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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Development of Luminescence Lifetime-Based Surface Temperature Mapping for Environmental Barrier Coatings

Luminescence lifetime-based temperature mapping for thermal barrier coatings (TBCs) has been previously demonstrated up to temperatures approaching 1200 °C. Advantages of this method include insensitivities to reflected radiation and emissivity uncertainties. Because of a push towards greater efficiency turbine engine operation using higher turbine inlet temperatures, there is an ongoing movement from TBC-coated superalloy turbine engine components to SiC/SiC ceramic matrix composite components protected by environmental barrier coatings (EBCs). The useful application of luminescence lifetime-based temperature mapping to EBCs requires a significant increase in high temperature capability from below 1200 °C up into the 1300 to 1500 °C temperature range where the much higher background thermal radiation is a challenging issue. In addition, the luminescing sensing layer must exhibit thermochemical compatibility with the EBC. To meet these requirements, Er-doped Y 2 SiO 5 was selected as the luminescing sensor layer material both for its enhanced temperature sensitivity above 1300 °C and its compatibility with rare-earth disilicate EBC topcoats. Both localized spot temperature measurements as well as luminescence lifetime imaging-based temperature mapping were demonstrated up to 1560 °C for Er-doped Y 2 SiO 5 disks. In addition, temperature mapping capability was demonstrated from a 15 µm thick Er-doped Y 2 SiO 5 layer at the surface of a Sc 2 Si 2 O 7 based EBC topcoat. Both localized spot and temperature mapping by luminescence lifetime imaging were demonstrated up to 1380 °C (upper temperature limit of this slurry-based layered EBC) with excellent suppression of background thermal radiation and no degradation of the Er-doped Y 2 SiO 5 temperature sensing surface layer. The source of the novel enhanced temperature sensitivity above 1300 °C will be discussed as well as a path towards compatibility between sensing layer and EBC topcoat to higher temperatures.

temperature measurement↗
NASA NTRS1994

Verifying Stiffness Parameters Of Filament-Wound Cylinders

Predicted engineering stiffness parameters of filament-wound composite-material cylinders verified with respect to experimental data, by use of equations developed straightforwardly from applicable formulation of Hooke's law. Equations derived in engineering study of filament-wound rocket-motor cases, also applicable to other cylindrical pressure vessels made of orthotropic materials.

Verderaime, V.↗
NASA NTRS1994

TEXCAD: Textile Composite Analysis for Design. Version 1.0: User's manual

The Textile Composite Analysis for Design (TEXCAD) code provides the materials/design engineer with a user-friendly desktop computer (IBM PC compatible or Apple Macintosh) tool for the analysis of a wide variety of fabric reinforced woven and braided composites. It can be used to calculate overall thermal and mechanical properties along with engineering estimates of damage progression and strength. TEXCAD also calculates laminate properties for stacked, oriented fabric constructions. It discretely models the yarn centerline paths within the textile repeating unit cell (RUC) by assuming sinusoidal undulations at yarn cross-over points and uses a yarn discretization scheme (which subdivides each yarn not smaller, piecewise straight yarn slices) together with a 3-D stress averaging procedure to compute overall stiffness properties. In the calculations for strength, it uses a curved beam-on-elastic foundation model for yarn undulating regions together with an incremental approach in which stiffness properties for the failed yarn slices are reduced based on the predicted yarn slice failure mode. Nonlinear shear effects and nonlinear geometric effects can be simulated. Input to TEXCAD consists of: (1) materials parameters like impregnated yarn and resin properties such moduli, Poisson's ratios, coefficients of thermal expansion, nonlinear parameters, axial failure strains and in-plane failure stresses; and (2) fabric parameters like yarn sizes, braid angle, yarn packing density, filament diameter and overall fiber volume fraction. Output consists of overall thermoelastic constants, yarn slice strains/stresses, yarn slice failure history, in-plane stress-strain response and ultimate failure strength. Strength can be computed under the combined action of thermal and mechanical loading (tension, compression and shear).

Naik, Rajiv A.↗
NASA NTRS1997

Advances in Thin Film Sensor Technologies for Engine Applications

Advanced thin film sensor techniques that can provide accurate surface strain and temperature measurements are being developed at NASA Lewis Research Center. These sensors are needed to provide minimally intrusive characterization of advanced materials (such as ceramics and composites) and structures (such as components for Space Shuttle Main Engine, High Speed Civil Transport, Advanced Subsonic Transports and General Aviation Aircraft) in hostile, high-temperature environments and for validation of design codes. This paper presents two advanced thin film sensor technologies: strain gauges and thermocouples. These sensors are sputter deposited directly onto the test articles and are only a few micrometers thick; the surface of the test article is not structurally altered and there is minimal disturbance of the gas flow over the surface. The strain gauges are palladium-13% chromium based and the thermocouples are platinum-13% rhodium vs. platinum. The fabrication techniques of these thin film sensors in a class 1000 cleanroom at the NASA Lewis Research Center are described. Their demonstration on a variety of engine materials, including superalloys, ceramics and advanced ceramic matrix composites, in several hostile, high-temperature test environments are discussed.

Lei, Jih-Fen↗
NASA NTRS1981

Composite structural materials

Physical properties of fiber reinforced composites; structural concepts and analysis; manufacturing; reliability; and life prediction are subjects of research conducted to determine the long term integrity of composite aircraft structures under conditions pertinent to service use. Progress is reported in (1) characterizing homogeneity in composite materials; (2) developing methods for analyzing composite materials; (3) studying fatigue in composite materials; (4) determining the temperature and moisture effects on the mechanical properties of laminates; (5) numerically analyzing moisture effects; (6) numerically analyzing the micromechanics of composite fracture; (7) constructing the 727 elevator attachment rib; (8) developing the L-1011 engine drag strut (CAPCOMP 2 program); (9) analyzing mechanical joints in composites; (10) developing computer software; and (11) processing science and technology, with emphasis on the sailplane project.

Ansell, G. S.↗
NASA NTRS1998

Key Issues for Aerospace Applications of Ceramic Matrix Composites

Ceramic matrix composites (CMC) offer significant advantages for future aerospace applications including turbine engine and liquid rocket engine components, thermal protection systems, and "hot structures". Key characteristics which establish ceramic matrix composites as attractive and often enabling choices are strength retention at high temperatures and reduced weight relative to currently used metallics. However, due to the immaturity of this class of materials which is further compounded by the lack of experience with CMC's in the aerospace industry, there are significant challenges involved in the development and implementation of ceramic matrix composites into aerospace systems. Some of the more critical challenges are attachment and load transfer methodologies; manufacturing techniques, particularly scale up to large and thick section components; operational environment resistance; damage tolerance; durability; repair techniques; reproducibility; database availability; and the lack of validated design and analysis tools. The presentation will examine the technical issues confronting the application of ceramic matrix composites to aerospace systems and identify the key material systems having potential for substantial payoff relative to the primary requirements of light weight and reduced cost for future systems. Current programs and future research opportunities will be described in the presentation which will focus on materials and processes issues.

Clinton, R. G., Jr.↗
NASA NTRS2002

Structural Health Monitoring of Composite Wound Pressure Vessels

The increasing use of advanced composite materials in the wide range of applications including Space Structures is a great impetus to the development of smart materials. Incorporating these FBG sensors for monitoring the integrity of structures during their life cycle will provide valuable information about viability of the usage of such material. The use of these sensors by surface bonding or embedding in this composite will measure internal strain and temperature, and hence the integrity of the assembled engineering structures. This paper focuses on such a structure, called a composite wound pressure vessel. This vessel was fabricated from the composite material: TRH50 (a Mitsubishi carbon fiber with a 710-ksi tensile strength and a 37 Msi modulus) impregnated with an epoxy resin from NEWPORT composites (WDE-3D-1). This epoxy resin in water dispersed system without any solvents and it cures in the 240-310 degrees F range. This is a toughened resin system specifically designed for pressure applications. These materials are a natural fit for fiber sensors since the polyimide outer buffer coating of fiber can be integrated into the polymer matrix of the composite material with negligible residual stress. The tank was wound with two helical patterns and 4 hoop wraps. The order of winding is: two hoops, two helical and two hoops. The wall thickness of the composite should be about 80 mil or less. The tank should burst near 3,000 psi or less. We can measure the actual wall thickness by ultrasonic or we can burst the tank and measure the pieces. Figure 1 shows a cylinder fabricated out of carbon-epoxy composite material. The strain in different directions is measured with a surface bonded fiber Bragg gratings and with embedded fiber Bragg gratings as the cylinder is pressurized to burst pressures. Figure 2 shows the strain as a function of pressure of carbon-epoxy cylinder as it is pressurized with water. Strain is measured in different directions by multiple gratings oriented in both axial and hoops directions.

Joseph Grant↗
NASA NTRS2013

Composite Crew Module (CCM) Permeability Characterization

In January 2007, the NASA Administrator chartered the NASA Engineering and Safety Center (NESC) to form an Agency team to design and build a composite crew module in 18 months in order to gain hands-on experience in anticipation that future exploration systems may be made of composite materials. One of the conclusions from this Composite Crew Module Primary Structure assessment was that there was a lack of understanding regarding the ability for composite pressure shells to contain consumable gases, which posed a technical risk relative to the use of a metallic design. After the completion of the Composite Crew Module test program, the test article was used in a new program to assess the overall leakage/permeability and identify specific features associated with high leak rates. This document contains the outcome of the leakage assessment.

Kirsch, Michael T.↗
NASA NTRS1991

Simplified micromechanical equations for thermal residual stress analysis of coated fiber composites

The fabrication of metal matrix composites poses unique problems to the materials engineer. The large thermal expansion coefficient (CTE) mismatch between the fiber and matrix leads to high tensile residual stresses at the fiber/matrix (F/M) interface which could lead to premature matrix cracking during cooldown. Fiber coatings could be used to reduce thermal residual stresses. A simple closed form analysis, based on a three phase composite cylinder model, was developed to calculate thermal residual stresses in a fiber/interphase/matrix system. Parametric studies showed that the tensile thermal residual stresses at the F/M interface were very sensitive to the CTE and thickness of the interphase layer. The modulus of the layer had only a moderate effect on tensile residual stresses. For a silicon carbide titanium aluminide composite, the tangential stresses were 20 to 30 pct. larger than the axial stresses, over a wide range of interphase layer properties, indicating a tendency to form radial matrix cracks during cooldown. Guidelines for the selection of appropriate material properties of the fiber coating were also derived in order to minimize thermal residual stresses in the matrix during fabrication.

Naik, R. A.↗
NASA NTRS1992

Simplified micromechanical equations for thermal residual stress analysis of coated fiber composites

The fabrication of metal matrix composites poses unique problems to the materials engineer. The large thermal expansion coefficient mismatch between the fiber and matrix leads to high tensile residual stresses at the fiber/matrix interface which could lead to premature matrix cracking during cooldown. Fiber coating could be used to reduce thermal residual stresses. A simple closed-form analysis, based on a three-phase composite cylinder model, was developed to calculate thermal residual stresses in a fiber/interface/matrix system. Guidelines, in the form of simple equations, for the selection of appropriate material properties of the fiber coating, were also derived to minimize thermal residual stresses in the matrix during fabrication.

Naik, Rajiv A.↗
NASA NTRS1999

Critical Needs for Robust and Reliable Database for Design and Manufacturing of Ceramic Matrix Composites

Ceramic matrix composite (CMC) components are being designed, fabricated, and tested for a number of high temperature, high performance applications in aerospace and ground based systems. The critical need for and the role of reliable and robust databases for the design and manufacturing of ceramic matrix composites are presented. A number of issues related to engineering design, manufacturing technologies, joining, and attachment technologies, are also discussed. Examples of various ongoing activities in the area of composite databases. designing to codes and standards, and design for manufacturing are given.

Singh, M.↗
NASA NTRSDate not supplied

Experimental Calibration of Flow Rule Coefficients for LS-Dyna Mat_213

Composite materials have become a popular choice in aerospace engineering applications due to their low weight, high specific stiffness, high specific energy absorption, and economic synthesis. As use of composite materials has proliferated, the need for accurate simulation under extreme loading conditions is of increasing importance. *MAT_213 is a tabulated plasticity and damage material model in LS-DYNA designed for such use cases. To account for the nonlinear material response, a plasticity algorithm is used, which employs a non-associative flow rule with coefficients requiring experimental calibration. This work outlines an experimental methodology for calibrating these coefficients using the macroscopic stress-strain response and microscopic in-plane strain measurements from coupon scale experiments. The model material used for the development and demonstration of this methodology is a plain weave woven fabric with T300 carbon fiber tows in the warp direction and Kevlar© 49 fiber tows in the weft direction, and an Epon© 828/Epikure© 3223 thermoset epoxy matrix. Coupon-scale tensile testing performed at multiple fiber angles (carbon fibers oriented 0º, 22.5º, 45º, 67.5º, and 90º relative to the loading axis) provides data for multiple calibration processes. The measured plastic strain increments in the principal material coordinate are used to set limits for ratios between flow rule coefficients. The identified ranges are used to bound the search for a set of coefficients, leading to convergence of different coupon responses in the effective stress – effective plastic strain space. Flow rule coefficients found by this methodology are then used as (i) input for LS-DYNA simulations of uniaxial tension coupon tests at varying fiber angles, and (ii) comparison of predicted values for the plastic Poisson’s ratio in global coordinates with the experimentally measured one for all off-axis orientations. These results are quantitatively and qualitatively compared to macroscopic stress-strain curves and experimental strain components. The conformity of the experimentally measured quantities with those derived from the simulations provide a means for assessing the quality of calibrated coefficients.

Polymer Matrix Composites↗
NASA NTRS2016

Development Status and Performance Comparisons of Environmental Barrier Coating Systems for SiCSiC Ceramic Matrix Composites

Environmental barrier coatings (EBC) and SiCSiC ceramic matrix composites (CMCs) will play a crucial role in future aircraft turbine engine systems, because of their ability to significantly increase engine operating temperatures, reduce engine weight and cooling requirements. This paper presents current NASA EBC-CMC development emphases including: the coating composition and processing improvements, laser high heat flux-thermal gradient thermo-mechanical fatigue - environmental testing methodology development, and property evaluations for next generation EBC-CMC systems. EBCs processed with various deposition techniques including Plasma Spray, Electron Beam - Physical Vapor Deposition, and Plasma Spray Physical Vapor Deposition (PS-PVD) will be particularly discussed. The testing results and demonstrations of advanced EBCs-CMCs in complex simulated engine thermal gradient cyclic fatigue, oxidizing-steam and CMAS environments will help provide insights into the coating development strategies to meet long-term engine component durability goals.

Processing and Properties↗
NASA NTRS2011

Composite Structures Materials Testing for the Orion Crew Vehicle Heat Shield

As research is being performed for the new heat shield for the Orion capsule, National Aeronautics and Space Administration (NASA) is developing the first composite heat shield. As an intern of the Structures Branch in the Engineering Directorate (ES 2), my main task was to set up a test plan to determine the material properties of the honeycomb that will be used on the Orion Crew Module heat shield to verify that the composite is suitable for the capsule. Before conducting composite shell tests, which are performed to simulate the crush performance of the heat shield on the capsule, it is necessary to determine the compression and shear properties of the composite used on the shell. During this internship, I was responsible for developing a test plan, designing parts for the test fixtures as well as getting them fabricated for the honeycomb shear and compression testing. This involved work in Pro/Engineer as well as coordinating with Fab Express, the Building 9 Composite Shop and the Structures Test Laboratory (STL). The research and work executed for this project will be used for composite sandwich panel testing in the future as well. As a part of the Structures Branch, my main focus was to research composite structures. This involves system engineering and integration (SE&I) integration, manufacturing, and preliminary testing. The procedures for these projects that were executed during this internship included design work, conducting tests and performing analysis.

Khemani, Farah N.↗
NASA NTRS1998

Damping Experiment of Spinning Composite Plates With Embedded Viscoelastic Material

One way to increase gas turbine engine blade reliability and durability is to reduce blade vibration. It is well known that vibration can be reduced by adding damping to metal and composite blade-disk systems. As part of a joint research effort of the NASA Lewis Research Center and the University of California, San Diego, the use of integral viscoelastic damping treatment to reduce the vibration of rotating composite fan blades was investigated. The objectives of this experiment were to verify the structural integrity of composite plates with viscoelastic material patches embedded between composite layers while under large steady forces from spinning, and to measure the damping and natural frequency variation with rotational speed.

Mehmed, Oral↗
NASA NTRS1991

Lessons learned for composite structures

Lessons learned for composite structures are presented in three technology areas: materials, manufacturing, and design. In addition, future challenges for composite structures are presented. Composite materials have long gestation periods from the developmental stage to fully matured production status. Many examples exist of unsuccessful attempts to accelerate this gestation period. Experience has shown that technology transition of a new material system to fully matured production status is time consuming, involves risk, is expensive and should not be undertaken lightly. The future challenges for composite materials require an intensification of the science based approach to material development, extension of the vendor/customer interaction process to include all engineering disciplines of the end user, reduced material costs because they are a significant factor in overall part cost, and improved batch-to-batch pre-preg physical property control. Historical manufacturing lessons learned are presented using current in-service production structure as examples. Most producibility problems for these structures can be traced to their sequential engineering design. This caused an excessive emphasis on design-to-weight and schedule at the expense of design-to-cost. This resulted in expensive performance originated designs, which required costly tooling and led to non-producible parts. Historically these problems have been allowed to persist throughout the production run. The current/future approach for the production of affordable composite structures mandates concurrent engineering design where equal emphasis is placed on product and process design. Design for simplified assembly is also emphasized, since assembly costs account for a major portion of total airframe costs. The future challenge for composite manufacturing is, therefore, to utilize concurrent engineering in conjunction with automated manufacturing techniques to build affordable composite structures. Composite design experience has shown that significant weight savings have been achieved, outstanding fatigue and corrosion resistance have been demonstrated, and in-service performance has been very successful. Currently no structural design show stoppers exist for composite structures. A major lesson learned is that the full scale static test is the key test for composites, since it is the primary structural 'hot spot' indicator. The major durability issue is supportability of thin skinned structure. Impact damage has been identified as the most significant issue for the damage tolerance control of composite structures. However, delaminations induced during assembly operations have demonstrated a significant nuisance value. The future challenges for composite structures are threefold. Firstly, composite airframe weight fraction should increase to 60 percent. At the same time, the cost of composite structures must be reduced by 50 percent to attain the goal of affordability. To support these challenges it is essential to develop lower cost materials and processes.

Whitehead, R. S.↗