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NASA NTRS2000

Directionally Solidified NiAl-Based Alloys Studied for Improved Elevated-Temperature Strength and Room-Temperature Fracture Toughness

Efforts are underway to replace superalloys used in the hot sections of gas turbine engines with materials possessing better mechanical and physical properties. Alloys based on the intermetallic NiAl have demonstrated potential; however, they generally suffer from low fracture resistance (toughness) at room temperature and from poor strength at elevated temperatures. Directional solidification of NiAl alloyed with both Cr and Mo has yielded materials with useful toughness and elevated-temperature strength values. The intermetallic alloy NiAl has been proposed as an advanced material to extend the maximum operational temperature of gas turbine engines by several hundred degrees centigrade. This intermetallic alloy displays a lower density (approximately 30-percent less) and a higher thermal conductivity (4 to 8 times greater) than conventional superalloys as well as good high-temperature oxidation resistance. Unfortunately, unalloyed NiAl has poor elevated temperature strength (approximately 50 MPa at 1027 C) and low room-temperature fracture toughness (about 5 MPa). Directionally solidified NiAl eutectic alloys are known to possess a combination of high elevated-temperature strength and good room-temperature fracture toughness. Research has demonstrated that a NiAl matrix containing a uniform distribution of very thin Cr plates alloyed with Mo possessed both increased fracture toughness and elevated-temperature creep strength. Although attractive properties were obtained, these alloys were formed at low growth rates (greater than 19 mm/hr), which are considered to be economically unviable. Hence, an investigation was warranted of the strength and toughness behavior of NiAl-(Cr,Mo) directionally solidified at faster growth rates. If the mechanical properties did not deteriorate with increased growth rates, directional solidification could offer an economical means to produce NiAl-based alloys commercially for gas turbine engines. An investigation at the NASA Glenn Research Center at Lewis Field was undertaken to study the effect of the directional solidification growth rate on the microstructure, room temperature fracture toughness, and strength at 1027 C of a Ni-33Al-31Cr-3Mo eutectic alloy. The directionally solidified rates varied between 7.6 and 508 millimeters per hour Essentially fault-free, alternating (Cr, Mo)/NiAl lamellar plate microstructures (left photograph) were formed during growth at and below 12.7 mm/hr, whereas cellular microstructures (right photograph) with the (Cr, Mo) phase in a radial spokelike pattern were developed at faster growth rates. The compressive strength at 1027 C continuously increased with increasing growth rate and did not indicate a maxima as was reported for directionally solidified Ni-33Al-34Cr. Surprisingly, samples with the lamellar plate microstructure (left photograph) possessed a room-temperature fracture toughness of approximately 12 MPa(sup square root of m), whereas all the alloys with a cellular microstructure had a toughness of about 17 MPa(sup square root of m). These results are significant since they clearly demonstrate that Ni-33Al-31Cr-3Mo can be directionally solidified at much faster growth rates without any observable deterioration in its mechanical properties. Thus, the potential to produce strong, tough NiAl-based eutectics at commercially acceptable growth rates exists. Additional testing and alloy optimization studies are underway.

Whittenberger, J. Daniel↗

NASA NTRS2000

Constituent-Based Life Models Being Developed for SiC/SiC Composites

For the successful utilization of ceramic matrix composites (CMC) as hot-section components in advanced aeropropulsion engines, the CMC constituents will need to be tailored and optimized to meet all the critical property demands of each component. Under the High-Speed Research (HSR) and Advanced High-Temperature Engine Materials Technology (HITEMP) Programs, the NASA Glenn Research Center at Lewis Field initiated research to develop mechanistic models for key CMC thermostructural properties. These models would describe the effects of different constituent factors (composition, geometry, and volume fraction) and of potential application conditions (stress, time, temperature, and environment) on these properties. Particular focus was placed on both analytical and numerical modeling of state-of-the-art SiC/SiC composites where the primary load-bearing constituents are stoichiometric SiC fibers in a complex multiphase SiC matrix produced by chemical vapor infiltration and melt infiltration. Recent studies have resulted in computer-based numerical models for the elastic modulus, thermal expansion, and thermal conductivity properties of the SiC/SiC system. Additional studies have generated analytical and empirical models for the time dependence of composite rupture strength at temperatures above 2200 F (1200 C), where CMC's have an important thermostructural advantage over current nickel-based superalloys. These life models utilize thermal activation theory and fiber stress-rupture results measured at Glenn to generate Larson-Miller (L M) plots of fiber rupture strength versus q, a single time- and temperature-dependent parameter. Assuming a worse case in which the SiC matrix is cracked, rupture is then controlled by the time-dependent fracture characteristics of the fiber bundles bridging the matrix cracks. With this as the controlling mechanism, one can then use simple composite theory and the fiber L M plots to predict CMC rupture strength versus the q parameter. The dashed line shows the predicted rupture strength of a SiC/SiC composite that is reinforced by a state-of-the-art stoichiometric SiC fiber. For the q parameter, time is in hours and temperature in degrees kelvin. To generate these predictions, a two-dimensional 0 /90 composite with approximately 16 percent fiber in the applied stress direction and an air test environment were assumed. As such, it is possible to compare the model predictions against limited stress-rupture data for this CMC as shown by the data points. The good agreement confirms the rupture model at least for the selected CMC and test conditions. Thus for this particular SiC/SiC composite, one can estimate a 1000-hr rupture strength of approximately 12 ksi at 2400 F (T = 1588 K and q = 39 700 K). At lower CMC application stresses, the SiC matrix is typically uncracked, so both the fiber and matrix constituents share the composite load. In this case, CMC rupture is controlled by the constituent with the longest rupture time based on the creep rate of the composite. Measured Monkman-Grant plots of rupture time versus creep rate for the two SiC constituents have been used to develop CMC life models for this important application condition. NASA and DOD are currently using this information to establish application and material goals for more advanced CMC's that can be used at even higher temperatures.

DiCarlo, James A.↗

NASA NTRS2000

Directionally Solidified Ceramics Produced

Produced Multiphase, interpenetrating structures are an alternative route to obtaining structural ceramic materials with adequate strength, toughness, and stability for high-temperature aerospace applications. The eutectic architecture, a continuous-reinforcing phase within a higher volume phase or matrix, can be described as a naturally occurring, in situ composite. The phases of a eutectic are thermodynamically compatible at high homologous temperatures. Strong and stable materials have been produced. Toughness, however, remains a technical obstacle. The potential for producing materials with enhanced toughness along with adequate strength and stability was demonstrated using the laser-heated float zone (LHFZ) growth method at the NASA Glenn Research Center at Lewis Field. LHFZ growth at Glenn provides a means to efficiently produce and record the underlying growth phenomena associated with two-phase structures. To initiate directional solidification, a seed of single-crystal sapphire (<0001> direction) was lowered onto the molten liquid until wetting occurred and then withdrawn at a constant rate. Neither the crystal nor the source rod was rotated. The materials produced were tested mechanically in tension, and the resulting microstructure was examined with a scanning electron microscope. Both the inherent properties of the constituent phases and the properties of the interface between them affect the mechanical behavior and the fracture surfaces. The following scanning electron micrographs show the microstructures of two different materials that were tested to failure in tension. In the left micrograph, the flat fracture surface is typical of a material that is strong but has low toughness. In the right micrograph, the crack is effectively deflected at the interface between the two phases, achieving higher toughness at moderately lower strength levels. Conducting mechanical tests to determine the high temperature properties of these materials is the next step in determining their eventual suitability.

Farmer, Serene C.↗

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↗