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Refractory composites of carbon-carbon material are considered for application in: (a) rocket motor nozzles and skirts, (b) a unique integrated propulsion structure, and (c) planetary atmospheric entry shells. Technical developments and plans in each of these areas are described.
The microstructure and some microstructural effects of oxidation have been investigated for laminar carbon fiber cloth/cloth binder matrix composite materials. It was found that cloth wave is important in determining the macrostructure of the composites X-ray diffraction analysis showed that the composites were more graphitic than the constituent fiber phases, indicating a graphitic binder matrix phase. Various tests which were conducted to investigate specific properties of the material are described. It was learned that under the moderate temperature and oxidant flow conditions studied, C-700, 730 materials exhibit superior oxidation resistance primarily because of the inhibiting influence of the graphitized binder matrix.
Research on three classes of materials that show potential for allowing significant increases in operating temperatures in gas turbine engines is discussed. Monolithic ceramics, ceramic matrix composites, and carbon-carbon composites are discussed. Sintering, hot pressing, and densification are discussed.
The disadvantages of carbon-carbon composites, in addition to the oxidation problem, are low thermal expansion, expensive fabrication procedures, and poor off axis properties. The background of carbon-carbon composites, their fabrication, oxidation, oxidation protection and mechanical testing in flexure are discussed.
Panels with integral stiffeners made with woven fabric in two-dimensional, cross-ply layups. Local skin buckling does not cause collapse of panels, and ultimate failure occurs at loads 10 to 20 percent above buckling loads. For panels subjected to in-plane loading, separation of stiffeners from panel skins was not problem. High-temperature structural applications on advanced aircraft and spacecraft include leading edges, fairings, and control surfaces.
A failure model which considers the stochastic nature of the damage accumulation process is essential to assess reliability and to accurately scale the results from standard test specimens to composite structures. A superior filamentary composite for high temperature applications is composed of carbon fibers in a carbon matrix. Carbon-carbon composites are the strongest known material at very high temperatures. Since there appears to be a significant randomness in C-C material strength which cannot be controlled or detected with current technology, a better model of the material failure based upon statistical principles should be used. Simple applications of the model based upon the limited data provide encouraging results that indicate that better design of test specimens would provide a substantially higher prediction for the design strength of C-C composites. An A-basis strength for the C-C tensile rings from a first stage D-5 billets was estimated. A statistical failure model was developed for these rings which indicates that this strength may be very conservative for larger C-C parts. The analysis may be improved by use of a heterogeneous/noncontinuum finite element approach on the minimechanical level.
Report presents data on physical properties of carbon-fiber-reinforced carbon-matrix and phenolic-matrix composite materials. Based on tests conducted on panels, cylinders, blocks, and formed parts. Data used by designers to analyze thermal-response and stress levels and develop structural systems ensuring high reliability at minimum weight.
Carbon-carbon composite materials offer greater thermal efficiency, stiffness to weight ratio, tailorability, and dimensional stability than aluminum. These lightweight thermal materials could significantly reduce the overall costs associated with satellite thermal control and weight. However, the high cost and long lead-time for carbon-carbon manufacture have limited their widespread usage. Consequently, an informal partnership between government and industrial personnel called the Carbon-Carbon Spacecraft Radiator Partnership (CSRP) was created to foster carbon-carbon composite use for thermally and structurally demanding space radiator applications. The first CSRP flight opportunity is on the New Millennium Program (NMP) Earth Orbiter-1 (EO-1) spacecraft, scheduled for launch in late 1999. For EO-1, the CSRP designed and fabricated a Carbon-Carbon Radiator (CCR) with carbon-carbon facesheets and aluminum honeycomb core, which will also serve as a structural shear panel. While carbon-carbon is an ideal thermal candidate for spacecraft radiators, in practice there are technical challenges that may compromise performance. In this work, the thermal and mechanical performance of the EO-1 CCR is assessed by analysis and testing. Both then-nal and mechanical analyses were conducted to predict the radiator response to anticipated launch and on-orbit loads. The thermal model developed was based on thermal balance test conditions. The thermal analysis was performed using SINDA version 4.0. Structural finite element modeling and analysis were performed using SDRC/1-DEAS and UAI/NASTRAN, respectively. In addition, the CCR was subjected to flight qualification thermal/vacuum and vibration tests. The panel meets or exceeds the requirements for space flight and demonstrates promise for future satellite missions.
This is part three of a development program to evaluate candidate nonablative aeroshell designs.
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The space shuttle wing leading edge and nose cap are composed of a carbon/carbon composite that is protected by silicon carbide. The coefficient of thermal expansion mismatch leads to cracks in the silicon carbide. The outer coating of the silicon carbide is a sodium-silicate-based glass that becomes fluid at the shuttles high reentry temperatures and fills these cracks. Small pinholes roughly 0.1 mm in diameter have been observed on these materials after 12 or more flights. These pinholes have been investigated by researchers at the NASA Johnson Space Center, Rockwell International, the Boeing Company, Lockheed Martin Corporation, and the NASA Glenn Research Center at Lewis Field to determine the possible sources and the extent of damage. A typical pinhole is illustrated in the photomicrographs. These pinholes are found primarily on the wing leading edges and not on the nose cap, which is covered when the orbiter is on the launch pad. The pinholes are generally associated with a bead of zincrich glass. Examination of the orbiter and launch structure indicates that weathering paint on the launch structure leads to deposits of zinc-containing paint flakes on the wing leading edge. These may become embedded in the crevices of the wing leading edge and form the observed zinc-rich glass. Laboratory experiments indicate that zinc oxide reacts vigorously with the glass coating on the silicon carbide. Thus, it is likely that this is the reaction that leads to pinhole formation (Christensen, S.V.: Reinforced Carbon/Carbon Pin Hole Formation Through Zinc Oxide Attack. Rockwell International Internal Letter, RDW 96 057, May 1996). Cross-sectional examination of pinholes suggests that they are enlarged thermal expansion mismatch cracks. This is illustrated in the photomicrographs. A careful microstructural analysis indicates that the pinhole walls consist of layers of zinc-containing glass. Thus, pinholes are likely formed by zinc oxide particles lodging in crevices and forming a corrosive zinc-rich glass that enlarges existing cracks. Having established the likely source of the pinholes, we next needed to model the damage. Our concern was that if a pinhole went through the silicon carbide to the carbon/carbon substrate, oxygen would have a clear path to oxidize the carbon at high temperatures. This possibility was examined with studies in a laboratory furnace. An ultrasonic drill was used to make artificial pinholes in a sample of protected carbon/carbon. After exposure, the specimens were weighed and cross-sectioned to quantify the extent of oxidation below the pinhole. The results at higher temperatures showed good agreement with a simple diffusion-control model. This model is based on the two-step oxidation of carbon to carbon monoxide and carbon dioxide. The fluxes are illustrated in the final figure. The model indicates a strong dependence on pinhole diameter. For smaller diameters and short times, the oxidation of carbon is very limited.
This paper discusses the current status of a fluorine-hydrazine rocket engine development program. Incorporation of a thin rhenium inner liner successfully eliminated corrosion of the carbon/carbon composite thrust chamber wall experienced during a previous test program. The results of hot-fire tests utilizing reworked and new injectors which provide increased fuel film cooling showed that thrust chamber head-end temperatures could be maintained at an acceptable level. As expected, the accompanying specific impulse performance loss requires optimizing the amount of film cooling to minimize the loss. The efforts to refine the rhenium liner vapor deposition process culminated in a carbon/carbon composite thrust chamber total test duration of 1008 seconds. Tasks presently in process include: (1) fabrication of two carbon/carbon composite thrust chambers incorporating 60:1 expansion ratio nozzles; (2) injector tests to optimize performance and cooling; (3) additional refinements to the rhenium lining process; and (4) fabrication and test of a freestanding rhenium thrust chamber.
Design eliminates thermal stress between composite cap and metal piston. New, conically surfaced, composite piston-cap structure, passively retained in metallic piston, made from carbon/carbon material, machined to shape. Shape includes conical faces, conical extensions intersect at common vertex on cylindrical axis of piston body, allowing thermal-stress-free retention of cap at all temperatures. When assembly heated or cooled, metal expands or contracts radially from coincident vertex. Where metal makes contact with carbon/carbon cap, snugly fitting conical faces slide without interference. Since metal body free to expand, no thermal stress produced in metal body or carbon/carbon cap.
Four major areas of interest with respect to utilizing strain gages on carbon/carbon (with SiC surfaces) and titanium matrix composites are addressed. Strain gage and adhesive combinations on carbon/carbon (C/C) at temperatures from minus 190 C to to 540 C, half-bridge gaging for reducing apparent strain on C/C using Poisson's ratio and bending configurations, a review of the 'field installation' techniques developed for gaging a C/C hypersonic generic elevon, and results of initial strain gaging efforts on titanium matrix composites are discussed. Current research in developing techniques for increasing the maximum temperature for strain gages on carbon/carbon are reviewed.
Four major areas of interest with respect to utilizing strain gages on carbon/carbon (with SiC surfaces) and titanium matrix composites are addressed. Strain gage and adhesive combinations on carbon/carbon (C/C) at temperatures from minus 190 C to 540 C, half-bridge gaging for reducing apparent strain on C/C using Poisson's ratio and bending configurations, review of the 'field installation' techniques developed for gaging a C/C hypersonic generic elevon, and results of initial strain gaging efforts on titanium matrix composites are discussed. Current research in developing techniques for increasing the maximum temperature for strain gages on carbon/carbon are reviewed.
With recent success of the NSTAR ion thruster on Deep Space 1, there is continued interest in long term, high propellant throughput thrusters to perform energetic missions. This requires flight qualified thrusters that can operate for long periods at high beam density, without degradation in performance resulting from sputter induced grid erosion. Carbon-based materials have shown nearly an order of magnitude improvement in sputter erosion resistance over molybdenum. NASA Glenn Research Center (GRC) has been active over the past several years pursuing carbon-based grid development. In 1995, NASA GRC sponsored work performed by the Jet Propulsion Laboratory to fabricate carbon/carbon composite grids using a machined panel approach. In 1999, a contract was initiated with a commercial vendor to produce carbon/carbon composite grids using a chemical vapor infiltration process. In 2001, NASA GRC purchased pyrolytic carbon grids from a commercial vendor. More recently, a multi-year contract was initiated with North Carolina A&T to develop carbon/carbon composite grids using a resin injection process. The following paper gives a brief overview of these four programs.
Some materials, such as steel, titanium, and tungsten, have a yield stress that depends on the strain rate, and actually are stronger at high rates of load or deformation. The increase in strength is relevant; and if not taken into account, the computer models will not match the experimental behavior observed in typical shock loading, ordnance, or ballistic tests. For higher velocity (hypervelocity impacts), an equation of state that accounts for non-linearities and temperature in the pressure-volume relation, may also be needed. This rate-dependent behavior of the strength has also been observed in some composite materials. Southwest Research Institute® (SwRI®) has started an internal research effort to measure and better model the behavior of materials, in particular carbon/carbon composites like ACC-6, at ultra-high temperatures for both static and high rates of deformation. The ultimate objective is to obtain reliable computer models of carbon/carbon material under hypersonic flight conditions, hypervelocity impacts, shock-loading situations such as booster-vehicle separation, and munition operation events. SwRI® has successfully modeled in the past ballistic impact on other composites, namely S-2 glass/epoxy, Kevlar/resin, polyethylene fibers/resin, and carbon fiber composites. This presentation will show test results relevant to the strength properties of the ACC-6 C/C material which were measured at quasistatic, medium, and the moderately high strain rates (~103 s—1) achievable in a conventional Split Hopkinson bar apparatus. Some of the tests were performed at both high-rates and high temperatures typical of hypersonic flight, something that, to the authors’ knowledge, has never been published in the past for this particular material. The test method will be presented, as well as the comparison of the stress-strain curves for the different temperatures and strain-rates of interest. A discussion of how the results can be used in the typical hydrocodes of interest will be included.