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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Phase Stability and Thermal Conductivity of Composite Environmental Barrier Coatings on SiC/SiC Ceramic Matrix Composites

Advanced environmental barrier coatings are being developed to protect SiC/SiC ceramic matrix composites in harsh combustion environments. The current coating development emphasis has been placed on the significantly improved cyclic durability and combustion environment stability in high-heat-flux and high velocity gas turbine engine environments. Environmental barrier coating systems based on hafnia (HfO2) and ytterbium silicate, HfO2-Si nano-composite bond coat systems have been processed and their stability and thermal conductivity behavior have been evaluated in simulated turbine environments. The incorporation of Silicon Carbide Nanotubes (SiCNT) into high stability (HfO2) and/or HfO2-silicon composite bond coats, along with ZrO2, HfO2 and rare earth silicate composite top coat systems, showed promise as excellent environmental barriers to protect the SiC/SiC ceramic matrix composites.

Benkel, Samantha↗
NASA NTRS2011

Characterization of the as Manufactured Variability in a CVI SiC/SiC Woven Composite

The microstructure of a 2D woven ceramic matrix composite displays significant variability and irregularity. For example, a chemical vapor infiltrated (CVI) SiC/SiC composite exhibits significant amount of porosity arranged in irregular patterns. Furthermore, the fiber tows within a ply frequently have irregular shape and spacing, and the stacked plies are often misaligned and irregularly nested within each other. The goal of an ongoing project at NASA Glenn is to investigate the effects of the complex microstructure and its variability on the properties and the durability of the material. One key requirement for this effort is the development of methods to characterize the distribution in as-fabricated ceramic matrix composite (CMC) microstructures with the objective of correlating microstructural distribution parameters with mechanical performance. An initial task in this effort was to perform quantitative image analysis of polished cross sections of CVI SiC/SiC composite specimens. This analysis provided sample distributions of various microstructural composite features, including: inter-tow pore sizes and shapes, transverse sectioned tow sizes and shapes, and within ply tow spacing. This information can then be used to quantify the effect of extreme values of these features on the local stress state with the goal of determining the likelihood of matrix cracking at a given external load.

Bonacuse, Peter J.↗
NASA NTRS2009

Architectural Effects on Impact Resistance of Uncoated MI SiC/SiC Composites

Impact tests were conducted on uncoated 2D and 2.5D MI SiC/SiC composite specimens at room temperature and 1316 C in air. The specimens were analyzed before and after impact using optical microscopy, pulsed thermography (PT) and computed tomography (CT). Preliminary results indicate the following. Both 2-D and 2.5D composites show increase in surface and volumetric damages with increasing impact velocity. However, 2-D composites are prone to delamination cracks. In both 2D and 2.5D composites, the magnitude of impact damage at a fixed impact velocity is slightly greater at room temperature than at 1315 C. At a fixed projectile velocity and test temperature, the depth of penetration of the projectile into the substrate is significantly lower in 2.5D composites than in 2D composites. Fiber architecture plays a significant role controlling impact damage in MI SiC/SiC composites.

Bhatt, R. T.↗
NASA NTRS2009

Electrical Resistance of SiC/SiC Ceramic Matrix Composites for Damage Detection and Life-Prediction

Ceramic matrix composites (CMC) are suitable for high temperature structural applications such as turbine airfoils and hypersonic thermal protection systems due to their low density high thermal conductivity. The employment of these materials in such applications is limited by the ability to accurately monitor and predict damage evolution. Current nondestructive methods such as ultrasound, x-ray, and thermal imaging are limited in their ability to quantify small scale, transverse, in-plane, matrix cracks developed over long-time creep and fatigue conditions. CMC is a multifunctional material in which the damage is coupled with the material s electrical resistance, providing the possibility of real-time information about the damage state through monitoring of resistance. Here, resistance measurement of SiC/SiC composites under mechanical load at both room temperature monotonic and high temperature creep conditions, coupled with a modal acoustic emission technique, can relate the effects of temperature, strain, matrix cracks, fiber breaks, and oxidation to the change in electrical resistance. A multiscale model can in turn be developed for life prediction of in-service composites, based on electrical resistance methods. Results of tensile mechanical testing of SiC/SiC composites at room and high temperatures will be discussed. Data relating electrical resistivity to composite constituent content, fiber architecture, temperature, matrix crack formation, and oxidation will be explained, along with progress in modeling such properties.

Smith, Craig↗
NASA NTRS2015

Mechanical Properties and Real-Time Damage Evaluations of Environmental Barrier Coated SiC/SiC CMCs Subjected to Tensile Loading Under Thermal Gradients

SiC/SiC ceramic matrix composites (CMCs) require new state-of-the art environmental barrier coatings (EBCs) to withstand increased temperature requirements and high velocity combustion corrosive combustion gasses. The present work compares the response of coated and uncoated SiC/SiC CMC substrates subjected to simulated engine environments followed by high temperature mechanical testing to asses retained properties and damage mechanisms. Our focus is to explore the capabilities of electrical resistance (ER) measurements as an NDE technique for testing of retained properties under combined high heat-flux and mechanical loading conditions. Furthermore, Acoustic Emission (AE) measurements and Digital Image Correlation (DIC) were performed to determine material damage onset and accumulation.

Ceramic matrix composites↗
NASA NTRS2017

Creep/Stress Rupture Behavior of 3D Woven SiC/SiC Composites with Sylramic-iBN, Super Sylramic-iBN and Hi-Nicalon-S Fibers at 2700F in Air

To determine the influence of fiber types on creep durability, 3D SiC/SiC CMCs were fabricated with Sylramic-iBN, super Sylramic-iBN and Hi-Nicalon-S fibers and the composite specimens were then tested under isothermal tensile creep at 14820C at 69, 103 and 138 MPa for up to 300hrs in air. The failed specimens were examined by scanning electron microscopy (SEM) and computed tomography (CT) for fracture mode analysis. The creep data of these composites are compared with those of other SiC/SiC composites in the literature. The results of this study will be presented.

failure modes↗
NASA NTRS2017

Cyclic Fatigue Durability of Uncoated and EBC Coated 3D SiC/SiC Composites Under Thermal Gradient Conditions at 2700F in Air

Ceramic matrix composites (CMCs) such as SiC/SiC are currently being designed and implemented in high temperature sections of aerospace turbine engines. Such components will be subject to through-thickness thermal gradients, which may affect the durability. In this study, SiC/SiC CMCs with a hybrid chemical vapor infiltrated (CVI) and polymer infiltration and pyrolysis (PIP) matrix were loaded in tension while one surface was heated with a laser and the opposite surface was cooled. Issues associated with laser testing will be discussed, along with initial results for coated and uncoated samples.

Ceramic matrix composite↗
NASA NTRS2017

Development of Advanced Environmental Barrier Coatings for SiC/SiC Composites at NASA GRC: Prime-Reliant Design and Durability Perspectives

Environmental barrier coatings (EBCs) are considered technologically important because of the critical needs and their ability to effectively protect the turbine hot-section SiC/SiC ceramic matrix composite (CMC) components in harsh engine combustion environments. The development of NASA's advanced environmental barrier coatings have been aimed at significantly improved the coating system temperature capability, stability, erosion-impact, and CMAS resistance for SiC/SiC turbine airfoil and combustors component applications. The NASA environmental barrier coating developments have also emphasized thermo-mechanical creep and fatigue resistance in simulated engine heat flux and environments. Experimental results and models for advanced EBC systems will be presented to help establishing advanced EBC composition design methodologies, performance modeling and life predictions, for achieving prime-reliant, durable environmental coating systems for 2700-3000 F engine component applications. Major technical barriers in developing environmental barrier coating systems and the coating integration with next generation composites having further improved temperature capability, environmental stability, EBC-CMC fatigue-environment system durability will be discussed.

Environmental barrier coatings (EBCs)↗
NASA NTRS2018

Aerospace Ceramic Materials: Thermal, Environmental Barrier Coatings and SiC/SiC Ceramic Matrix Composites for Turbine Engine Applications

Ceramic materials play increasingly important roles in aerospace applications because ceramics have unique properties, including high temperature capability, high stiffness and strengths, excellent oxidation and corrosion resistance. Ceramic materials also generally have lower densities as compared to metallic materials, making them excellent candidates for light-weight hot-section components of aircraft turbine engines, rocket exhaust nozzles, and thermal protection systems for space vehicles when they are being used for high-temperature and ultra-high temperature ceramics applications. Ceramic matrix composites (CMCs), including non-oxide and oxide CMCs, are also recently being incorporated in gas turbine engines for high pressure and high temperature section components and exhaust nozzles. However, the complexity and variability of aerospace ceramic processing methods, compositions and microstructures, the relatively low fracture toughness of the ceramic materials, still remain the challenging factors for ceramic component design, validation, life prediction, and thus broader applications. This ceramic material section paper presents an overview of aerospace ceramic materials and their characteristics. A particular emphasis has been placed on high technology level (TRL) enabling ceramic systems, that is, turbine engine thermal and environmental barrier coating systems and non-oxide type SiC/SiC CMCs. The current status and future trend of thermal and environmental barrier coatings and SiC/SiC CMC development and applications are described.

Thermal Barrier Coatings↗
NASA NTRS2020

Characterization of SiC/SiC Composites Subjected to Sequential Tensile Creep and Dwell Fatigue in Air under Thermal Gradient Conditions

Uncoated SiC/SiC composites, with 2D and 3D fiber architectures, were investigated under steady state thermal gradient conditions with sequential tensile creep and dwell fatigue. Melt infiltration (MI), chemical vapor infiltration (CVI), polymer impregnation and pyrolysis (PIP), and hybrid (CVI and PIP) techniques were used to fabricate ceramic matrix composites (CMCs) with a 2D balanced fiber architecture. CMCs with 3D fiber weaves were also fabricated using MI and hybrid methods. Steady state through the thickness thermal gradients were generated for the tensile specimens using laser heating on the front (hot side) and forced air cooling on the back (cold side). Hot side and cold side temperatures of 2400 and 2200 °F, respectively, were used for testing CMCs fabricated with the MI process, whereas hot side and cold side temperatures of 2700 and 2400 °F, respectively, were used for CMCs fabricated with CVI, PIP, and hybrid processes. Each CMC specimen was initially tested under tensile creep at 69 MPa (10 ksi) for 80 hours, which was then followed by tensile dwell fatigue testing at a maximum stress of 69 MPa (10 ksi) for another 80 hours for a total of 160 hours. This type of sequential tensile creep followed by tensile dwell fatigue testing was performed to ascertain the integrity of uncoated CMCs under steady state thermal gradient conditions. Tensile creep and dwell fatigue test results, generated under steady state thermal gradient conditions on different types of SiC/SiC composites, are compared with corresponding creep behaviors observed under isothermal conditions to determine the influence of both monotonic creep (static fatigue) and dwell fatigue on accumulated strains and deformation behaviors of the CMCs.

Kalluri, Sreeramesh↗
NASA NTRSDate not supplied

Synchrotron Tomography of SiC/SiC Minicomposites to Observe and Quantify Damage Evolution

Composite performance is dictated by its microstructure – property relationships. For example, the characteristic response of ceramic matrix composites (CMCs) depends on the distribution of its constituents (i.e. fibers, matrix, fiber coatings, matrix cracks, and voids). Micro x-ray computed tomography (micro-CT) provides an opportunity to characterize the distribution of these constituents and to quantify the CMC microstructure in three-dimensions. To this end, In-situ micro-CT was performed at the Advanced Light Source (ALS) in combination with uniaxial tensile testing on SiC/SiC minicomposites. This work will describe the tensile load-dependent damage evolution within the microstructure of the SiC/SiC CMC specimens. The results from the micro-CT datasets can be used to develop micromechanical models that effectively capture damage initiation and progression in CMCs. In addition, details regarding the segmentation tools and techniques employed to understand and quantify these large tomography datasets will be presented.

Ashley Hilmas↗
NASA NTRSDate not supplied

Effects of Cooling Holes on SiC/SiC Strength and Durability

Ceramic Matrix Composites (CMCs) such as SiC/SiC are currently operating in select high temperature components of turbine engines. When these materials are implemented in components at higher operating temperatures, film cooling may be necessary. Film cooling requires holes to be fabricated at appropriate locations within these components. This study examines the effect of cooling holes on SiC/SiC composite strength and durability. Mechanical test data on specimens with multiple holes is reported for isothermal conditions at room and elevated temperatures. Tools such as Digital Image Correlation (DIC) and Acoustic Emission (AE) are used to monitor strain and cracking upon loading.

Ceramic matrix composite↗
DOE OSTI2025

Formation of Composite SiC/SiC Joints by Embedded Wire Chemical Vapor Deposition

The joining of ceramic monoliths or composites to date has primarily been limited to the formation of brittle monolithic joints using heterogeneous (dissimilar) materials, similar to brazing in metals. The development of a damage-tolerant joint layer by SiC fiber reinforcements is demonstrated here. Tube workpieces made of SiC fiber-SiC matrix composite are joined using a nonwoven SiC fiber mat densified by embedded wire chemical vapor deposition (EWCVD), creating a fiber-reinforced weld-like joint by homogeneous joining. EWCVD uses a localized heating method to target deposition and growth to the joint region specifically, while minimizing thermal damage to the surrounding composite tube material. X-ray computed tomography (XCT) is used to nondestructively characterize as-made joints for relative density, adhesion, and composition. In situ XCT analysis during mechanical testing revealed crack deflections in the bonding layer, which indicates a toughening mechanism typical of ceramic matrix composite phase. Gas permeation testing of these proof-of-concept composite joints identified relatively high leak rates in comparison to fully coated SiC/SiC composite tube workpieces. In conclusion, the novelty of the composite joining method and current technology challenges, including gas permeability, are discussed in comparison with traditional ceramic joints and materials.

SiC↗
NASA NTRS1997

An Investigation of SiC/SiC Woven Composite Under Monotonic and Cyclic Loading

The desirable properties in ceramic matrix composites (CMCs), such as high temperature strength, corrosion resistance, high toughness, low density, or good creep resistance have led to increased use of CMCs in high-speed engine structural components and structures that operate in extreme temperature and hostile aero-thermo-chemical environments. Ceramic matrix composites have been chosen for turbine material in the design of 21 st-century civil propulsion systems to achieve high fuel economy, improved reliability, extended life, and reduced cost. Most commercial CMCs are manufactured using a chemical vapor infiltration (CVI) process. However, a lower cost fabrication known as melt-infiltration process is also providing CMCs marked for use in hot sections of high-speed civil transports. The scope of this paper is to report on the material and mechanical characterization of the CMCs subjected to this process and to predict the behavior through an analytical model. An investigation of the SiC/SiC 8-harness woven composite is ongoing and its tensile strength and fatigue behavior is being characterized for room and elevated temperatures. The investigation is being conducted at below and above the matrix cracking stress once these parameters are identified. Fractography and light microscopy results are being studied to characterize the failure modes resulting from pure uniaxial loading. A numerical model is also being developed to predict the laminate properties by using the constituent material properties and tow undulation.

Lang, J.↗
NASA NTRS1999

SiC/SiC Leading Edge Turbine Airfoil Tested Under Simulated Gas Turbine Conditions

Silicon-based ceramics have been proposed as component materials for use in gas turbine engine hot-sections. A high pressure burner rig was used to expose both a baseline metal airfoil and ceramic matrix composite leading edge airfoil to typical gas turbine conditions to comparatively evaluate the material response at high temperatures. To eliminate many of the concerns related to an entirely ceramic, rotating airfoil, this study has focused on equipping a stationary metal airfoil with a ceramic leading edge insert to demonstrate the feasibility and benefits of such a configuration. Here, the idea was to allow the SiC/SiC composite to be integrated as the airfoil's leading edge, operating in a "free-floating" or unrestrained manner. and provide temperature relief to the metal blade underneath. The test included cycling the airfoils between simulated idle, lift, and cruise flight conditions. In addition, the airfoils were air-cooled, uniquely instrumented, and exposed to the same internal and external conditions, which included gas temperatures in excess of 1370 C (2500 F). Results show the leading edge insert remained structurally intact after 200 simulated flight cycles with only a slightly oxidized surface. The instrumentation clearly suggested a significant reduction (approximately 600 F) in internal metal temperatures as a result of the ceramic leading edge. The object of this testing was to validate the design and analysis done by Materials Research and Design of Rosemont, PA and to determine the feasibility of this design for the intended application.

Robinson, R. Craig↗
NASA NTRS2001

Thermal Conductivity and Thermal Gradient Cyclic Behavior of Refractory Silicate Coatings on SiC/SiC Ceramic Matrix Composites

Plasma-sprayed mullite and BSAS coatings have been developed to protect SiC/SiC ceramic matrix composites from high temperature environmental attack. In this study, thermal conductivity and thermal barrier functions of these coating systems are evaluated using a laser high-heat-flux test rig. The effects of water vapor on coating thermal conductivity and durability are studied by using alternating furnace and laser thermal gradient cyclic tests. The influence of laser high thermal-gradient cycling on coating failure modes is also investigated.

Zhu, Dongming↗
NASA NTRS2002

RQL Sector Rig Testing of SiC/SiC Combustor Liners

Combustor liners, manufactured from silicon carbide fiber-reinforced silicon carbide (SiC/SiC) were tested for 260 hr using a simulated gas turbine engine cycle. This report documents the results of the last 56 hr of testing. Damage occurred in one of the six different components that make up the combustor liner set, the rich zone liner. Cracks in the rich zone liner initiated at the leading edge due to stresses resulting from the component attachment configuration. Thin film thermocouples and fiber optic pyrometers were used to measure the rich zone liner's temperature and these results are reported.

Verrilli, Michael J.↗