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All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Mission Cycle Life Prediction for C/SiC Composites

The residual strength and life of C/SiC is dominated by carbon interface and fiber oxidation if thermal and mechanical stresses combine with thermal expansion mismatch in a manner such that seal coat and matrix cracks are open to allow oxygen ingress. Under these circumstances life can be predicted by simple oxidation based models based on reaction controlled kinetics at low temperature and gas phase diffusion controlled kinetics at high temperature. Key life governing variables in these models include temperature, applied stress, initial strength, oxygen partial pressure and total pressure. In this paper these models are described and extended to mission cycle life prediction.

Levine, Stanley R.↗
NASA NTRS2008

Mechanical Properties and Durability of "Waterless Concrete"

Waterless concrete consists of molten elementary sulfur and aggregate. The aggregates in lunar environment will be lunar rocks and soil. Sulfur is present on the Moon in Troilite soil (FeS) and by oxidation soil iron and sulfur can be produced. Iron can be used to reinforce the sulfur concrete. Sulfur concrete specimens were cycled between liquid nitrogen (approximately 191 C) and room temperature (approximately 21 C) to simulate exposure to a lunar environment. Cycled and control specimens were subsequently tested in compression at room temperatures (approximately 21 C) and approximately 101 C. Test results showed that due to temperature cycling, compressive strength of cycled specimens was 20% of those non-cycled. Microscopic examination of the fracture surfaces from the cycled samples showed clear de-bonding of the sulfur from the aggregate material whereas it was seen well bonded in those non-cycled. This reduction in strength can be attributed to the large differences in thermal coefficients of expansion of the materials constituting the concrete which promoted cracking. Similar sulfur concrete mixtures were strengthened with short and long glass fibers. The glass fibers from lunar regolith simulant was melted in a 25 cc Pt-Rh crucible in a Sybron Thermoline high temperature MoSi2 furnace at melting temperatures of 1450 to 1600 C for times of 30 min to 1 hour. Glass fibers were cast from the melt into graphite crucibles and were annealed for a couple of hours at 600 C. Glass fibers and small rods were pulled from the melt. The glass melt wets the ceramic rod and long continuous glass fibers were easily hand drawn. The glass fibers were immediately coated with a protective polymer to maintain the mechanical strength. The glass fibers were used to reinforce sulfur concrete plated to improve the flexural strength of the sulfur concrete. Prisms beams strengthened with glass fibers were tested in 4-point bending test. Beams strengthened with glass fiber showed to exhibit an increase in the flexura strength by as much as 45%.

Toutanji, Houssam↗
NASA NTRS2009

NDE for Characterizing Oxidation Damage in Reinforced Carbon-Carbon

In this study, coated reinforced carbon-carbon (RCC) samples of similar structure and composition as that from the NASA space shuttle orbiter s thermal protection system were fabricated with slots in their coating simulating craze cracks. These specimens were used to study oxidation damage detection and characterization using NDE methods. These specimens were heat treated in air at 1143 and 1200 C to create cavities in the carbon substrate underneath the coating as oxygen reacted with the carbon and resulted in its consumption. The cavities varied in diameter from approximately 1 to 3 mm. Single-sided NDE methods were used since they might be practical for on-wing inspection, while x-ray micro-computed tomography (CT) was used to measure cavity sizes in order to validate oxidation models under development for carbon-carbon materials. An RCC sample having a naturally-cracked coating and subsequent oxidation damage was also studied with x-ray micro-CT. This effort is a follow-on study to one that characterized NDE methods for assessing oxidation damage in an RCC sample with drilled holes in the coating. The results of that study are briefly reviewed in this article as well. Additionally, a short discussion on the future role of simulation to aid in these studies is provided.

Roth, Don J.↗
NASA NTRS2009

Performance of "Waterless Concrete"

Waterless concrete consists of molten elementary sulfur and aggregate. The aggregates in a lunar environment will be lunar rocks and soil. Sulfur is present on the Moon in Troilite soil (FeS) and, by oxidation of the soil, iron and sulfur can be produced. Sulfur concrete specimens were cycled between liquid nitrogen (approx.]91 C) and room temperature (^21 C) to simulate exposure to a lunar environment. Cycled and control specimens were subsequently tested in compression at room temperatures (^21 C) and ^-101 C. Test results showed that due to temperature cycling, the compressive strength of cycled specimens was 20% of those non-cycled. This reduction in strength can be attributed to the large differences in thermal coefficients of expansion of the materials constituting the concrete which promoted cracking. Similar sulfur concrete mixtures were strengthened with short and long glass fibres. The lunar regolith simulant was melted in a 25 cc Pt- Rh crucible in a Sybron Thermoline high temperature MoSi2 furnace at melting temperatures of 1450 to 1600 C for times of 30 min to i hour. Glass fibres and small rods were pulled from the melt. The glass fibres were used to reinforce sulfur concrete plated to improve the flexural strength of the sulfur concrete. Beams strengthened with glass fibres showed to exhibit an increase in the flexural strength by as much as 45%.

Toutanji, H. A.↗
NASA NTRS2009

Polyimide-Foam/Aerogel Composites for Thermal Insulation

Composites of specific types of polymer foams and aerogel particles or blankets have been proposed to obtain thermal insulation performance superior to those of the neat polyimide foams. These composites have potential to also provide enhanced properties for vibration dampening or acoustic attenuation. The specific type of polymer foam is denoted "TEEK-H", signifying a series, denoted H, within a family of polyimide foams that were developed at NASA s Langley Research Center and are collectively denoted TEEK (an acronym of the inventors names). The specific types of aerogels include Nanogel aerogel particles from Cabot Corporation in Billerica, MA. and of Spaceloft aerogel blanket from Aspen Aerogels in Northborough, MA. The composites are inherently flame-retardant and exceptionally thermally stable. There are numerous potential uses for these composites, at temperatures from cryogenic to high temperatures, in diverse applications that include aerospace vehicles, aircraft, ocean vessels, buildings, and industrial process equipment. Some low-temperature applications, for example, include cryogenic storage and transfer or the transport of foods, medicines, and chemicals. Because of thermal cycling, aging, and weathering most polymer foams do not perform well at cryogenic temperatures and will undergo further cracking over time. The TEEK polyimides are among the few exceptions to this pattern, and the proposed composites are intended to have all the desirable properties of TEEK-H foams, plus improved thermal performance along with enhanced vibration or acoustic-attenuation performance. A composite panel as proposed would be fabricated by adding an appropriate amount of TEEK friable balloons into a mold to form a bottom layer. A piece of flexible aerogel blanket material, cut to the desired size and shape, would then be placed on the bottom TEEK layer and sandwiched between another top layer of polyimide friable balloons so that the aerogel blanket would become completely encased in an outer layer of TEEK friable balloons. Optionally, the process could be further repeated to produce multiple aerogel-blanket layers interspersed with and encased by TEEK friable balloons.

Williams, Martha↗
NASA NTRS2014

Sintering Characteristics of Multilayered Thermal Barrier Coatings Under Thermal Gradient and Isothermal High Temperature Annealing Conditions

Pyrochlore oxides have most of the relevant attributes for use as next generation thermal barrier coatings such as phase stability, low sintering kinetics and low thermal conductivity. One of the issues with the pyrochlore oxides is their lower toughness and therefore higher erosion rate compared to the current state-of-the-art TBC material, yttria (6 to 8 wt%) stabilized zirconia (YSZ). In this work, sintering characteristics were investigated for novel multilayered coating consisted of alternating layers of pyrochlore oxide viz Gd2Zr2O7 and t' low k (rare earth oxide doped YSZ). Thermal gradient and isothermal high temperature (1316 C) annealing conditions were used to investigate sintering and cracking in these coatings. The results are then compared with that of relevant monolayered coatings and a baseline YSZ coating.

Thermal Barrier Coatings↗
NASA NTRS1992

Superconductivity devices: Commercial use of space

High T sub C superconducting thick film were prepared by a screen printing process. Y-based (YBa2Cu3O(7-x) superconducting thick film were printed on 211/Al2O3, SNT/Al2O3, and YSZ substrates. Because of poor adhesion of the superconductor thick films to 211/Al2O3 and SNT/Al2O3 substrates, relatively low T sub C and J sub C values were obtained from the films printed on these substrates. Critical temperatures (T sub C) of YBa2Cu3O(7-x) thick films deposited on 211/Al2O3 and SNT/Al2O3 substrates were about 80 K. The critical current densities (J sub C) of these films were less than 2 A/sq cm. Higher T sub C and J sub C YBa2Cu3O(7-x) thick films were printed on YSZ substrates. A YBa2Cu3O(7-x) thick film with T sub C=86.4 and J sub C= 50.4 A/sq cm was prepared by printing the film on YSZ substrate and firing at 990 C for 10 minutes. Multiple-lead samples were also prepared on the YSZ substrates. The multiple-lead samples showed lower T sub C and/or J sub C values than those of the plain samples. The electrical properties of YBa2Cu3O(7-x) thick films were determined by the microstructures of the films. The YBa2Cu3O(7-x) thick films printed on the YSZ substrates, which had the best properties among the films printed on the three different kinds of substrates, had the highest density and the best particle interconnection. The YBa2Cu3O(7-x) thick films with preferred orientation in (001) direction were obtained on the YSZ substrates. Cracks, which retard the properties of the films, were found from the films deposited on the YSZ substrates. Currently, a MSZ (Magnesium Stabilized Zirconia) substrate, which had higher thermal expansion coefficient than the YSZ substrate, is used as substrate for the YBa2Cu3O(7-x) thick film in order to eliminate the cracks on the film. Bi-based superconductor thick films were printed on polycrystalline MgO and YSZ substrates. Interactions between BSCCO thick films and the YSZ substrates were observed. Various buffer layer materials were applied onto the substrates in order to avoid the interactions between the BSCCO thick films and the ZrO2-based substrates. So far, a BSCCO printed on MgO substrate with T Sub C=89K was obtained. The J sub C of the film was lower than 0.1 A/sq cm by reason of poor interconnectivity of the BSCCO particles.

Haertling, Gene↗
NASA NTRS1996

Probabilistic Fatigue Life Analysis of High Density Electronics Packaging

The fatigue of thin film metal interconnections in high density electronics packaging subjected to thermal cycling has been evaluated using a probabilistic fracture mechanics methodology. This probabilistic methodology includes characterization of thin film stress using an experimentally calibrated finite element model and simulation of flaw growth in the thin films using a stochastic crack growth model.

thermal cycling fatigue of thin film metal interco↗
NASA NTRS1981

Development of improved high temperature coatings for IN-792 + HF

The development for t-55 l712 engine of high temperature for integral turbine nozzles with improved thermal fatigue resistance without sacrificing oxidation/corrosion protection is discussed. The program evaluated to coating systems which comprised one baseline plasma spray coating (12% Al-NiCoCrALY), three aluminide coatings including the baseline aluminide (701), two CoNiCrAly (6% Al) + aluminide systems and four NiCoCrY + aluminide coating were evaluated. The two-step coating processes were investigated since it offered the advantage of tailoring the composition as well as properly coating surfaces of an integral or segmented nozzle. Cyclic burner rig thermal fatigue and oxidation/corrosion tests were used to evaluate the candidate coating systems. The plasma sprayed 12% Al-NiCoCrAlY was rated the best coating in thermal fatigue resistance and outperformed all coatings by a factor between 1.4 to 2.5 in cycles to crack initiation. However, this coatings is not applicable to integral or segmented nozzles due to the line of sight limitation of the plasma spray process. The 6% Al-CoNiCrAlY + Mod. 701 aluminide (32 w/o Al) was rated the best coating in oxidation/corrosion resistance and was rated the second best in thermal fatigue resistance.

Profant, D. D.↗
NASA NTRS1988

High-temperature combustor liner tests in structural component response test facility

Jet engine combustor liners were tested in the structural component response facility at NASA Lewis. In this facility combustor liners were thermally cycled to simulate a flight envelope of takeoff, cruise, and return to idle. Temperatures were measured with both thermocouples and an infrared thermal imaging system. A conventional stacked-ring louvered combustor liner developed a crack at 1603 cycles. This test was discontinued after 1728 cycles because of distortion of the liner. A segmented or float wall combustor liner tested at the same heat flux showed no significant change after 1600 cycles. Changes are being made in the facility to allow higher temperatures.

Moorhead, Paul E.↗
NASA NTRS1948

Preliminary Investigation of a Ceramic Lining for a Combustion Chamber for Gas-turbine Use

Combustion chamber liners for gas turbines and experimental set-ups were tested for failure. A ceramic-lined test chamber was operated at fuel/air ratios up to 0.050. Thermal-shock evaluation indicated that a ceramic lining, which expands after firing, would crack but would not fall apart during operation. Refractoriness of the lining and the resistance to mechanical shock were adequate. In general, shell temperature reductions of approximately 400 deg F were effected by the use of this lining at fuel/air ratios of 0.016 and 0.050. The mechanism of failure of the ceramic lining was induced by sudden heating and cooling during operation.

Woodward, William H↗
NASA NTRS2005

Thermostructural Properties Of Sic/Sic Panels With 2.5d And 3d Fiber Architectures

CMC hot-section components in advanced engines for power and propulsion will typically require high cracking strength, high ultimate strength and strain, high creep- rupture resistance, and high thermal conductivity in all directions. In the past, NASA has demonstrated fabrication of a variety of SiC/SiC flat panels and round tubes with various 2D fiber architectures using the high-modulus high-performance Sylramic-iBN Sic fiber and Sic-based matrices derived by CVI, MI, and/or PIP processes. The thermo- mechanical properties of these CMC have shown state-of-the-art performance, but primarily in the in-plane directions. Currently NASA is extending the thermostructural capability of these SiC/SiC systems in the thru-thickness direction by using various 2.5D and 3D fiber architectures. NASA is also using specially designed fabrication steps to optimize the properties of the BN-based interphase and Sic-based matrices. In this study, Sylramic-iBN/SiC panels with 2D plain weave, 2.5D satin weave, 2.5D ply-to-ply interlock weave, and 3D angle interlock fiber architectures, all woven at AITI, were fabricated using matrix densification routes previously established between NASA and GEPSC for CVI-MI processes and between NASA and Starfire-Systems for PIP processes. Introduction of the 2.5 D fiber architecture along with an improved matrix process was found to increase inter-laminar tensile strength from 1.5 -2 to 3 - 4 ksi and thru-thickness thermal conductivity from 15-20 to 30-35 BTU/ft.hr.F with minimal reduction in in-plane strength and creep-rupture properties. Such improvements should reduce thermal stresses and increase the thermostructural operating envelope for SiC/SiC engine components. These results are analyzed to offer general guidelines for selecting fiber architectures and constituent processes for high-performance SiC/SiC engine components.

Yun, H. M.↗
NASA NTRS1984

Thermochemical generation of hydrogen and carbon dioxide

Mixing of carbon in the form of high sulfur coal with sulfuric acid reduces the temperature of sulfuric acid decomposition from 830.degree. C. to between 300.degree. C. and 400.degree. C. The low temperature sulfuric acid decomposition is particularly useful in thermal chemical cycles for splitting water to produce hydrogen. Carbon dioxide is produced as a commercially desirable byproduct. Lowering of the temperature for the sulfuric acid decomposition or oxygen release step simplifies equipment requirements, lowers thermal energy input and reduces corrosion problems presented by sulfuric acid at conventional cracking temperatures. Use of high sulfur coal as the source of carbon for the sulfuric acid decomposition provides an environmentally safe and energy efficient utilization of this normally polluting fuel.

Lawson, Daniel D.↗
NASA NTRS1988

Fatigue life prediction modeling for turbine hot section materials

This paper presents a summary of the life prediction methods developed under the NASA Lewis Research Center's Hot Section Technology (HOST) program. A major objective of the fatigue and fracture efforts under the HOST program was to significantly improve the analytic life prediction tools used by the aeronautical gas turbine engine industry. This has been achieved in the areas of high-temperature thermal and mechanical fatigue of bare and coated high-temperature superalloys. Such technical improvements will eventually reduce life cycle costs. The cyclic crack initiation and propagation resistance of nominally isotropic polycrystalline alloys and highly anisotropic single crystal alloys has been addressed. A sizeable data base has been generated for three alloys [cast PWA 1455 (B-1900 + Hf), wrought Inconel 718, and cast single crystal PWA 1480] in bare and coated conditions. Two coatings systems, diffusion aluminide (PWA 273) and plasma sprayed MCrAIY overlay (PWA 286) were employed. Life prediction modeling efforts were devoted to creep-fatigue interaction, oxidation, coatings interactions, multiaxiality of stress-strain states, mean stress effects, cumulative damage, and thermomechanical fatigue. The fatigue crack initiation life models developed to date include the Cyclic Damage Accumulation (CDA) Model of Pratt & Whitney and the Total Strain Version of Strainrange Partitioning (TS-SRP) of NASA Lewis for nominally isotropic materials, and the Tensile Hysteretic Energy Model of Pratt & Whitney for anisotropic superalloys. The fatigue model being developed by the General Electric Company is based upon the concepts of Path-lndependent Integrals (PII) for describing cyclic crack growth under complex nonlinear response at the crack tip due to thermomechanical loading conditions. A micromechanistic oxidation crack extension model has been derived by researchers at Syracuse University. The models are described and discussed in the paper. Only limited verification has been achieved to-date as several of the technical programs are still in progress and the verification tasks are scheduled, quite naturally, near the conclusion of the program. To-date, efforts have concentrated on development of independent models for cyclic constitutive behavior, cyclic crack initiation, and cyclic crack propagation. The transition between crack initiation and crack propagation has not been thoroughly researched as yet, and the integration of these models into a unified life prediction method has not been addressed.

Metal fatigue↗
NASA NTRS1979

Energy absorption mechanisms during crack propagation in metal matrix composites

The stress distributions around individual fibers in a unidirectional boron/aluminum composite material subjected to axial and transverse loadings are being studied utilizing a generalized plane strain finite element analysis. This micromechanics analysis was modified to permit the analysis of longitudinal sections, and also to incorporate crack initiation and propagation. The analysis fully models the elastoplastic response of the aluminum matrix, as well as temperature dependent material properties and thermal stress effects. The micromechanics analysis modifications are described, and numerical results are given for both longitudinal and transverse models loaded into the inelastic range, to first failure. Included are initially cracked fiber models.

Murphy, D. P.↗
NASA NTRS2010

Improvements to a Flow Sensor for Liquid Bismuth-Fed Hall Thrusters

Recently, there has been significant interest in using bismuth metal as a propellant in Hall Thrusters [1, 2]. Bismuth offers some considerable cost, weight, and space savings over the traditional propellant--xenon. Quantifying the performance of liquid metal-fed Hall thrusters requires a very precise measure of the low propellant flow rates [1, 2]. The low flow rates (~10 mg/sec) and the temperature at which free flowing liquid bismuth exists (above 300 C) preclude the use of off-the-shelf flow sensing equipment [3]. Therefore a new type of sensor is required. The hotspot bismuth flow sensor, described in Refs. [1-5] is designed to perform a flow rate measurement by measuring the velocity at which a thermal feature moves through a flow chamber. The mass flow rate can be determined from the time of flight of the thermal peak, [4, 5]. Previous research and testing has been concerned mainly with the generation of the thermal peak and it's subsequent detection. In this paper, we present design improvements to the sensor concept; and the results of testing conducted to verify the functionality of these improvements. A ceramic material is required for the sensor body (see Fig. 1), which must allow for active heating of the bismuth flow channel to keep the propellant in a liquid state. The material must be compatible with bismuth and must be bonded to conductive elements to allow for conduction of current into the liquid metal and measurement of the temperature in the flow. The new sensor requires fabrication techniques that will allow for a very small diameter flow chamber, which is required to produce useful measurements. Testing of various materials has revealed several that are potentially compatible with liquid bismuth. Of primary concern in the fabrication and testing of a robust, working prototype, is the compatibility of the selected materials with one another. Specifically, the thermal expansion rates of the materials relative to the ceramic body cannot expand so much as to cause cracks in the body or cause the bond between parts to delaminate. Those parts that will carry the current pulse must be electrically conductive while the sensor body must be an electrical insulator. Generally, the material choices as well as the sensor design must aid to preserve the integrity of the thermal feature to obtain accurate measurements. The present aim is to also incorporate, into the sensor body, an active heating arrangement based on ceramic heater technology similar to that used in semiconductor manufacturing.

Bonds, Kevin↗
NASA NTRS1982

Effects of thermal cycling on residual mechanical properties of C6000/PMR-15 graphite polyimide

An experimental study to determine the effects of thermal cycling on residual mechanical properties of a graphite/polyimide composite has been conducted. Interlaminar shear, flexure and compression strengths were measured at room temperature and 316 C on unidirectional and quasi-isotropic laminates subjected to 150 and 500 thermal cycles between -156 C and 316 C. Thermal cycling produced transverse microcracks and delaminations in the laminates. The linear density of the microcracks (35/cm) was about the same after 150 and 500 cycles. Although the crack density did not change from 150 to 500 cycles, crack growth did occur with intralamina cracks growing into adjacent lamina. The matrix controlled properties of the quasi-isotropic laminate at both room temperature and 316 C were significantly reduced by thermal cycling. However, the properties of the unidirectional laminate were significantly reduced only at 316 C.

Tompkins, S. S.↗