatures of (2200 - 2700 F). Samples that survived creep tests were evaluated via RT fast fracture tensile tests to determine residual properties, with the use of acoustic emission (AE) to assess stress dependent damage initiation and progression. Microscopy of regions within the gage section of the tested specimens was performed. Observed material degradation mechanisms are discussed.
creep↗
Evolution of damage and plasticity in titanium-based, fiber-reinforced composites
The inelastic deformation mechanisms were evaluated for a model titanium-based, fiber-reinforced composite: a beta titanium alloy (Ti-15V-3Al-3Cr-3Sn) reinforced with SiC (SCS-6) fibers. The primary emphasis of this article is to illustrate the sequence in which damage and plasticity evolved for this system. The mechanical responses and the results of detailed microstructural evaluations for the 0(8), 90(8), and +/- 45(2s) line oriented laminates are provided. It is shown that the characteristics of the reaction zone around the fiber play a very important role in the way damage and plasticity evolve, particularly in the microyield regime of deformation, and must be included in any realistic constitutive model. Fiber-matrix debonding was a major damage mode for the off-axis systems. The tension test results are also compared with the predictions of a few constitutive models.
Majumdar, B. S.↗
Estimation of gamma phase composition in nickel-base superalloys /based on geometric analysis of a four-component phase diagram/
Estimation of gamma phase composition in nickel base heat resistant alloys based on analysis of quaternary phase diagrams
Dreshfield, R. L.↗
Combined MODIS/AMSR-E SST Composites for Regional Weather Applications
Recent applications of a high resolution MODlS composite SST product have clearly shown the importance of developing high-resolution SST data sets for coastal applications and modeling. In general, coupling between the oceans and atmospheres has been closely linked to SST gradients and fronts, indicating a need for high resolution SSTs, specifically in the areas of large gradients associated with coastal regions. Thus an accurate determination of SST gradients has become critical for determining the appropriate air-sea coupling and the influence on ocean modeling. Recent research is focused on improving the accuracy and spatial coverage of the current operational MODIS SST composite product provided by the Short-term Prediction Research and Transition (SPORT) project and distributed to the community. GHRSST-PP MODlS data and microwave AMSR-E data are being combined to produce composite data sets for both the West Coast and East Coast of the United States, including the Gulf of Mexico. The use of 1 km MODIS data has explicit advantages over other SST products including its global coverage and high resolution. The AMSR-E data will reduce the latency of the composites. A strategy for utilizing the error characteristics contained in the GHRSST data has been developed. This strategy will include using the error characteristics directly to calculate weights in the SST composites, uncertainty maps based on the composite biases and RMS errors, and latency products calculated in the compositing process. Recent accomplishments include the development of an enhanced compositing approach based on the error-weighted combination of recent clear MODIS SST values, where the error contributions come from measurement error, potential cloud contamination, and data latency sources. Future plans call for the inclusion of AMSR-E SST values with appropriate weights based upon measurement accuracy, MODIS-AMSR-E SST bias, and latency.
Jedlovec, Gary↗
A micromechanics-based progressive failure model for laminated composite structures
A micromechanics-based mechanistic model for progressive failure analysis of laminated composite shell structures is developed. A finite-element program for laminated shell analysis is coupled with a micromechanical elasticity solution for predicting failure and effective composite properties. The laminate model is based on a third-order shell theory which allows for both transverse normal and shearing deformations. Results are presented for the progressive failure of a (0/90(4)s graphite/epoxy laminate under uniaxial tension. The effect of fiber volume fraction in the 90-deg plies on laminate behavior was studied, and it was found that decreasing the fiber-volume fraction in the off-axis plies did not affect the laminate stiffness or the ultimate failure load, but significantly increased the load at which initial failure occurred.
Averill, R. C.↗
Estimation of conjugate gamma and gamma-prime compositions in Ni-base superalloys
To control the formation of unwanted phases, superalloy metallurgists have developed methods of estimating the composition of the matrix phase of alloys. That composition is then used to estimate the alloy's propensity toward sigma and other unwanted phase formations upon prolonged exposure to elevated temperatures in service. This paper reviews two approaches for estimating phase composition from the melt composition. One method is based on assigning essentially fixed stoichiometry to precipitating phases and is typified by 'PHACOMP'. The second method uses analytical geometry to interpret phase diagrams and is shown to be applicable to a two-phase region of a six-component Ni-base system. The geometric method is also shown to be applicable to commercial Ni-base superalloys.
Dreshfield, R. L.↗
Composite Bond Line Measurements Based on a Bayesian Analysis of Flash Thermography Data
For bonded composite materials, an accurate characterization of the adhesive bond line is needed to predict failure modes and fracture toughness. In this paper, bond line thickness was estimated from data obtained using through transmission flash thermography. The forward model that predicts back surface temperature is based on a three layer heat diffusion equation with varying diffusivity and flux boundary conditions. The corresponding inverse problem of estimating bond line thickness from measurement data was solved using a Bayesian approach that assumed Gaussian priors for the bond line thickness and thermal diffusivity of the adherends. Finally, the outputs of the thermography based method were compared to measurements that were collected using a micrometer and ultrasound testing.
Flash thermography↗
Composite Bond Line Measurements Based on A Bayesian Analysis of Flash Thermography Data
For bonded composite materials, an accurate characterization of the adhesive bond line is needed to predict failure modes and fracture toughness. In this paper, bond line thickness was estimated from data obtained using through transmission flash thermography. The forward model that predicts back surface temperature is based on a three layer heat diffusion equation with varying diffusivity and flux boundary conditions. The corresponding inverse problem of estimating bond line thickness from measurement data was solved using a Bayesian approach that assumed Gaussian priors for the bond line thickness and thermal diffusivity of the adherends. Finally, the outputs of the thermography based method were compared to measurements that were collected using a micrometer and ultrasound testing.
Flash thermography↗
Prediction of properties of intraply hybrid composites
Equations based on the mixtures rule are presented for predicting the physical, thermal, hygral, and mechanical properties of unidirectional intraply hybrid composites (UIHC) from the corresponding properties of their constituent composites. Bounds were derived for uniaxial longitudinal strengths, tension, compression, and flexure of UIHC. The equations predict shear and flexural properties which agree with experimental data from UIHC. Use of these equations in a composites mechanics computer code predicted flexural moduli which agree with experimental data from various intraply hybrid angleplied laminates (IHAL). It is indicated, briefly, how these equations can be used in conjunction with composite mechanics and structural analysis during the analysis/design process.
Chamis, C. C.↗
HITCAN: High temperature composite analyzer
A computer code, HITCAN (High Temperature Composite Analyzer) was developed to analyze/design metal matrix composite structures. HITCAN is based on composite mechanics theories and computer codes developed at NASA LeRC over the last two decades. HITCAN is a general purpose code for predicting the global structural and local stress-strain response of multilayered (arbitrarily oriented) metal matrix structures both at the constituent (fiber, matrix, and interphase) and the structure level and including the fabrication process effects. The thermomechanical properties of the constituents are considered to be nonlinearly dependent on several parameters including temperature, stress, and stress rate. The computational procedure employs an incremental iterative nonlinear approach utilizing a multifactor-interaction material behavior model. HITCAN features and analysis capabilities (static, load stepping, modal, and buckling) are demonstrated through typical example problems.
Singhal, Surendra N.↗
Effect of composition and thermal treatments on the weldability of nickel-base 718 alloy.
Composition and thermal treatment effects on weldability of precipitation hardened Ni base alloy, analyzing heat affected zone cracking sensitivity
Steinman, J. B.↗