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NASA NTRS1996

Integrated Design Software Predicts the Creep Life of Monolithic Ceramic Components

Significant improvements in propulsion and power generation for the next century will require revolutionary advances in high-temperature materials and structural design. Advanced ceramics are candidate materials for these elevated-temperature applications. As design protocols emerge for these material systems, designers must be aware of several innate features, including the degrading ability of ceramics to carry sustained load. Usually, time-dependent failure in ceramics occurs because of two different, delayedfailure mechanisms: slow crack growth and creep rupture. Slow crack growth initiates at a preexisting flaw and continues until a critical crack length is reached, causing catastrophic failure. Creep rupture, on the other hand, occurs because of bulk damage in the material: void nucleation and coalescence that eventually leads to macrocracks which then propagate to failure. Successful application of advanced ceramics depends on proper characterization of material behavior and the use of an appropriate design methodology. The life of a ceramic component can be predicted with the NASA Lewis Research Center's Ceramics Analysis and Reliability Evaluation of Structures (CARES) integrated design programs. CARES/CREEP determines the expected life of a component under creep conditions, and CARES/LIFE predicts the component life due to fast fracture and subcritical crack growth. The previously developed CARES/LIFE program has been used in numerous industrial and Government applications.

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NASA NTRS1997

Thermal and Mechanical Durability of Graphite-Fiber-Reinforced PMR-15 Composites

Earlier work, which reported relationships between compression properties and elevated temperature aging times and weight losses, also pointed out the apparent influence of surface layer formation and growth on the retention of compression properties during extended aging times. Since that time, studies have been directed toward evaluating the growth of the surface layer. This layer was found to change in its composition and features as the aging temperature changed. Microcracks and small voids initiated and advanced inward at all temperatures. Visible oxidation at the surface occurred only at temperatures above 260 C. Relationships between layer thickness and aging time and temperature were evaluated and empirically formulated. Then, the compression properties were graphically related to the surface layer thickness with excellent correlation. The surface layer was observed to influence the compression strength of thin samples only.

Bowles, Kenneth J.↗

NASA NTRS1998

Thermal and Mechanical Durability of Graphite-Fiber-Reinforced PMR-15 Composites

Earlier work, which reported relationships between compression properties and elevated temperature aging times and weight losses, also pointed out the apparent influence of surface layer formation and growth on the retention of compression properties during extended aging times. Since that time, studies have been directed toward evaluating the growth of the surface layer. This layer was found to change in its composition and features as the aging temperature changed. Microcracks and small voids initiated and advanced inward at all temperatures. Visible oxidation at the surface occurred only at temperatures above 260 deg. C. Relationships between layer thickness and aging time and temperature were evaluated and empirically formulated. Then, the compression properties were graphically related to the surface layer thickness with excellent correlation. The surface layer was observed to influence the compression strength of thin samples only.

Bowles, Kenneth J.↗

NASA NTRS1993

The Fermi paradox: An approach based on percolation theory

If even a very small fraction of the hundred billion stars in the galaxy are home to technological civilizations which colonize over interstellar distances, the entire galaxy could be completely colonized in a few million years. The absence of such extraterrestrial civilizations visiting Earth is the Fermi paradox. A model for interstellar colonization is proposed using the assumption that there is a maximum distance over which direct interstellar colonization is feasible. Due to the time lag involved in interstellar communications, it is assumed that an interstellar colony will rapidly develop a culture independent of the civilization that originally settled it. Any given colony will have a probability P of developing a colonizing civilization, and a probability (1-P) that it will develop a non-colonizing civilization. These assumptions lead to the colonization of the galaxy occuring as a percolation problem. In a percolation problem, there will be a critical value of percolation probability, P(sub c). For P less than P(sub c), colonization will always terminate after a finite number of colonies. Growth will occur in 'clusters', with the outside of each cluster consisting of non-colonizing civilizations. For P greater than P(sub c), small uncolonized voids will exist, bounded by non-colonizing civilizations. For P approximately = to P(sub c), arbitrarily large filled regions exist, and also arbitrarily large empty regions.

Landis, Geoffrey A.↗

NASA NTRS1997

First Single-Crystal Mullite Fibers

Ceramic-matrix composites strengthened by suitable fiber additions are being developed for high-temperature use, particularly for aerospace applications. New oxide-based fibers, such as mullite, are particularly desirable because of their resistance to high-temperature oxidative environments. Mullite is a candidate material in both fiber and matrix form. The primary objective of this work was to determine the growth characteristics of single-crystal mullite fibers produced by the laser-heated floating zone method. Directionally solidified fibers with nominal mullite compositions of 3Al2O3 2SiO2 were grown by the laser-heated floating zone method at the NASA Lewis Research Center. SEM analysis revealed that the single-crystal fibers grown in this study were strongly faceted and that the facets act as critical flaws, limiting fiber strength. The average fiber tensile strength is 1.15 GPa at room temperature. The mullite fibers exhibit superior strength retention (80 percent of their room temperature tensile strength at 1450 C). Examined by transmission electron microscopy, these mullite single crystals are free of dislocations, low-angle boundaries, and voids. In addition, they show a high degree of oxygen vacancy ordering. High-resolution digital images from an optical microscope furnish evidence of the formation of a liquid-liquid miscibility gap during crystal growth. These images represent the first experimental evidence of liquid immiscibility for these compositions and temperatures. Continuing investigation with controlled seeding of mullite single crystals is planned.

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NASA NTRS1984

Microstructural development of protective Al2O3 scales

Microstructural characteristics of Al2O3 scales grown as protective coatings on NiCrAl alloys used in jet engines are described. The alloys were pure or doped with 0.3 percent Zr or Y and oxidized in 1 atm air at 1100 C for 0.1, 1 or 20.0 hr. The scales were then examined under a microscope. Transient epitaxial scales, formed during the 0.1 hr treatment and containing Ni, Cr and Al, consisted of a mosaic of subgrains and precipitates of different phases. The Y and Zr dopants had no effect on the nucleation site locations. The appearance of intergranular porosity at 0.1 hr was exacerbated after the 1 hr treatment. A bimodal void distribution appeared after 20 hr, when no porosity was evident. The detection of local areas of preferred orientation is taken as a spur to further studies of scale growth to gain control of the grain size or even to produce single crystal scales.

Smialek, J. L.↗

NASA NTRS2006

Comets, Asteroids, Meteorites, and the Origin of the Biosphere

During the past few decades, the delivery of water, organics, and prebiotic chemicals to the Biosphere of Earth during the Hadean (4.5-3.8 Ga) period of heavy bombardment by comets and asteroids has become more widely accepted. Comets are still largely regarded as frigid, pristine bodies of protosolar nebula material that are devoid of liquid water and therefore unsuitable for life. Complex organic compounds have been observed in comets and on the water-rich asteroid 1998 KY26 and near IR observations have indicated the presence of crystalline water ice and ammonia hydrate on the large Kuiper Belt object (50000) Quaoar that has resurfacing suggesting cryovolcanic outgassing. Spacecraft observations of the chemical compositions and characteristics of the nuclei of several comets (Halley, Borrelly, Wild 2, and Tempel 1) have shown that comets contain complex organic chemicals; that water is the predominant volatile; and that extremely high temperatures (approx. 350-400 K) can be reached on the surfae of the very black (albedo approx. 0.03) nuclei of comets when they approach the Sun. Impact craters and pinnacles observed on comet Wild 2 suggest a thick crust. Episodic outbursts and jets from the nuclei of several comets indicate that localized regimes of liquid water and water vapor can periodically exist beneath the comet crust. The Deep Impact mission found the temperature of the nucleus of comet Tempel 1 at 1.5 AU varied from a minimum of 280 plus or minus 8 K the 330K (57 C) on the sunlit side. In this paper it is argued that that pools and films of liquid water exist (within a wide range of temperatures) in cavities and voids just beneath the hot, black crust. The possibility of liquid water existing over a wide range of temperatures significantly enhances the possibility that comets might contain niches suitable for the growth of microbial communities and ecosystems. These regimes would be ideal for the growth of psychrophilic, mesophilic, and thermophilic photoautotrophs and chemolithotrophs such as the motile filamentous cyanobacteria (e.g., Calothrix, Oscillatoria, Phormidium, and Spirulina) that grow in geothermal springs and geysers of Earth at temperatures ranging fiom 320K to 345K and are also found growing in cold polar desert soils. The mineralized remains of morphotypes of all of these cyanobacteria have also been found in the Orgueil CI1 and the Murchison CN2 carbonaceous meteorites that may derive from cometary parent bodies. Observational results that support the hypothesis that liquid water can in active regions just beneath the surface of comets and that comets, carbonaceous meteorites, and asteroids may have played a significant role in the origin and evolution of the Biosphere and in the distribution of microbial life throughout the Solar System.

Hoover, Richard B.↗

NASA NTRS1999

Development of GENOA Progressive Failure Parallel Processing Software Systems

A capability consisting of software development and experimental techniques has been developed and is described. The capability is integrated into GENOA-PFA to model polymer matrix composite (PMC) structures. The capability considers the physics and mechanics of composite materials and structure by integration of a hierarchical multilevel macro-scale (lamina, laminate, and structure) and micro scale (fiber, matrix, and interface) simulation analyses. The modeling involves (1) ply layering methodology utilizing FEM elements with through-the-thickness representation, (2) simulation of effects of material defects and conditions (e.g., voids, fiber waviness, and residual stress) on global static and cyclic fatigue strengths, (3) including material nonlinearities (by updating properties periodically) and geometrical nonlinearities (by Lagrangian updating), (4) simulating crack initiation. and growth to failure under static, cyclic, creep, and impact loads. (5) progressive fracture analysis to determine durability and damage tolerance. (6) identifying the percent contribution of various possible composite failure modes involved in critical damage events. and (7) determining sensitivities of failure modes to design parameters (e.g., fiber volume fraction, ply thickness, fiber orientation. and adhesive-bond thickness). GENOA-PFA progressive failure analysis is now ready for use to investigate the effects on structural responses to PMC material degradation from damage induced by static, cyclic (fatigue). creep, and impact loading in 2D/3D PMC structures subjected to hygrothermal environments. Its use will significantly facilitate targeting design parameter changes that will be most effective in reducing the probability of a given failure mode occurring.

Abdi, Frank↗

NASA NTRS2008

Quiet Cruise Efficient Short Take-off and Landing Subsonic Transport System

This NASA funded study conceived a revolutionary airplane concept to enable future traffic growth by using regional air space. This requires a very quiet airplane with STOL capability. Starting with a Blended Wing Body that is cruise efficient with inherent low noise characteristics from forward noise shielding and void of aft downward noise reflections, integration of embedded distributed propulsion enables incorporation of the revolutionary concept for jet noise shielding. Embedded distributed propulsion also enables incorporation of a fan bleed internally blown flap for quiet powered lift. The powered lift provides STOL capability for operation at regional airports with rapid take-off and descent to further reduce flyover noise. This study focused on configuring the total engine noise shielding STOL concept with a BWB airplane using the Boeing Phantom Works WingMOD multidisciplinary optimization code to define a planform that is pitch controllable. The configuration was then sized and mission data developed to enable NASA to assess the flyover and sideline noise. The foundational technologies needed are identified including military dual use benefits.

Kawai, Ron↗

NASA NTRS1983

An experimental investigation of the internal methane pressure in hydrogen attack

An experimental investigation of the internal methane pressure that is the driving force for bubble growth in hydrogen attack (HA) was done on pure iron (204 ppm C) and on two low carbon steels of slightly different compositions. The methane content N (c.c gas/g. material) in attacked specimens was measured by a vacuum extraction technique. The total void volume V (c.c) was determined from density measurements before and after HA exposure. The two values, N and V, were then used in an equation of state to calculate an average methane pressure P for the attack stages beyond a density loss (d.l.) greater than 0.05 pct. It was determined that N and P depend on hydrogen exposure conditions and the presence of traces of strong carbide forming alloying elements (in steel). They are independent of specimen size and grain size over a limited range. P varies as the bubble volume increases, showing a generally decreasing trend which brings it to values lower than calculated equilibrium pressures, although well within the same order of magnitude. Possible reasons for this behavior are discussed.

Natan, M.↗

NASA NTRS2026

AC and DC Fault Management for Megawatt Electrified Aircraft Electrical Powertrains Task 3: Lifetime and Reliability of Electrical Insulators

This research project was a collaborative investigation between researchers at the RTX Technology Research Center (RTRC) and the University of Texas at Austin and made a significant contribution to enabling electric aircraft. The transport of electric power between the points of generation and use requires power cables. These cables must be smaller, lighter and provide a more predictable life than power cables used in stationary applications. Consequently, this investigation provided heretofore unavailable information supporting the safety and reliability of smaller lighter power cables for electrified aircraft. In addition, the research identified key additional engineering data needed to support quantitative reliability assessments. Important advances included: • Demonstrated that at least one manufacturer can make a novel, smaller, lighter power cable that is free from serious defects. • Developed and published an appropriate analytical construct to describe the life of this novel cable. This is a necessary step for use in aviation where the understanding of remaining life is critical. • Demonstrated thermal-mechanical aging that suggested 1000+ flights before the thermal-mechanical processes produced defects large enough that the defect growth was accelerated electrically. • Showed that electrical aging took place at two rates. The first possibly lasting weeks to months and the second possibly days to weeks. If robust, this provides a good diagnostic for cable replacement. • Demonstrated that the traditional electrical testing of cable materials using manufactured voids can be misleading due to the size of the voids. Emerging laser drilling technology permitted demonstration that the physics of failure in realistically small voids is different from that in the unrealistically large voids used in earlier research, which is very important for high-quality, high-performance, small aircraft cables. Although this project represents a significant contribution to the specifics of cable aging in the aircraft environment, important additional research remains to be completed, including: • Non-uniform thermal cycling by applying the heat from the center conductor to maximize thermal stress next to the core area where the electric gradient is the strongest. This builds on the uniform thermal cycling that has been completed. • The augmentation of the thermal-mechanical failure rate by electrical processes. Better understanding of these time constants strongly affects the ability to predict life. • Termination design: Terminations provide not only electrical reflection potential, but a location for a series arc fault and an area where ozone can diffuse into the center conductor and negatively affect cable insulation. • The abrasion and ozone resistance of the cable jacket. • Pressure cycling as an accelerant of thermal, mechanical, and/or electrical aging. • Possible methods for online PD detection and offline PD localization

model↗

NASA NTRS2006

Comets, Asteroids, and the Origin of the Biosphere

During the past few decades, the role of comets in the delivery of water, organics, and prebiotic chemicals to the Biosphere of Earth during the Hadean (4.5-3.8 Ga) period of heavy bombardment has become more widely accepted. However comets are still largely regarded as frigid, pristine bodies of protosolar nebula material that are entirely devoid of liquid water and consequently unsuitable for life in any form. Complex organic compounds have been observed comets and on the water rich asteroid 1998 KY26, which has color and radar reflectivity similar to the carbonaceous meteorites. Near infrared observations have indicated the presence of crystalline water ice and ammonia hydrate on the large Kuiper Belt object (50000) Quaoar with resurfacing that may indicate cryovolcanic outgassing and the Cassini spacecraft has detected water-ice geysers on Saturn s moon Enceladus. Spacecraft observations of the chemical compositions and characteristics of the nuclei of several comets (Halley, Borrelly, Wild 2, and Tempel 1) have now firmly established that comets contain a suite of complex organic chemicals; water is the predominant volatile; and that extremely high temperatures (approx.350-400 K) can be reached on the surface of the very black (albedo-0.03) nuclei when the comets are with 1.5 AU from the Sun. Impact craters and pinnacles observed on comet Wild 2 suggest a thick crust and episodic outbursts and jets observed on the nuclei of several comets are interpreted as indications that localized regimes of liquid water and water vapor can periodically exist beneath the crust of some comets. The Deep Impact observations indicate that the temperature on the nucleus of of comet Tempel 1 at 1.5 AU varied from 330K on the sunlit side to a minimum of 280+/-8 K. It is interesting that even the coldest region of the comet surface was slightly above the ice/liquid water phase transition temperature. These results suggest that pools and films of liquid water can exist in a wide range of temperatures in cavities and voids at different depths just beneath the crust of a comet. The possibility that liquid water may exist over a wide range of temperatures on comets significantly enhances the possibility that these bodies may harbor niches suitable for microbial communities and ecosystems. Such niches would by ideal for the growth of psychrophilic, mesophilic, and possibly even thermophilic chemolithotrophs and photoautotrophs such as the motile filamentous cyanobacteria (e.g., Calothrix, Oscillatoria, Phormidium, and Spirulina) that can grow in geothermal springs and geysers at temperatures ranging from 320K to 345K and in cold polar desert soils. This paper reviews the observational data in support of the hypothesis that liquid water can exist in permafrost-like active regions just beneath the surface of comets when near perihelion and provides additional arguments in support of the hypothesis that comets, carbonaceous meteorites, and asteroids may have played a significant role in the origin and evolution of the Biosphere and in the distribution of microbial life throughout the Solar System.

Hoover, Richard B.↗

NASA NTRS1985

Compatibility of grain-stabilized platinum with candidate propellants for resistojets

Resistojets are candidates for space station auxiliary propulsion, and should be characterized by both long life and multipropellant operations, requirements limited by available materials. Grain stabilized platinum is examined for use as a resistojet thruster material. Use of platinum in other applications indicates it can be used at moderately high temperatures for extended periods of time. Past results indicate that grain-stabilized platinum should be sufficiently inert in candidate propellant environments. Therefore, compatibility of platinum-yttria (P/Y2O3) and platinum-zirconia (Pt/ZrO2) with carbon dioxide, methane, hydrogen and ammonia is examined. A series of 1000 hr tests in CO2, H2, and NH3 is conducted at 1400 C and a series of 1000 hr tests in CH4 is conducted at about 500 C. Scanning electron microscopy, Auger electron spectroscopy and depth profiling analysis are then used to determine the effects of propellants on the material surface, to evaluate possible material contamination and to evaluate grain growth. The results indicate that there is carbon deposition on the surface of the Pt/Y2O3 and Pt/ZrO2 in both the CO2 and CH4 environments. In the H2 environment, the Pt/Y2O3 and Pt/ZrO2 specimen surfaces are roughened. After exposure to the NH3 environment, the Pt/Y2O3 and Pt/ZrO2 are roughened and pitted over the entire heated area with some pitted areas along the grain boundaries. SEM photos show grain growth in cross-sectional views of all the Pt/Y2O3 samples and the Pt/ZrO2 samples, except that tested in methane. Mass loss measurements indicate that Pt/Y2O3 and Pt/ZrO2 would last in excess of 200,000 hr in each propellant environment. However, in NH3 both Pt/Y2O3 and Pt/ZrO2 are severely pitted, with voids up to 50 percent into the material. Pt/Y2O3 and Pt/ZrO2 are not recommended for high temperature service in NH3.

Whalen, M. V.↗

NASA NTRS1998

Void Management in MEPHISTO and Other Space Experiments

The second flight of NASA's Shuttle Flight experiment program known as MEPHISTO suffered from a void in the liquid portion of the sample, even though a piston arrangement was in place to keep the ampoule filled. In preparations for the next flight of the MEPHISTO furnace an animated computer program, called MEPHISTO Volume Visualizer (MVV), was written to help avoid the formation of unwanted voids. A piston system on MEPHISTO has the ability to move approximately 5 mm in compression, to accommodate expansion of the solid during heating; then from the completely compressed position, the piston can move up to 25 mm in towards the sample, effectively making the ampoule smaller and hopefully eliminating any voids. Due to the nature of the piston design and ampoule and sample arrangement, the piston has gotten stuck during normal directional solidification; this creates the risk of a void. To eliminate such a void, the liquid in the hot zones of the furnace can be heated, thereby expanding the liquid and consuming any void. The problem with this approach is that if the liquid is heated too much an overpressure could result, breaking the ampoule and ending the experiment catastrophically. The MVV has been found to be a useful tool in the assessment of the risks associated with the formation of a void and the additional heating of the liquid in the hot zone of this Bridgman type furnace. The MVV software will be discussed and copies available; it is written in the Delphi 2 programming language and runs under Windows 95 and NT. The strategies used in other flight experiments, such as the Isothermal Dendritic Growth Experiment, will also be presented.

deGroh, Henry C., III↗

NASA NTRS1977

The interaction of bubbles with solidification interfaces

The behavior of bubbles at a dendritic solidification interface was studied during the coasting phase of a sounding rocket flight. Sequential photographs of the gradient freeze experiment showed nucleation, growth and coalescence of bubbles at the moving interface during both the low-gravity and one-gravity tests. In the one-gravity test the bubbles were observed to detach from the interface and float to the top of the melt. However, in the low-gravity tests no bubble detachment from the interface or steady state bubble motion occurred and large voids were grown into the crystal. These observations are discussed in terms of the current theory of thermal migration of bubbles and in terms of their implications on the space processing of metals.

Papazian, J. M.↗

NASA NTRS1979

Effects of isothermal and cyclic exposures on interface structure and mechanical properties of FPalpha-Al2O3/aluminum composites

The microstructural and interface stability of FPalpha-Al203/Al-Li composites are investigated as a function of isothermal exposure at 500 C or thermal cycling between 140 and 500 C with hold time at Tmax. Interfacial morphology, growth kinetics, crystal structure, and composition of interfacial reaction products are characterized. Strength is monitored in the transverse orientation, and fracture mechanics is analyzed in terms of interface reaction products. The interfacial reaction product in FP/Al is Li2O.5Al2O3. Significant fiber-matrix reaction occurs during fabrication. The number of thermal cycles rather than total time at Tmax is the determining factor in strength degradation, thermal cycling giving rise to voids at the fiber-matrix interface. Extensive interface failures occur at composite fracture stresses below about 128 MPa; above this stress level failure is attributed to ductile matrix fracture.

Kim, W. M.↗

NASA NTRS1990

The stability of a collisionless cosmological shell

The P3 M technique is used here to simulate the evolution of collisionless shells in an Omega = 1 universe. Starting from the spherical similarity solution, a bootstrap technique is used to follow the evolution over very large expansion factors. It is found that the overall structure follows the similarity solution for a long period during which bound clumps grow within the shell. At late times the growth of structure depends on induced velocity perturbations in material outside the shell. If such perturbations are suppressed, structure on the shell becomes self-similar. When induced motions in the background medium are included, the evolution at late times is dominated by large-scale modes as predicted by linear stability analysis. The stable final state appears to consist of one or two massive clumps on the edge of a spherical void. The possible application of these results to the origin of galaxies and large-scale structure is discussed.

White, Simon D. M.↗

NASA NTRS1983

Relation of cyclic loading pattern to microstructural fracture in creep fatigue

Creep-fatigue-environment interaction is discussed using the 'strainrange partitioning' (SRP) framework as a basis. The four generic SRP strainrange types are studied with a view of revealing differences in micromechanisms of deformation and fatigue degradation. Each combines in a different manner the degradation associated with slip-plane sliding, grain-boundary sliding, migration, cavitation, void development and environmental interaction; hence the approch is useful in delineating the relative importance of these mechanisms in the different loadings. Micromechanistic results are shown for a number of materials, including 316 SS, wrought heat resistant alloys, several nickel-base superalloys, and a tantalum base alloy, T-111. Although there is a commonality of basic behavior, the differences are useful in delineation several important principles of interpretation. Some quantitative results are presented for 316 SS, involving crack initiation and early crack growth, as well as the interaction of low-cycle fatigue with high-cycle fatigue.

Manson, S. S.↗