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NASA NTRS2000

Mesoscopic Nonlinear Elastic Modulus of Thermal Barrier Coatings Determined by Cylindrical Punch Indentation

Cylindrical punch indentations are performed to determine the effective modulus of a plasma-sprayed ZrO2-8Wt%Y2O3 thermal barrier coating (TBC) as a function of coating depth. Cylindrical punch indentations offer significant advantages over pointed (Vickers, Berkovich, or Knoop) indentations for materials that do not exhibit linear elastic behavior. Cyclic loading with a cylindrical punch clearly shows the TBCs to exhibit nonlinear elastic behavior with significant hysteresis that is related to the compaction and internal sliding within the plasma-spray splat microstructure. In addition, the effect of a high heat flux laser treatment was shown to produce a gradient both in the effective TBC modulus and degree of loading/unloading hysteresis with depth.

Eldridge, Jeffrey I.↗

NASA NTRS2001

Higher-Order Theory for Functionally Graded Materials

Functionally graded materials (FGM's) are a new generation of engineered materials wherein the microstructural details are spatially varied through nonuniform distribution of the reinforcement phase(s). Engineers accomplish this by using reinforcements with different properties, sizes, and shapes, as well as by interchanging the roles of the reinforcement and matrix phases in a continuous manner (ref. 1). The result is a microstructure that produces continuously or discretely changing thermal and mechanical properties at the macroscopic or continuum scale. This new concept of engineering the material's microstructure marks the beginning of a revolution both in the materials science and mechanics of materials areas since it allows one, for the first time, to fully integrate the material and structural considerations into the final design of structural components. Functionally graded materials are ideal candidates for applications involving severe thermal gradients, ranging from thermal structures in advanced aircraft and aerospace engines to computer circuit boards. Owing to the many variables that control the design of functionally graded microstructures, full exploitation of the FGM's potential requires the development of appropriate modeling strategies for their response to combined thermomechanical loads. Previously, most computational strategies for the response of FGM's did not explicitly couple the material's heterogeneous microstructure with the structural global analysis. Rather, local effective or macroscopic properties at a given point within the FGM were first obtained through homogenization based on a chosen micromechanics scheme and then subsequently used in a global thermomechanical analysis.

Aboudi, J.↗

NASA NTRS2016

Evaluation of the MICAST #2-12 AI-7wt%Si Sample Directionally Solidified Aboard the International Space Station

The US team of the European led "MIcrostructure Formation in CASTing of Technical Alloys under Diffusive and Magnetically Controlled Convective Conditions" (MICAST) program recently received a third Aluminum - 7wt% silicon alloy that was processed in the microgravity environment aboard the International Space Station. The sample, designated MICAST#2-12, was directionally solidified in the Solidification with Quench Furnace (SQF) at a constant rate of 40micometers/s through an imposed temperature gradient of 31K/cm. Procedures taken to evaluate the state of the sample prior to sectioning for metallographic analysis are reviewed and rational for measuring the microstructural constituents, in particular the primary dendrite arm spacing (Lambda (sub1)), is given. The data are presented, put in context with the earlier samples, and evaluated in view of a relevant theoretical model.

Tewari, Surendra N.↗

NASA NTRS1984

NDE for heat engine ceramics

Radiographic, ultrasonic, and scanning laser acoustic microscopy (SLAM) techniques were used to characterize silicon nitride and silicon carbide MOR bars in various stages of fabrication. Conventional and microfocus x-ray techniques were found capable of detecting minute high density inclusions in as-received powders, green compacts, and fully densified specimens. Significant density gradients in sintered bars were observed by radiography, ultrasonic velocity, and SLAM. Ultrasonic attenuation was found sensitive to microstructural variations due to grain and void morphology and distribution. SLAM was also capable of detecting voids, inclusions, and cracks in finished test bars. It was determined that thermoacoustic microscopy techniques have promise for application to green and densified ceramics.

Klima, S. J.↗

NASA NTRS1986

NDE of structural ceramics

Radiographic, ultrasonic, scanning laser acoustic microscopy (SLAM), and thermo-acoustic microscopy techniques were used to characterize silicon nitride and silicon carbide modulus-of-rupture test specimens in various stages of fabrication. Conventional and microfocus X-ray techniques were found capable of detecting minute high density inclusions in as-received powders, green compacts, and fully densified specimens. Significant density gradients in sintered bars were observed by radiography, ultrasonic velocity, and SLAM. Ultrasonic attenuation was found sensitive to microstructural variations due to grain and void morphology and distribution. SLAM was also capable of detecting voids, inclusions and cracks in finished test bars. Consideration is given to the potential for applying thermo-acoustic microscopy techniques to green and densified ceramics. The detection probability statistics and some limitations of radiography and SLAM also are discussed.

Klima, S. J.↗

NASA NTRS1986

NDE of advanced ceramics

Radiographic, ultrasonic, and scanning laser acoustic microscopy (SLAM) techniques were used to characterize silicon nitride and silicon carbide modulus-of-rupture test specimens in various stages of fabrication. Conventional and microfocus X-ray techniques were found capable of detecting minute high-density inclusions in as-received powders, green compacts, and fully densified specimens. Significant density gradients in sintered bars were observed by radiography, ultrasonic velocity, and SLAM. Ultrasonic attenuation was found sensitive to microstructural variations due to grain and void morphology and distribution. SLAM was capable also of detecting voids, inclusions, and cracks in finished test bars. Consideration is given to the potential for applying thermoacoustic microscopy techniques to green and densified ceramics. Some limitations and the detection probability statistics of the aforementioned nondestructive evaluation (NDE) processes are also discussed.

Klima, S. J.↗

NASA NTRS1986

NDE of structural ceramics

Klima, S. J.↗

NASA NTRS1993

Establishing the relationship between manufacturing and component performance in stretch formed thermoplastic composites

Flexible manufacturing methods are needed to reduce the cost of using advanced composites in structural applications. One method that allows for this is the stretch forming of long discontinuous fiber materials with thermoplastic matrices. In order to exploit this flexibility in an economical way, a thorough understanding of the relationship between manufacturing and component performance must be developed. This paper reviews some of the recent work geared toward establishing this understanding. Micromechanics models have been developed to predict the formability of the material during processing. The latest improvement of these models includes the viscoelastic nature of the matrix and comparison with experimental data. A finite element scheme is described which can be used to model the forming process. This model uses equivalent anisotropic viscosities from the micromechanics models and predicts the microstructure in the formed part. In addition, structural models have been built to account for the material property gradients that can result from the manufacturing procedures. Recent developments in this area include the analysis of stress concentrations and a failure model each accounting for the heterogeneous material fields.

Santare, Michael H.↗

NASA NTRS1994

Thermal analysis of a functionally graded material subject to a thermal gradient using the boundary element method

The boundary element method is utilized in this study to conduct thermal analysis of functionally graded composites, materials in which the internal microstructure or properties are explicitly tailored in order to obtain an optimal response, on the micromechanical (constituent) scale. A unique feature of the boundary element formulations used here is the use of circular shape functions to convert the two-dimensional integrations of the composite fibers to one dimensional integrations. Using the computer code BEST-CMS, the through the thickness temperature profiles are computed for a representative material with varying numbers of fibers and fiber spacing in the thickness direction. The computed temperature profiles are compared to those obtained using an alternate analytical theory which explicitly couples the heterogeneous microstructure to the global analysis. The boundary element results compared favorably to the analytical calculations, with discrepancies that are explainable based on the boundary element formulation. The results serve both to demonstrate the ability of the boundary element method to analyze these types of materials, and to verify the accuracy of the analytical theory.

Goldberg, Robert K.↗

NASA NTRS1992

Influence of convection on microstructure

The primary motivation for this research has been to determine the cause for space processing altering the microstructure of some eutectics, especially the MnBi-Bi eutectic. Prior experimental research at Grumman and here showed that the microstructure of MnBi-Bi eutectic is twice as fine when solidified in space or in a magnetic field, is uninfluenced by interfacial temperature gradient, adjusts very quickly to changes in freezing rate, and becomes coarser when spin-up/spin-down (accelerated crucible rotation technique) is used during solidification. Theoretical work at Clarkson predicted that buoyancy driven convection on earth could not account for the two fold change in fiber spacing caused by solidification in space. However, a lamellar structure with a planar interface was assumed, and the Soret effect was not included in the analysis. Experimental work at Clarkson showed that the interface is not planar, and that MnBi fibers project out in front of the Bi matrix on the order of one fiber diameter. Originally four primary hypotheses were to be tested under this current grant: (1) a fibrous microstructure is much more sensitive to convection than a lamellar microstructure, which was assumed in our prior theoretical treatment; (2) an interface with one phase projecting out into the melt is much more sensitive to convection than a planar interface, which was assumed in our prior theoretical treatment; (3) the Soret effect is much more important in the absence of convection and has a sufficiently large influence on microstructure that its action can explain the flight results; and (4) the microstructure is much more sensitive to convection when the composition of the bulk melt is off eutectic. As reported previously, we have learned that while a fibrous microstructure and a non-planar interface are more sensitive to convection than a lamellar microstructure with a planar interface, the influence of convection remains too small to explain the flight and magnetic field results. Similarly addition of the Soret effect does not explain the flight and magnetic field results.

Wilcox, William R.↗

NASA NTRS1992

NASA-UVA light aerospace alloy and structures technology program (LA(sup 2)ST)

The general objective of the Light Aerospace Alloy and Structures Technology (LA(sup 2)ST) Program is to conduct interdisciplinary graduate student research on the performance of next generation, light weight aerospace alloys, composites, and thermal gradient structures in collaboration with Langley researchers. Specific technical objectives are established for each research project. We aim to produce relevant data and basic understanding of material behavior and microstructure, new monolithic and composite alloys, advanced processing methods, new solid and fluid mechanics analyses, measurement advances, and critically, a pool of educated graduate students for aerospace technologies. Four research areas are being actively investigated, including: (1) Mechanical and Environmental Degradation Mechanisms in Advanced Light Metals and Composites; (2) Aerospace Materials Science; (3) Mechanics of Materials and Composites for Aerospace Structures; and (4) Thermal Gradient Structures.

Gangloff, Richard P.↗

NASA NTRSDate not supplied

Disorder to Order in Interface Patterns: Thermal Noise to Limit Cycle Transition in Dendrite Sidebranch Formation

Thin sample directional solidification experiments have been carried out in the model succinonitrile-camphor system to examine the origin of secondary branches in dendrite morphologies. Thermal noise at the dendrite tip creates interface instabilities which amplify to form sidebranches. This is accepted as the primary mode of sidebranching in dendritic growth from an undercooled melt and occurs in directional solidification of dendrites. The proposed limit cycle couples the growth of the tip with the initiation of the sidebranch. Directional solidification of curved interfaces is a driven dissipative system with the potential to form a limit cycle. Two sets of experiments were performed, the first holding velocity constant and evolving the gradient and the second imposing oscillating velocities around the natural period of sidebranching. Both experimental methods were found to characterize a transition from disordered sidebranching induced by thermal noise to ordered sidebranching produced by the limit cycle mechanisms. This is the first quantitative measurement of previously hypothesized limit cycle growth. These experiment sets have been quantitatively analyzed for dynamic behavior seen in limit cycles. High-quality data sets of the tip and instability enable the measurement of the FFT and analysis through a power spectrum. At low gradients, the sidebranches are found to be excited by thermal noise far away from the tip. As the gradient increases and velocity is held constant, the distance between the instability and tip decreases until limit cycle growth is found between the tip of the primary dendrite and the first forming sidebranch. An alternative to the deterministic limit cycles seen in experiments of gradient evolution is a limit cycle actively driven through the square wave oscillation of velocity. Crucial observations of the solidified microstructure conclude that this produced periodic interconnected bridges between the primary dendrites. This is a finding with potentially significant implications for commercial applications.

Trevor Lyons↗

NASA NTRS1990

Influence of convection on microstructure

In eutectic growth, as the solid phases grow they reject atoms to the liquid. This results in a variation of melt composition along the solid/liquid interface. In the past, mass transfer in eutectic solidification, in the absence of convection, was considered to be governed only by the diffusion induced by compositional gradients. However, mass transfer can also be generated by a temperature gradient. This is called thermotransport, thermomigration, thermal diffusion or the Soret effect. A theoretical model of the influence of the Soret effect on the growth of eutectic alloys is presented. A differential equation describing the compositional field near the interface during unidirectional solidification of a binary eutectic alloy was formulated by including the contributions of both compositional and thermal gradients in the liquid. A steady-state solution of the differential equation was obtained by applying appropriate boundary conditions and accounting for heat flow in the melt. Following that, the average interfacial composition was converted to a variation of undercooling at the interface, and consequently to microstructural parameters. The results obtained show that thermotransport can, under certain circumstances, be a parameter of paramount importance.

Wilcox, William R.↗

NASA NTRS1992

NASA-UVA light aerospace alloy and structures technology program (LA2ST)

The NASA-UVa Light Aerospace Alloy and Structure Technology (LAST) Program continues to maintain a high level of activity, with projects being conducted by graduate students and faculty advisors in the Departments of Materials Science and Engineering, Civil Engineering and Applied Mechanics, and Mechanical and Aerospace Engineering at the University of Virginia. This work is funded by the NASA-Langley Research Center under Grant NAG-1-745. Here, we report on progress achieved between January 1 and June 30, 1992. The objectives of the LA2ST Program is to conduct interdisciplinary graduate student research on the performance of the next generation, light weight aerospace alloys, composites and thermal gradient structures in collaboration with Langley researchers. Technical objectives are established for each research project. We aim to produce relevant data and basic understanding of material mechanical response, corrosion behavior, and microstructure; new monolithic and composite alloys; advanced processing methods; new solid and fluid mechanics analyses; measurement advances; and critically, a pool of educated graduate students for aerospace technologies. The accomplishments presented in this report cover topics including: (1) Mechanical and Environmental Degradation Mechanisms in Advance Light Metals and Composites; (2) Aerospace Materials Science; (3) Mechanics of Materials and Composites for Aerospace Structures; and (4) Thermal Gradient Structures.

Gangloff, Richard P.↗

NASA NTRS2012

ISS-Experiments of Columnar-to-Equiaxed Transition in Solidification Processing

The main topic of the research project CETSOL in the framework of the Microgravity Application Promotion (MAP) programme of the European Space Agency (ESA) is the investigation of the transition from columnar to equiaxed grain growth during solidification. Microgravity environment allows for suppression of buoyancy-driven melt flow and for growth of equiaxed grains free of sedimentation and buoyancy effects. This contribution will present first experimental results obtained in microgravity using hypo-eutectic AlSi alloys in the Materials Science Laboratory (MSL) on-board the International Space Station (ISS). The analysis of the experiments confirms the existence of a columnar to equiaxed transition, especially in the refined alloy. Temperature evolution and grain structure analysis provide critical values for the position, the temperature gradient and the solidification velocity at the columnar to equiaxed transition. These data will be used to improve modeling of solidification microstructures and grain structure on different lengths scales.

Sturz, Laszlo↗

NASA NTRS1986

Directional solidification and characterization of near eutectic Sm2CO17/Co alloys

The effects of directional solidification processing on the microstructural, compositional, and magnetic properties of near eutectic Co-Sm alloys (about 9 at. pct Sm) have been studied. Initial investigations have been performed at modest thermal gradients in the liquid, G(L) less than 60 C/cm and over a range of furnace (solidification) velocities, V = 0.8 45.4 cm/h. The primary dendrite spacing for near eutectic Sm2Co17/Co scaled with 1/sq rt V and varied from about 50 microns for V greater than or equal to 20 cm/h to hundreds of microns for V less than 10 cm/h, while the rod eutectic diameter and interrod spacing were an order of magnitude smaller. For both dendritic and cooperative growth, the associated permanent magnet properties were rather poor, e.g., remanence less than 4 kG and coercive force less than 1 kOe for the smallest dendrite and rod diameter dimensions encountered, although the magnetic hardness for the rod eutetic was larger than for the dendritic microstructure. Magnetization as a function of sample orientation indicated that the easy axis of magnetization was primarily along the direction of solidification for both ferromagnetic phases.

Pirich, Ronald G.↗

NASA NTRSDate not supplied

Comparison of In-situ Near Infrared Melt Pool Imagery to Optical Microscopy Measurements

Additive manufacturing (AM) is a rapidly growing technology. An area of major importance is the integrity and repeatability of AM parts. The goal is to reduce obstacles to certify AM built parts to allow for use in critical aerospace applications. In-situ nondestructive evaluation sensors can be used for build assessment and can potentially play a key role in certifying AM parts. For example, melt pool features are understood to have a strong correlation to microstructural defects and the use of a near infrared (NIR) camera can be used to record the melt pool, cooling areas, and temperature gradients during the build. This work explores the use of a low cost NIR camera to obtain single line track imagery of the Ti-6Al-4V melt pools for various processing parameters. The NIR camera is radiometrically calibrated and configured in-line with the laser source to obtain high resolution imagery of the melt pool shape and dynamics. The challenge to measure melt pool shapes is to identify the transition points between the metal solid to liquid phase. Factors for melt pool measurements such as thermal camera pixel resolution, surface emissivity, and blurring due to the laser beam movement are discussed. Lastly, the melt pool imagery are compared to optical microscopy measurements for validation.

additive manufacturing↗

NASA NTRS1980

The microstructure of MnBi/Bi eutectic alloys

Directionally solidified eutectic alloys of the system MnBi/Bi have been investigated with reference to the dependence of the fiber spacing on the growth rate and the interfacial temperature gradient. It is found that the fiber spacing varies as the inverse square root of the growth rate and does not depend on the temperature gradient in contrast to the claims that all faceted/non-faceted eutectics should show a temperature gradient influence.

Ravishankar, P. S.↗