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At least 451 records · Page 25

Method of making single crystal fibers

Single crystal fibers are made from miniature extruded ceramic feed rods. A decomposable binder is mixed with powders to inform a slurry which is extruded into a small rod which may be sintered, either in air or in vacuum, or it may be used in the extruded and dried condition. A pair of laser beams focuses onto the tip of the rod to melt it thereby forming a liquid portion. A single crystal seed fiber of the same material as the feed rod contacts this liquid portion to establish a zone of liquid material between the feed rod and the single crystal seed fiber. The feed rod and the single crystal feed fiber are moved at a predetermined speed to solidify the molten zone onto the seed fiber while simultaneously melting additional feed rod. In this manner a single crystal fiber is formed from the liquid portion.

Westfall, Leonard J.↗

Lightweight, Actively Cooled Ceramic Matrix Composite Thrustcells Successfully Tested in Rocket Combustion Lab

In a joint effort between the NASA Glenn Research Center and the NASA Marshall Space Flight Center, regeneratively cooled ceramic matrix composite (CMC) thrustcells were developed and successfully tested in Glenn's Rocket Combustion Lab. Cooled CMC's offer the potential for substantial weight savings over more traditional metallic parts. Two CMC concepts were investigated. In the first of these concepts, an innovative processing approach utilized by Hyper-Therm, Inc., allowed woven CMC coolant containment tubes to be incorporated into the complex thruster design. In this unique design, the coolant passages had varying cross-sectional shapes but maintained a constant cross-sectional area along the length of the thruster. These thrusters were silicon carbide matrix composites reinforced with silicon carbide fibers. The second concept, which was supplied by Ceramic Composites, Inc., utilized copper cooling coils surrounding a carbon-fiber-reinforced carbon matrix composite. In this design, a protective gradient coating was applied to the inner thruster wall. Ceramic Composites, Inc.'s, method of incorporating the coating into the fiber and matrix eliminated the spallation problem often observed with thermal barrier coatings during hotfire testing. The focus of the testing effort was on screening the CMC material's capabilities as well as evaluating the performance of the thermal barrier or fiber-matrix interfacial coatings. Both concepts were hot-fire tested in gaseous O2/H2 environments. The test matrix included oxygen-to-fuel ratios ranging from 1.5 to 7 with chamber pressures to 400 psi. Steady-state internal wall temperatures in excess of 4300 F were measured in situ for successful 30-sec test runs. Photograph of actively cooled composite thrustcell fabricated by Hyper-Therm is shown. The thrustcell is a silicon-carbide-fiber-reinforced silicon carbide matrix composite with woven cooling channels. The matrix is formed via chemical vapor infiltration. Photograph of hot-fire test of an actively cooled carbon-fiber-reinforced carbon matrix composite thrustcell is also shown. This composite thrustcell, which was fabricated by CCI, Inc., was wound with copper cooling coils to contain the water coolant. The tests were run with oxygen fuel ratios up to seven with chamber pressures of 200 psia.

Jaskowiak, Martha H.↗

2021 CMH-17 Vol 5 Virtual Meeting CMC M&P Brief Overview

This overview (several slides) describes 1) the overall Goals of the CMH-17 Vol 5 CMC M&P (Materials and Processes) Working Group, 2) M&P sections in the existing CMH-17 Vol 5A that have been targeted for updating, 3) challenges to updating that content for the next edition of Vol 5, and 4) M&P plans for updating CMH-17 Vol 5A. M&P Working Group chairs Kiser and Lehman are leading a group of technical experts to address the sections that require the most attention in terms of updating information. A virtual meeting is providing an opportunity to recruit CMC, fiber, and EBC technical experts to address those sections. Goals will be defined for completing the updating of those sections, taking into account the need to have the updated content reviewed by SME (subject matter experts) well in advance of the publishing date.

Environmental Barrier Coating (EBC)↗

Film Cooling Effectiveness Measurements on a CMC-Simulated Flat Plate

Ceramic matrix composites (CMC) are high temperature materials that can allow higher operating turbomachinery engine temperatures with less coolant required. One method of fabricating ceramic matrix composites is by weaving fibers into the shape of an airfoil. Generally, CMC fiber tows are assembled with various weave patterns, but this uneven surface could introduce aerodynamic losses, and it will be necessary to determine the best film cooling hole arrangement for minimal thermal engine efficiency loss. As part of an effort to assess the impact of geometric constraints of CMC implementation relative to metallic high pressure turbine blades, an experimental study was performed to investigate the effect of film cooling on a CMC-like surface roughened flat plate. Film cooling effectiveness measurements were acquired on a large-scale surface with a ceramic matrix composite weave pattern and on a smooth surface for comparison. A single row and a 2-row cooling hole arrangement were investigated with different hole sizes. Infrared thermography data was acquired at several Reynolds numbers and blowing ratios. Results showed that the effect on span averaged film cooling effectiveness was small between a weave surface pattern and a smooth surface, while hole spacing dependence had a much stronger effect.

infrared↗

Modeling the Nonlinear, Strain Rate Dependent Deformation of Woven Ceramic Matrix Composites With Hydrostatic Stress Effects Included

An analysis method based on a deformation (as opposed to damage) approach has been developed to model the strain rate dependent, nonlinear deformation of woven ceramic matrix composites with a plain weave fiber architecture. In the developed model, the differences in the tension and compression response have also been considered. State variable based viscoplastic equations originally developed for metals have been modified to analyze the ceramic matrix composites. To account for the tension/compression asymmetry in the material, the effective stress and effective inelastic strain definitions have been modified. The equations have also been modified to account for the fact that in an orthotropic composite the in-plane shear stiffness is independent of the stiffness in the normal directions. The developed equations have been implemented into a commercially available transient dynamic finite element code, LS-DYNA, through the use of user defined subroutines (UMATs). The tensile, compressive, and shear deformation of a representative plain weave woven ceramic matrix composite are computed and compared to experimental results. The computed values correlate well to the experimental data, demonstrating the ability of the model to accurately compute the deformation response of woven ceramic matrix composites.

Goldberg, Robert K.↗

Acousto-ultrasonic evaluation of ceramic matrix composite materials

Acousto-ultrasonic nondestructive evaluation of ceramic composite specimens with a lithium-alumino-silicate glass matrix reinforced with unidirectional silicon carbide (NICALON) fibers was conducted to evaluate their reserve of strength. Ceramic composite specimens with different amount of damage were prepared by four-point cyclic fatigue loading of the specimens at 500 C for a different number of cycles. The reserve of strength of the specimens was measured as the maximum bending stress recorded during four-pointed bending test with the load monotonically increased until failure occurs. It was observed that the reserve of strength did not correlate with the number of fatigue cycles. However, it was also observed that higher values of the stress wave factor measurements correspond to higher values of the reserve of strength test data. Therefore, these results show that the acousto-ultrasonic approach has the potential of being used to monitor damage and to estimate the reserve of strength of ceramic composites.

Dosreis, Henrique L. M.↗

The Characterization of the Selected Materials for Space Shuttle

The harsh conditions to which the Space Shuttles are exposed during flight required the development and use of many unique materials. These materials were specially designed to withstand extreme temperatures, in some cases over 1600 C, while other material must withstand the cryogenic conditions of -253 C, and others must operate while under extreme loads. All of these materials must not only operate in the harsh condition but they must be light weight as well. The Space Shuttle is composed of three major components when configured for launch, Figure 1; the Shuttle, solid rocket boosters, and external tank (ET). The different heat shields of the Shuttle make up the thermal protection system (TPS); this system consists of many different types of components designed to operate on various parts of the vehicle. The body of the Shuttle and ET are composed mainly of aluminum alloy and graphite epoxy. The TPS consists of reinforced carbon-carbon (RCC) used on the wing leading edges and nose cap areas while the upper forward fuselage areas, the entire underside of the Shuttle, the Orbiter maneuvering system, and reaction control system utilize blacc high temperature reusable surface insulation (HRSI) tiles, Figure 2. Other areas of the Orbiter are protected by fibrous refractory composite insulation (FRCI) tiles. Areas where the temperature stays below 649 C, such as the forward fuselage, mid-fuselage, aft fuselage, vertical tail, and upper wing, are protected by other material such as, white low temperature reusable surface insulation (LRSI) tiles, advanced flexible reusable surface insulation (AFRSI) blankets, and felt reusable surface insulation (FRSI) white blankets. The RCC is a pyrolized laminated carbon with the outer surface converted to silicon carbide to prevent oxidation. The FiRST tiles are made of a low-density, high purity silica 99.8-percent amorphous fiber insulation that is made rigid by ceramic bonding resulting in 90-percent void and 10-percent materials. The RCC and HRSI are used in areas where the temperature rises above 1260 T. The FRCI tiles are high strength tiles derived by adding alumina-bososilicate fiber to the pure silica tile slurry that welds the micron-sizes fibers of pure silica into a rigid structure during sintering. The FRCI is composed of 20-percent alumina-borosilicate fibers and 80-percent silica fibers, and provided improved strength, durability and resistance to coating cracking and weight reduction than HRSI.

Kim, Hae-Soo↗

Thermal Insulative Elastomers for Clustered Large Liquid Propellant Rocket Engines

As thrust levels increase and as rocket engines fire for longer periods of time, the difficulties encountered in the protection of critical components from the effects of excessively high temperatures greatly increase. To protect these components a series of filled elastomeric composites have been evaluated. A brief discussion is presented of the problems of hot gas recirculation, radiation, and base plane heating with particular reference to large, clustered, liquid propellant rocket engines. The effect on components is discussed and an evaluation of a series of insulators based on filled elastomeric composites is presented. The evaluations are based on specialized thermal tests which were designed to simulate as far as possible, conditions during flight. The most promising of these elastomeric composites are compared to three alternative insulative systems, a filled, castable ceramic, a metal foil-silica fiber batting, and an asbestos-inconel wire mesh composite, in terms of weight, cost, and ease of fabrication and repair.

Peters, S. T.↗

Materials for advanced rocket engine turbopump turbine blades

A study program was conducted to identify those materials that will provide the greatest benefits as turbine blades for advanced liquid propellant rocket engine turbines and to prepare technology plans for the development of those materials for use in the 1990 through 1995 period. The candidate materials were selected from six classes of materials: single-crystal (SC) superalloys, oxide dispersion-strengthened (ODS) superalloys, rapid solidification processed (RSP) superalloys, directionally solidified eutectic (DSE) superalloys, fiber-reinforced superalloy (FRS) composites, and ceramics. Properties of materials from the six classes were compiled and evaluated and property improvements were projected approximately 5 years into the future for advanced versions of materials in each of the six classes.

Chandler, W. T.↗

Polymer derived Nicalon/Si-C-O composites - Processing and mechanical behavior

Ceramic matrix composites fabricated using Nicalon fiber and several polysilsesquioxane-derived Si-C-O matrices were characterized by optical and SEM and in four-point bending. In the matrix material linear shrinkages of up to 19 percent were observed for the vinylmethyl copolymer pyrolyzed to 1200 C, and up to 13 percent for the phenylmethyl material pyrolyzed to the same temperature, resulting in considerable matrix cracking. Under four-point loading, most composite samples fractured in a brittle manner as the result of strong fiber-matrix bonding. Flexural strengths, moduli, and ultimate strain varied with fiber sizing and processing parameters. Testing and analysis is being applied to promote more fibrous pullout during fracture.

Hurwitz, Frances I.↗

Near-Earth asteroids: Metals occurrence, extraction, and fabrication

Near-earth asteroids occur in three principle types of orbits: Amor, Apollo, and Aten. Amor asteroids make relatively close (within 0.3 AU) approaches to the earth's orbit, but do not actually overlap it. Apollo asteroids spend most of their time outside the earth's orbital path, but at some point of close approach to the sun, they cross the orbit of the earth. Aten asteroids are those whose orbits remain inside the earth's path for the majority of their time, with semi-major axes less than 0.1 AU. Near-earth orbit asteroids include: stones, stony-irons, irons, carbonaceous, and super-carbonaceous. Metals within these asteroids include: iron, nickel, cobalt, the platinum group, aluminum, titanium, and others. Focus is on the extraction of ferrous and platinum group metals from the stony-iron asteroids, and the iron asteroids. Extraction of the metal fraction can be accomplished through the use of tunnel-boring-machines (TBM) in the case of the stony-irons. The metals within the story-iron asteroids occur as dispersed granules, which can be separated from the stony fraction through magnetic and gaseous digestion separation techniques. The metal asteroids are processes by drilling and gaseous digestion or by gaseous digestion alone. Manufacturing of structures, housings, framing networks, pressure vessels, mirrors, and other products is accomplished through the chemical vapor deposition (CVD) of metal coating on advanced composites and on the inside of contour-defining inflatables (CDI). Metal coatings on advanced composites provide: resistance to degradation in the hostile environments of space; superior optical properties; superior heat dissipation; service as wear coatings; and service as evidential coatings. Metal coatings on the inside of CDI produce metal load-bearing products. Fibers such as graphite, kevlar, glass, ceramic, metal, etc., can be incorporated in the metal coatings on the inside of CDI producing metal matrix products which exhibit high strength and resist crack propagation.

Westfall, Richard↗

Characterization of Ceramic Matrix Composite Combustor Components: Pre and Post Exposure

The pursuit of lower emissions and higher performance from gas turbine engines requires the development of innovative concepts and the use of advanced materials for key engine components. One key engine component is the combustor, where innovative design and material improvements have the potential to lower emissions. Efforts to develop a High Speed Civil Transport with low emissions were focused on the evaluation of combustor concepts with liners fabricated from a ceramic matrix composite of silicon carbide fibers in a silicon carbide matrix (SiC/SiC). The evaluation of SiC/SiC composites progressed from simple coupons (to establish a first-order database and identify operant failure mechanisms and damage accumulation processes), to feature-based subelements (to assess fabricability and in situ material response), to actual components (to assess structural integrity, dimensional, and compositional fidelity) tested under simulated engine conditions. As in the case of all evolutionary material and process work, a key element to resolving fabrication issues is the evaluation of witness areas taken from fabricated components before testing the actual component. The witness material from these components allowed microstructural and mechanical testing to be performed and compared to the ideal, flat panel, conditions and data that are typical of basic characterization. This also allowed samples of similar design to be taken from components after 115 hours of combustion exposure. Testing consisted of tensile, double notch shear, ring burst, and thermal conductivity that sampled various regions of the components. The evaluation of the witness material allowed an understanding of the fabrication process, highlighting critical issues, in an early phase of the learning curve development of these configuration and material unique parts. Residual property testing, after exposure, showed if degradation of the material under actual service conditions was occurring. This paper will present the results of this critical testing. Evaluations that consider the degree of complexity of the fabricated part were established to relate in situ performance to that of flat panel based coupons. Nondestructive evaluation was used throughout the evaluation process. These results will also be discussed as an aid in understanding the test results.

Ojard, G.↗

Life Modeling and Design Analysis for Ceramic Matrix Composite Materials

The primary research efforts focused on characterizing and modeling static failure, environmental durability, and creep-rupture behavior of two classes of ceramic matrix composites (CMC), silicon carbide fibers in a silicon carbide matrix (SiC/SiC) and carbon fibers in a silicon carbide matrix (C/SiC). An engineering life prediction model (Probabilistic Residual Strength model) has been developed specifically for CMCs. The model uses residual strength as the damage metric for evaluating remaining life and is posed probabilistically in order to account for the stochastic nature of the material s response. In support of the modeling effort, extensive testing of C/SiC in partial pressures of oxygen has been performed. This includes creep testing, tensile testing, half life and residual tensile strength testing. C/SiC is proposed for airframe and propulsion applications in advanced reusable launch vehicles. Figures 1 and 2 illustrate the models predictive capabilities as well as the manner in which experimental tests are being selected in such a manner as to ensure sufficient data is available to aid in model validation.

Source record↗

Long-persistence blue phosphors

This invention relates to phosphors including long-persistence blue phosphors. Phosphors of the invention are represented by the general formula: MO . mAl.sub.2 O.sub.3 :Eu.sup.2+,R.sup.3+ wherein m is a number ranging from about 1.6 to about 2.2, M is Sr or a combination of Sr with Ca and Ba or both, R.sup.3+ is a trivalent metal ion or trivalent Bi or a mixture of these trivalent ions, Eu.sup.2+ is present at a level up to about 5 mol % of M, and R.sup.3+ is present at a level up to about 5 mol % of M. Phosphors of this invention include powders, ceramics, single crystals and single crystal fibers. A method of manufacturing improved phosphors and a method of manufacturing single crystal phosphors are also provided.

Yen, William M.↗

Phosphors with long-persistent green phosphorescence

This invention relates to phosphors including long-persistence green phosphors. Phosphors of the invention are represented by the general formula: M.sub.k Al.sub.2 O.sub.4 :2xEu.sup.2+,2yR.sup.3+ wherein k-1-2x-2y, x is a number ranging from about 0.0001 to about 0.05, y is a number ranging from about x to about 3x, M is an alkaline earth metal, and R.sup.3+ is one or more trivalent metal ions. Phosphors of this invention include powders, ceramics, single crystals and single crystal fibers. A method of manufacturing improved phosphors and a method of manufacturing single crystal phosphors are also provided.

Yen, William M↗

Two-Dimensional Nonlinear Finite Element Analysis of CMC Microstructures

Detailed two-dimensional finite element analyses of the cross-sections of a model CVI (chemical vapor infiltrated) SiC/SiC (silicon carbide fiber in a silicon carbide matrix) ceramic matrix composites are performed. High resolution images of the cross-section of this composite material are generated using serial sectioning of the test specimens. These images are then used to develop very detailed finite element models of the cross-sections using the public domain software OOF2 (Object Oriented Analysis of Material Microstructures). Examination of these images shows that these microstructures have significant variability and irregularity. How these variabilities manifest themselves in the variability in effective properties as well as the stress distribution, damage initiation and damage progression is the overall objective of this work. Results indicate that even though the macroscopic stress-strain behavior of various sections analyzed is very similar, each section has a very distinct damage pattern when subjected to in-plane tensile loads and this damage pattern seems to follow the unique architectural and microstructural details of the analyzed sections.

Mital, Subodh K.↗