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In the production of mesoscopically-engineered materials based on single-walled carbon nanotubes (SWNTs), monitoring the stages of chemical modification will be an important step in the fabrication of usable composite materials. In our research program we developed tools for studying high-temperature composites with a long-term goal of having such instrumentation available for SWNT composite analyses.
Future Space Shuttle Main Engine (SSME)-type rocket engines can benefit from the use of fiber-reinforced ceramix matrix composites (FRCMC). Ceramics reinforced with long continuous fibers exhibit improved tolerance to severe thermomechanical and environmental exposures. An in-house NASA-Lewis program to evaluate the durability of FRCMC in simulated SSME environments is described. Primary tests involve multiple (one second) exposures of FRCMC specimens in a hydrogen/oxygen rocket test rig. This rig generates surface heating rates of 1000 to 2500 C/second. The FRCMC durability evaluation involves measurement of retained strength as a function of thermal shock severity and number of upshock cycles. Preliminary test results for monolithic silicon nitride (Si3N4) and silicon carbide (SiC), and one type of silicon based FRCMC, are presented. The test data are examined in terms of simple thermal shock theory.
Silicon carbide based advanced ceramics and fiber reinforced composites are under active consideration for use in wide variety of high temperature applications within the aeronautics, space transportation, energy, and nuclear industries. The engineering designs of ceramic and composite component require fabrication and manufacturing of large and complex shaped parts of various thicknesses. In many instances, it is more economical to build up complex shapes by joining simple geometrical shapes. In addition these components have to be joined or assembled with metallic sub-components. Thus, joining and attachment have been recognized as enabling technologies for successful utilization of ceramic components in various demanding applications. In this presentation, various challenges and opportunities in design, fabrication, and testing o high temperature joints in ceramic matrix composites will be presented. Silicon carbide based advanced ceramics (CVD and hot pressed), and C/SiC and SiC/SiC composites, in different shapes and sizes, have been joined using an affordable, robust ceramic joining technology (ARCJoinT). Microstructure and high temperature mechanical properties of joints in silicon carbide ceramics and CVI and melt infiltrated SiC matrix composites will,be reported. Various joint design philosophies and design issues in joining of ceramics and composites well be discussed.
Advanced ceramics and fiber reinforced composites are under active consideration for use in a wide variety of high temperature applications within the aeronautics, space transportation, energy, and nuclear industries. The engineering designs of ceramic and composite components require fabrication and manufacturing of large and complex shaped parts of various thicknesses. In many instances, it is more economical to build up complex shapes by joining simple geometrical shapes. In addition, these components have to be joined or assembled with metallic sub-components. Thus, joining and attachment have been recognized as enabling technologies for successful utilization of ceramic components in various demanding applications. In this presentation, various challenges and opportunities in design, fabrication, and testing of high temperature joints in advanced ceramics and ceramic matrix composites will be presented. Silicon carbide based advanced ceramics and fiber reinforced composites in different shapes and sizes, have been joined using an affordable, robust ceramic joining technology. In addition, some examples of metal-ceramic brazing will also be presented. Microstructure and high temperature mechanical properties of joints in silicon carbide ceramics and composites will be reported. Various joint design philosophies and design issues in joining of ceramics and composites will be discussed.
The NASA Langley COmbined Loads Test System (COLTS) Facility was designed to accommodate a range of fuselage structures and wing sections and subject them to both quasistatic and cyclic loading conditions. Structural tests have been conducted in COLTS that address structural integrity issues of metallic and fiber reinforced composite aerospace structures in support of NASA Programs (i.e. the Aircraft Structural Integrity (ASIP) Program, High-Speed-Research program and the Supersonic Project, NASA Engineering and Safety Center (NESC) Composite Crew Module Project, and the Environmentally Responsible Aviation Program),. This paper presents experimental results for curved panels subjected to mechanical and internal pressure loads using a D-box test fixture. Also, results are presented that describe use of a checkout beam for development of testing procedures for a combined mechanical and pressure loading test of a Multi-bay box. The Multi-bay box test will be used to experimentally verify the structural performance of the Multi-bay box in support of the Environmentally Responsible Aviation Project at NASA Langley.
An assessment concerning the possibilities of a use of advanced composites in aerospace and space technology identified a lack of confidence and high cost as the major factors inhibiting composite applications. Attention is given to the present employment of composites and plans for its future use in the Army, Navy, and Air Force. Various programs conducted by NASA are concerned with the development of a technological base for the extended use of advanced composites in aerospace and space applications. A future commercial transport is considered in which virtually the entire airframe could be of advanced composites. The attitude of aircraft manufacturers, engine manufacturers, airlines, spacecraft users, and material suppliers with regard to an employment of composites is also examined.
The advantages of replacing metals in aircraft turbine engines with high-temperature polymer matrix composites (PMC's) include weight savings accompanied by strength improvements, reduced part count, and lower manufacturing costs. Successfully integrating high-temperature PMC's into turbine engines requires several long-term characteristics. Resistance to surface erosion is one rarely reported property of PMC's in engine applications because PMC's are generally softer than metals and their erosion resistance suffers. Airflow rates in stationary turbine engine components typically exceed 2.3 kg/sec at elevated temperatures and pressures. In engine applications, as shown in the following photos, the survivability of PMC components is clearly a concern, especially when engine and component life-cycle requirements become longer. Although very few publications regarding the performance of erosion coatings on PMC's are available particularly in high-temperature applications the use of erosion-resistant coatings to significantly reduce wear on metallic substrates is well documented. In this study initiated by the NASA Glenn Research Center at Lewis Field, a low-cost (less than $140/kg) graphite-fiber-reinforced T650 35/PMR 15 sheet-molding compound was investigated with various coatings. This sheet-molding compound has been compression molded into many structurally complicated components, such as shrouds for gas turbine inlet housings and gearboxes. Erosion coatings developed for PMC s in this study consisted of a two-layered system: a bondcoat sprayed onto a cleaned PMC surface, followed by an erosion-resistant, hard topcoat sprayed onto the bondcoat as shown in following photomicrograph. Six erosion coating systems were evaluated for their ability to withstand harsh thermal cycles, erosion resistance (ASTM G76 83 "Standard Practice for Conducting Erosion Tests by Solid Particle Impingement Using Gas Jets") using Al2O3, and adhesion to the graphite fiber polyimide composite (ASTM D 4541 95 "Pull Off Strength of Coatings"). Glenn and Allison Advanced Development Company collaborated to optimize erosion coatings for gas turbine fan and compressor applications. All the coating systems survived aggressive thermal cycling without spalling. During erosion tests (see the final photo), the most promising coating systems tested had Cr3C2-NiCr and WC-Co as the hard topcoats. In all cases, these coating systems performed significantly better than that with a TiN hard topcoat. When material depth (thickness) loss is considered, the Cr3C2-NiCr and WC-Co coating systems provided, on average, an erosion resistance 8.5 times greater than that for the uncoated PMR 15/T650 35 composite. Similarly, Cr3C2-NiCr and WC-Co coating systems adhered to the PMC substrate during tensile tests significantly better than systems containing a TiN topcoat. Differences in topcoats of Cr3C2-NiCr and WC-Co were determined by considering issues such as cost and environmental impact. The preferred erosion-resistant coating system for PMR 15/T650 35 has WC-Co as the hard topcoat. This system provides the following benefits in comparison to the coating system with Cr3C2-NiCr topcoat: lower powder material cost (15 to 20 percent), environmentally friendly materials (Cr3C2-NiCr is hazardous), and higher deposition yield (10 to 15 percent), which results in less waste.
The thermal and mechanical properties of pitch-based graphite fiber reinforced copper matrix (Gr/Cu) composites usable for space applications such as radiator fins were investigated. Thermal conductivity was measured as a function of fiber volume fraction and architecture. Results showed for unidirectional P-100 Gr/Cu composites, the longitudinal thermal conductivity was nearly independent of fiber volume fraction. Transverse thermal conductivities (perpendicular to the fibers) were strongly affected by the fiber volume fraction with higher volume fractions resulting in lower thermal conductivities. The effect of architecture on thermal conductivity followed the cosine squared law for simple architectures. Insufficient data are available currently to model more complex architectures, but adding fibers in the direction of the heat flow increases the thermal conductivity as low conductivity plies are supplemented by high conductivity plies. Thermal expansion tests were conducted on the Gr fibers and Gr/Cu composites. The results show a considerable thermal expansion mismatch between the fibers and the Cu matrix. The longitudinal thermal expansion showed a strong dependence on the architecture of the Gr/Cu composites. The composites also show a thermal expansion hysteresis. The hysteresis was eliminated by an engineered interface. Mechanical testing concentrated on the dynamic modulus and strength of the composites. The dynamic modulus of the Gr/Cu composites was 305 GPa up to 400 C, a value equivalent to Be. The strengths of the composites were less than expected, but this is attributed to the poor bond across the interface between the Gr fibers and Cu matrix. Testing of composites with an engineered interface is expected to yield strengths nearer the values predicted by the rule of mixtures.
The purpose of the RPI composites program is to develop advanced technology in the areas of physical properties, structural concepts and analysis, manufacturing, reliability and life prediction. Concommitant goals are to educate engineers to design and use composite materials as normal or conventional materials. A multifaceted program was instituted to achieve these objectives.
In spite of great improvements in accuracy through the use of computers, design methods, which can be equally critical in establishing the commercial success of a material, have been treated as afterthoughts. Early investment in design and development technologies can easily reduce manufacturing costs later in the product cycle. To avoid lengthy product development times for ceramic composites, funding agencies for materials research must commit resources to support design and development technologies early in the material life cycle. These technologies need not focus on designing the material, rather, the technology must focus on designing with the material, i. e., developing methods to design components fabricated from the new material. Thus a basic tenet that motivated this research effort is that a persistent need exists for improvements in the analysis of components fabricated from CMC material systems. From an aerospace design engineer's perspective the new generation of ceramic composites offers a significant potential for raising the thrust/weight ratio and reducing NOx emissions of gas turbine engines. Continuous ceramic fiber composites exhibit an increase in work of fracture, which allows for 'graceful' rather than catastrophic failure. When loaded in the fiber direction, these composites retain substantial strength capacity beyond the initiation of transverse matrix cracking despite the fact that neither of its constituents would exhibit such behavior if tested alone. As additional load is applied beyond first matrix cracking, the matrix tends to break in a series of cracks bridged by the ceramic fibers. Thus any additional load is born increasingly by the fibers until the ultimate strength of the composite is reached. Establishing design protocols that enable the engineer to analyze and predict this type of behavior in ceramic composites was the general goal of this project.
Thermodynamic properties and equilibrium chemical composition of materials for use as moderator coolants or as particle seeds to control radiant heat transfer in gaseous nuclear rocket engines
There is a need for lightweight, durable materials and structures to reduce the weight of propulsion systems. Polymer matrix composites (PMC's) are promising materials for aerospace applications because of their high strength-to-weight ratio relative to metals. Unfortunately, they are limited to applications where they are not exposed to hightemperature oxidizing atmospheres and/or particulates from ingested air. This is because oxidation and erosion occur on the surface, leading to weight loss, nodulation, and/or cracking on the surface, and a consequent decline of mechanical properties over time. Although prior research has shown that oxidation can be slowed when metallic or ceramic coatings are applied onto PMC's, there remains a need for erosion-resistant coatings that protect PMC's from high-velocity particulates in the engine flow path. These erosionresistant coatings could extend the life of polymer composites. Polymer composites are heavily damaged without an erosion-resistant coating because they are not as hard as metallic engine structures. The effectiveness and life of the coatings depends on their inherent properties as well as on the interaction between the coating and the PMC. Since polymers, in general, have high thermal expansion coefficients in comparison to metals and ceramics, failure of the coatings often occurs at this interface. The objective of this research is to develop strategies to improve this interface and tailor overlays for erosion resistance. The bondcoat, which was developed at the NASA Glenn Research Center, is composed of zinc blended with polyimides to improve the compatibility between the PMC and the overlay material. Initial coating trials at AADC produced vanes that had poor bonding between the overlay and bondcoats. Subsequently, Glenn successfully demonstrated that high-quality plasma-sprayed erosion coating systems could be applied to these guide vanes. Inlet guide vanes from AE 3007 engines fiber composites were coated using a coating system composed of a bondcoat and a hard topcoat. Optimization of the plasma spray process has led to plans for future erosion testing in gas turbine engine environments.
Propellant composition variation for improving cooling characteristics of Surveyor vernier propulsion system
The NASA Engineering and Safety Center (NESC) was requested to examine processing sensitivities (e.g., cure temperature control/variance, debonds, density variations) of polybenzimidazole nitrile butadiene rubber (PBI-NBR) insulation, case fiber, and resin systems and to evaluate nondestructive evaluation (NDE) and damage tolerance methods/models required to support human-rated composite motor cases. The proposed use of composite motor cases in Blocks IA and II was expected to increase performance capability through optimizing operating pressure and increasing propellant mass fraction. This assessment was to support the evaluation of risk reduction for large booster component development/fabrication, NDE of low mass-to-strength ratio material structures, and solid booster propellant formulation as requested in the Space Launch System NASA Research Announcement for Advanced Booster Engineering Demonstration and/or Risk Reduction. Composite case materials and high-energy propellants represent an enabling capability in the Agency's ability to provide affordable, high-performing advanced booster concepts. The NESC team was requested to provide an assessment of co- and multiple-cure processing of composite case and PBI-NBR insulation materials and evaluation of high-energy propellant formulations.
The development of 2700 degF capable environmental barrier coating (EBC) systems, particularly, the Rare Earth "Hafnium" Silicon bond coat systems, have significantly improved the temperature capability and environmental stability of SiC/SiC Ceramic Matrix Composite Systems. We have specifically developed the advanced 2700 degF EBC systems, integrating the EBC to the high temperature SA Tyrannohex SiC fiber composites, for comprehensive performance and durability evaluations for potential turbine engine airfoil component applications. The fundamental mechanical properties, environmental stability and thermal gradient cyclic durability performance of the EBC - SA Tyrannohex composites were investigated. The paper will particularly emphasize the high pressure combustion rig recession, cyclic thermal stress resistance and thermomechanical low cycle fatigue testing of uncoated and environmental barrier coated Tyrannohex SiC SA composites in these simulated turbine engine combustion water vapor, thermal gradients, and mechanical loading conditions. We have also investigated high heat flux and flexural fatigue degradation mechanisms, determined the upper limits of operating temperature conditions for the coated SA composite material systems in thermomechanical fatigue conditions. Recent progress has also been made by using the self-healing rare earth-silicon based EBCs, thus enhancing the SA composite hexagonal fiber columns bonding for improved thermomechanical and environmental durability in turbine engine operation environments. More advanced EBC- composite systems based on the new EBC-Fiber Interphases will also be discussed.
The preparation of a composite material of eutectic composition directly from the molten state is investigated. The manufacture of eutectic composites by unidirectional solidification is reviewed, and it is shown how two-phase composite structures of given relative volume fraction can be produced with a range of particle sizes. Crystallographic relationships and the thermal stability of interfaces in controlled eutectic structures are examined, the mechanical behavior of aligned eutectic microstructures is discussed, and characteristics of eutectic composites having mechanical properties of engineering significance are evaluated. Specific properties of the Ni-Nb eutectic alloy are reviewed to demonstrate the effect of structure control (through directional solidification) on the mechanical response of a eutectic composite. It is noted that unidirectionally solidified eutectic composites possess highly aligned and thermally stable microstructures and also exhibit excellent combinations of strength and ductility to very high temperature levels.
One of the major thrusts established under the FAA's National Aging Aircraft Research Program is to foster new technologies associated with civil aircraft maintenance. Recent DOD and other government developments in the use of bonded composite patches on metal structures has supported the need for research and validation of such doubler applications on U.S. certificated airplanes. Composite patching is a rapidly maturing technology which shows promise of cost savings on aging aircraft. Sandia Labs is conducting a proof-of-concept project with Delta Air Lines, Lockheed Martin, Textron, and the FAA which seeks to remove any remaining obstacles to the approved use of composite doublers. By focusing on a specific commercial aircraft application - reinforcement of the L-1011 door frame - and encompassing all 'cradle-to-grave' tasks such as design, analysis, installation, and inspection, this program is designed to prove the capabilities of composite doublers. This paper reports on a series of structural tests which have been conducted on coupons and subsize test articles. Tension-tension fatigue and residual strength tests attempted to grow engineered flaws in coupons with composite doublers bonded to aluminum skin. Also, structures which modeled key aspects of the door corner installation were subjected to extreme tension, shear, and bending loads. In this manner it was possible to study strain fields in and around the Lockheed-designed composite doubler using realistic aircraft load scenarios and to assess the potential for interply delaminations and disbonds between the aluminum and the laminate. The data acquired was also used to validate finite element models (FEM) and associated Damage Tolerance Analyses.
The design of tow-steered composites is one of the most popular and promising topics under the class of variable stiffness structures. In this work, the authors propose a new design framework and tool for the optimization of tow-steered composites. Mechanics of structure genome (MSG) provides accurate computation of plate/shell section properties including thick and highly curved structures. The computed section properties can be directly used in commercial computer-aided engineering tools. Tow-steered composites are modeled through a design framework wherein tow paths are parameterized in a general way and projected onto a finite element mesh, and MSG calculates the local shell/plate properties. The result is a complete workflow from design parameter input to structural performance evaluation. An open-source optimization software package is used to enable constrained optimization of structural stiffness for the broad tow-steered composite design space. Numerical examples are provided to demonstrate the capabilities of this tool and the promise and potential of tow-steered designs that optimize structural performance while satisfying manufacturing constraints.