Search NASA⌕ Search

SEARCH · Search NASA

Results for “Ceramic Matrix Composites (CMCs)”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Steam oxidation and microstructural evolution of rare earth silicate environmental barrier coatings

A primary failure mode for environmental barrier coatings (EBCs) on SiC ceramic matrix composites (CMCs) is the oxidation of the intermediate Si-bond coating, where the formation of SiO 2 at the bond coating–EBC interface results in debonding and spallation. This work compares the microstructure evolution and steam oxidation kinetics of the Si-bond coating beneath yttrium/ytterbium disilicate ((Y/Yb)DS) and ytterbium disilicate/monosilicate (YbDS/YbMS) EBCs to better understand the impact of EBC composition on oxidation kinetics. After 500 1-h cycles at 1350°C, (Y/Yb)DS displayed a decreasing concentration of the monosilicate minor phase and increasing concentration of porosity as furnace cycling time increased, whereas the YbDS/YbMS EBC displayed negligible microstructural evolution. For both EBC systems, thermally grown oxide growth rates in steam were found to increase by approximately an order magnitude compared to dry air oxidation. The (Y/Yb)DS EBC displayed a reduced steam oxidation rate compared to YbDS/YbMS.

36 MATERIALS SCIENCE↗
DOE OSTI2026

SiC Substrate Composition Effect on TGO Scale Growth in EBC Systems During High‐Temperature Steam Exposure

A systematic investigation was conducted on the oxidation behavior of silicon-bond coats within environmental barrier coating (EBC) systems applied to Si-carbide (SiC) substrates, aiming to understand how different underlying SiC substrates influence the bond coat's thermally grown oxide (TGO) and its properties. The study examined (Y/Yb) 2 Si 2 O 7 /Si coatings on three cost-effective surrogate SiC substrates (chemical vapor deposition [CVD]-grown β-SiC, sintered α-SiC, and reaction-bonded [RB] SiC) for SiC fiber /SiC matrix ceramic matrix composites (CMCs). Discrepancies in TGO growth were observed, with noticeably higher growth rates reported for the coated CMC specimens than for the four monolithic SiC specimens. The CMC samples produce an amorphous TGO, whereas the other monolithic substrates formed a crystalline TGO, which lowered the oxygen permeability through the SiO 2 scale. In conclusion, the vitrification of the TGO in the (Y/Yb) 2 Si 2 O 7 /Si/CMC system resulted from the migration of boron species from the CMC substrate to the SiO 2 scale, leading to network modification via boron doping.

EBC↗
DOE OSTI2023

Tailoring the Toughening Effects in Two-Dimensional Nanomaterial-Reinforced Ceramic Matrix Composites

Abstract Ceramic matrix composites (CMCs) reinforced by two-dimensional (2D) nanomaterials have shown extraordinary load-carrying capacities, even in the harsh environments required by emerging applications. Their exceptional mechanical performance, especially fracture toughness, primarily arises from their heterogeneous microstructures. The deliberate dispersion of 2D reinforcements enables toughening mechanisms that are extrinsic to the matrix and thus endows the composites with substantial resistance to catastrophic failure. However, the incomplete understanding of the fracture behavior of such nanocomposites, especially the complex energy dissipation process of the matrix/reinforcement interface, limits the development of stronger and tougher CMCs. To overcome these limitations, we investigate crack deflection and energy dissipation in nanocomposites using an extended cohesive shear-lag model. This new model accounts for interfacial debonding and friction, which critically control the toughening of nanocomposites. Our analysis provides mechanistic insights for optimizing the toughening effects of CMCs.

Mechanics↗
DOE OSTI2024

Understanding EBC Lifetimes and Performance for Industrial Gas Turbines

Hydrogen or hydrogen blend fuels are expected to replace natural gas in land-based industrial gas turbines (IGTs) to support a greener power economy. Silicon carbide (SiC) base ceramic matrix composites (CMCs) are considered for replacement of Ni-based superalloys to facilitate future efficiency improvements. SiC CMCs require environmental barrier coatings (EBCs) to mitigate volatilization from high-temperature steam, thus making the EBC lifetime critical information for identifying CMC component lifetimes. The goal of this project is to determine the maximum bond coating temperature underneath the EBC for achieving an IGT component lifetime goal of 25,000 h, which is far greater than current CMC component lifetime requirements for aero-turbine applications. To provide data for the lifetime model, laboratory testing used plasma-sprayed rare-earth silicate EBCs on monolithic SiC substrates with an intermediate Si bond coating. Specimens exposed to 1-h thermal cycles in flowing air-steam environments and reaction kinetics were assessed from 700°-1350°C by measuring the thickness of the thermally grown silica scales. The silica growth and phase transformation appear critical in predicting EBC lifetime and several strategies have been explored to reduce the oxide growth rate and improve EBC durability at elevated temperatures. Advanced characterization using Raman spectroscopy has helped clarify this system.

Ridley, Mackenzie↗
DOE OSTI2021

Effects of as-received defects on ceramic matrix composites properties using high-fidelity microstructures with periodic boundary conditions

The presence of microstructural defects in as-received specimens of ceramic matrix composites (CMCs) significantly influences their constitutive response and damage, highlighting the importance of characterization and quantification of these defects for accurate assessment of damage and failure in the service environment. In a recent effort, the authors developed an algorithm to generate stochastic representative volume elements (SRVEs) of Carbon fiber Silicon-Carbide-Nitride matrix (C/SiNC) CMCs based on extensive multiscale material and defect characterization data. This paper implements this algorithm within a commercial finite element solver with periodic boundary conditions (PBCs) for high-fidelity micromechanics analysis and investigation of macroscopic material behavior of C/SiNC composites. Different loading directions are used to predict the global mechanical properties, and the results are in excellent agreement with theoretical (rule of mixture) predictions. Subsequently, the effects of as-received defects on the global and local responses are investigated. The results show that intratow porosity has pronounced degradation effects on the global elastic properties and results in complex stress localization patterns, which can be attributed to potential damage initiation sites.

Khafagy, Khaled H.↗
DOE OSTI2022

Deep Neural Network Algorithm for CMC Microstructure Characterization and Variability Quantification

Microstructure characterization and variability quantification are crucial for understanding ceramic matrix composites (CMCs) mechanical behavior and deformation mechanisms across length scales. Traditionally, analyses of the micrographs obtained from microscopy are labor-intensive. However, with the vast improvement in computer vision (CV) and deep learning (DL), an automated algorithm can be designed to extract essential microstructure variability from micrographs which can then be used to construct a statistically representative volume element (SRVE). The DL-based algorithm spans the taxonomy of microstructure analyses, including semantic segmentation of microstructure constituents, secondary phases, matrix/fiber interface, and defects, and quantifying the microstructure variability in terms of probability distributions. In this work, C/SiNC and SiC/SiNC CMCs microstructures are semantically segmented through a deep convolutional neural network, followed by variability quantification through the implementation of a fully connected regression layer, hence forming a deep regression network. The deep regression network operates in a feedforward regime, in which the neuron output signal traverses through the network in a unidirectional manner. The weight tensor associated with each layer is updated through a backpropagation stochastic gradient descent approach. The input gray-scale image obtained through in-house scanning electron microscope and confocal microscope micrographs is augmented through affine transformations to increase the training set size, which is then processed through four strided convolutional layers. This compresses the image resolution by half at each layer while increasing the image depth by applying different filters (image encoding). The class activation maps (CAMs) corresponding to the applied filters highlight the key architectural features and assist with the semantic segmentation of the microstructure.

Hamza, Mohamed H.↗
DOE OSTI2026

Water Vapor Resistant SiC/SiC Composite for Hydrogen-Based Turbines (Final Scientific Technical Report)

New material innovations are needed for the extreme environments of next generation, hydrogen-fueled turbine engines. Ceramic matrix composites (CMCs) offer high-temperature capability but are susceptible to degradation in high-temperature water vapor. Pratt & Whitney’s (P&W) baseline silicon carbide (SiC)/SiC CMC was initially applied to design a component in a hydrogen-fueled engine, verifying the existence of a design space and extracting boundary conditions to inform testing parameters. Several material innovations, including two fibers, interface coatings (IFC), and self-healing matrices (SHM), were investigated to improve high-temperature performance in water vapor. A boron-doped pyrocarbon (B-PyC) IFC and a SHM matrix with layers of zirconium nitride (ZrN) or zirconium diboride (ZrB 2 ) were developed to fabricate minicomposites with either standard Hi-Nicalon™ Type S (HNS) fibers or new Tyranno® SA4 fibers (SA4). The B-PyC IFC is functional but lacks in providing improved durability. A matrix consisting of thick layers of SiC and thin layers of ZrB 2 shows promise as a SHM that can effectively seal matrix cracks in this extreme environment. Minicomposites with HNS fibers generally outperform those with SA4 fibers.

08 HYDROGEN↗
DOE OSTI2020

Multiscale Thermomechanical Damage Model with Internal State Variables for Ceramic Matrix Composites

A length scale-dependent matrix damage model has been developed to simulate the response of ceramic matrix composites (CMCs). This model captures damage initiation and propagation in the brittle matrix material by employing internal state variable (ISV) theory within a multiscale modeling framework to obtain damaged matrix stress-strain constitutive relationships at each length scale. Material degradation due to matrix cracking is captured by a damage variable determined using fracture mechanics and the self-consistent scheme. An additional state variable is introduced to capture the nucleation and growth of matrix porosity, a key mechanism contributing to matrix nonlinearity. Porosity occurs as a result of material diffusion around grain boundaries and the growth of the porosity state variable is related to the material entropy dissipation and the volumetric strain. The nonlinear predictive capabilities of the material model are demonstrated for monolithic silicon carbide, unidirectional (UD) carbon fiber/silicon carbide matrix (C/SiC) CMC, and five-harness satin (5HS) woven C/SiC CMC.

Skinner, Travis D.↗
DOE OSTI2024

High Temperature Mechanical Behavior of Refractory Alloys with Digital Image Correlation

Gas turbine efficiency is typically limited by the maximum allowable temperature for components at the inlet side and in the hot gas flow. Refractory alloys and SiC/SiC ceramic-matrix composites (CMCs) are promising candidates for advancing operating temperatures beyond those of Ni-based alloys (>1200 °C). Refractory alloys are more suitable than SiC/SiC CMCs for dynamic components, due to the latter's low toughness and ductility. However, it is well known that refractory alloys suffer from poor oxidation behavior under service lifetimes and conditions, leading to embrittlement concerns. The ARPA-E ULTIMATE program has set out to combine new alloys with advanced coatings to mitigate oxidation/embrittlement effects, while increasing the mechanical performance benefits of refractory materials. Low oxygen (inert gas) or vacuum systems are needed to assess high temperature mechanical performance of developed alloys. To investigate the environmental sensitivity of candidate alloys and develop high temperature testing capabilities, four argon tensile frames were upgraded as well as a single vacuum system at Oak Ridge National Laboratory. Digital image correlation was incorporated into the vacuum frame allowing for surface strain determination and refined insight into thermomechanical response. Creep testing was performed at 1300 °C on two alloys, C-103 and MHC in vacuum and high purity argon environments. The Mo-based alloy showed less sensitivity to oxygen, indicating that testing in well-controlled argon environments may be suitable. The C-103 alloy demonstrated a stronger sensitivity to oxygen in the well-controlled argon environment, illustrating the need for the developed vacuum testing capabilities. “Small” 25 mm and “large” 76 mm MHC specimens showed comparable results in terms of strain rate during creep testing and ultimate tensile strength during tensile testing, suggesting the viability of smaller geometries that use less material of advanced developmental alloys.

Bell, Sam↗
NASA NTRS1990

Composites boost 21st-century aircraft engines

Research and development in light-weight, high-temperature composite materials for ultrahigh-bypass engines to be used in high-speed civil transport/rotocraft is presented. It is noted that the expected benefits to be attained by this R&D include weight reduction, lowered fuel consumption, and lower direct operating costs. A major effort underway in this area is the Advanced High Temperature Engine Materials Technology Program (HITEMP) of NASA, which focuses on providing revolutionary high-temperature composite materials: to 425 C (800 F) for polymer-matrix composites (PMCs), to 1250 C (2280 F) for metal-matrix/intermetallic-matrix composites (MMCs/IMCs), and to as high as 1650 C (3000 F) for ceramic-matrix composites (CMCs). Analytical modeling is being used to investigate the structural behavior of these advanced materials in six distinct areas: micromechanics, deformation and damage, fatigue, fracture, trade-off studies, and load definition. It is concluded that the development of advanced materials such as high-temperature composites is highly dependent on the availability of high-temperature fibers. The wide range of fiber characteristics needed will require the development of more than one fiber. In general, a candidate fiber should have low density, high strength, high stiffness, a CTE matching the matrix, chemical compatibility with the matrix, environmental stability and appropriate fiber diameter.

Stephens, Joseph R.↗
NASA NTRS1995

An Investigation of Theories of Failure for Ceramic Matrix Composites

In order to further advance the understanding of the mechanical behavior of ceramic matrix composites (CMCs), acoustic emission (AE) techniques were imple mented to monitor and identify damage mechanisms in CMCs under tensile loading. In addition to real-time AE monitoring techniques, a data acquisition system was developed and implemented in order to capture AE waveforms resulting from stress-induced damage. Waveforms were inspected for multiple events, separated in distinct events, and then analyzed to determine waveform characteristics in the time and frequency domains. Waveform characteristics included peak amplitude, event duration, MARSE, energy, and dominant and centroidal frequency. In addition to conventional methods for determining a damage discrimination criteria, a study of the distribution and correlation the waveform characteristics was performed to aid in the determination of a damage discrimination criteria. The damage discrimination criteria was tested for "uniqueness", i.e., the effectiveness of the criteria to identify and monitor damage independent of the stress-strain relationship. Insitu radiography was used to substantiate the damage accumulation.

Hemann, John H.↗
NASA NTRS1999

Oxidation Resitant HfC-TaC Rocket Thruster for High Performance Propellants

The purpose of this reasearch effort was to develop high temperature, oxidation resistant thrusters which would lessen the thruster cooling requirements, resulting in increased performance and longer life for onboard propulsion systems for spacecraft. This research effort focussed on developing ceramic matrix composites (CMCs) for this application, and specifically investigated the use of HfC stabilized with TaC. This material composition can potentially operate in a stoichiometric oxygen to hydrogen ratio at a temperature of 5000 deg F (2760 deg C) in a radiatively cooled mode. Various compositions of Hafnium Carbide (HfC) and Tantalum Carbide (TaC) were deposited by chemical vapor deposition (CVD) and tested, in an attempt to identify the composition which offered the best oxidation resistance. Although it was identified that small amounts of TaC appeared to offer improved oxidation resistance over HfC alone, an optimal composition was not identified. A 251bf thruster was fabricated from a novel CMC sandwich construction with a HfC-TaC matrix, and survived two test firings, each of 5 seconds before a failure in the injector caused the run to be aborted. It was not possible to control the relative stoichiometry of the HfC and TaC composition throughout the reactor due to the large difference in the thermodynamics of the HfC and TaC formation from their respective chlorides. This also resulted in an inability to infiltrate TaC into the preform under the experimental conditions investigated. Other material compositions were fabricated and tested and two material systems; HfC-SiC functionally graded to C(sub f)/C and Re functionally graded to C(sub f)/C were selected for further testing. These functionally graded composites have use in a number of propulsion applications presently of interest to NASA and the defense industry. Their ability to withstand extremely hostile thermal environments and the light-weight and high-strength exhibited from the C(sub f)/C composite make these materials particularly suited for these applications. In the Phase III which is presently underway, Re functionally graded to C(sub f)/C is being further developed and tested for application in the thrust cells for the Linear Aerospike Engine for the X33 and RLV.

Patterson, Mark↗
NASA NTRS2001

Mechanical Behavior of Notched SiC/SiC Composites

Gas turbine components such as combustor liners or turbine vanes are subject to regions of high stress-concentration, e.g., attachment to the frame or at cooling holes. Ceramic matrix composites (CMCs) are potential materials for high temperature applications in gas turbines. They offer some capability to relieve stress at regions of high stress-concentration via matrix damage accumulation. In this study notch sensitivity was examined for woven SiC fiber reinforced, melt-infiltrated SiC matrix composites with a BN interphase, utilizing either Hi-Nicalo(TM) fibers or the stiffer Sylramic fibers. The double-edge notched tensile test approach was used for a wide range of notch sizes and specimen widths. Both composite systems exhibited mild notch sensitivity similar to other CMC systems. Acoustic emission, detected during the tensile tests, indicated that matrix cracking occurred around notches at net-section stresses below the stress where matrix cracking first occurs in unnotched specimens. However, thermoelastic stress analysis did not show any measurable stress relief around notches after the specimens were preloaded.

Morscher, Gregory N.↗
NASA NTRS2001

Notch Sensitivity of Woven Ceramic Matrix Composites Under Tensile Loading: An Experimental, Analytical, and Finite Element Study

The stress concentrations associated with circular notches and subjected to uniform tensile loading in woven ceramic matrix composites (CMCs) have been investigated for high-efficient turbine engine applications. The CMC's were composed of Nicalon silicon carbide woven fabric in SiNC matrix manufactured through polymer impregnation process (PIP). Several combinations of hole diameter/plate width ratios and ply orientations were considered in this study. In the first part, the stress concentrations were calculated measuring strain distributions surrounding the hole using strain gages at different locations of the specimens during the initial portion of the stress-strain curve before any microdamage developed. The stress concentration was also calculated analytically using Lekhnitskii's solution for orthotropic plates. A finite-width correction factor for anisotropic and orthotropic composite plate was considered. The stress distributions surrounding the circular hole of a CMC's plate were further studied using finite element analysis. Both solid and shell elements were considered. The experimental results were compared with both the analytical and finite element solutions. Extensive optical and scanning electron microscopic examinations were carried out for identifying the fracture behavior and failure mechanisms of both the notched and notched specimens. The stress concentration factors (SCF) determined by analytical method overpredicted the experimental results. But the numerical solution underpredicted the experimental SCF. Stress concentration factors are shown to increase with enlarged hole size and the effects of ply orientations on stress concentration factors are observed to be negligible. In all the cases, the crack initiated at the notch edge and propagated along the width towards the edge of the specimens.

Haque, A.↗
NASA NTRS2003

Ceramic Matrix Composites (CMC) Life Prediction Development - 2003

Accurate life prediction is critical to successful use of ceramic matrix composites (CMCs). The tools to accomplish this are immature and not oriented toward the behavior of carbon fiber reinforced silicon carbide (C/SiC), the primary system of interest for many reusable and single mission launch vehicle propulsion and airframe applications. This paper describes an approach and progress made to satisfy the need to develop an integrated life prediction system that addresses mechanical durability and environmental degradation of C/SiC.

Levine, Stanley R.↗
NASA NTRS2004

Recent Advances in the Development of Thick-Section Melt-Infiltrated C/SiC Composites

Using a pressureless melt infiltration and in situ reaction process to form the silicon carbide (SiC) matrix, Ultramet has been developing a means to rapidly fabricate ceramic matrix composites (CMCs) targeting thicker sections. The process also employs a unique route for the application of oxide fiber interface coatings designed to protect the fiber and impart fiber-matrix debond. Working toward a 12 inch diameter, 2.5 inch thick demonstrator component, the effect of various processing parameters on room temperature flexure strength is being studied with plans for more extensive elevated temperature mechanical strength evaluation to follow this initial optimization process.

Babcock, Jason R.↗
NASA NTRS2004

Goals and Progress for Mil Handbook 17, Vol. 5 on Ceramic Matrix Composites: Testing and Characterization

The initial edition of the Mil Handbook 17, Vol. 5 on ceramic matrix composites (CMCs) was recently published. Part C of this CMC volume describes procedures for characterization of the thermal, physical, and mechanical properties of CMCs and subsequent data analysis procedures. As is the case for entire CMC volume, this chapter is a "work in progress" with sections on recommended test plans and matrices, data reduction, and test methods. This presentation will describe the current status in development of this section of the CMC volume and will highlight examples of critical issues that will be addressed in this volume. CMC systems are a different class of material than metals or polymer matrix composite with different mechanical response and failure modes, design rules, test methods, and characterization techniques. The CMC test protocols need to include guidance on how to generate enough reliable data in order to estimate, with reasonable confidence, the lower bounds of performance properties, such as strength and life. Strength data sets on two material systems, C/SiC and Nicalon/SiNC, and a creep rupture data set on C/SiC, will be presented to highlight this issue. The structural properties of CMC parts can sometimes be significantly different than those obtained from flat panels because of changes in fiber architecture often required to make shapes and spatial and lot-to-lot variations in processing conditions. To illustrate an example, the hoop tensile properties of SiC/SiC cylinders will be compared to properties obtained from flat panels fabricated from the same composites. These CMC testing-design issues are being defined and documented in the Mil Handbook 17 CMC volume.

Verrilli, Michael J.↗
NASA NTRS2004

An Assessment of Variability in the Average Tensile Properties of a Melt-Infiltrated SiC/SiC Composite

Woven SiC/SiC Ceramic Matrix Composites (CMCs), manufactured by the slurry-cast, melt-infiltration process are under consideration as combustor liner materials in aircraft gas turbine engines. Tensile properties (elastic modulus, proportional limit strength, in-plane tensile strength and strain to failure) of the CMC, manufactured during two separate time periods (9/99 and 1/01) were determined at 816 and 1024 C by conducting tensile tests on specimens machined from the CMC plates. A total of 24 tensile tests were conducted for each temperature and CMC variant combination. In this study average tensile properties of the two cMC variants were statistically compared to evaluate significant differences, if any, within the CMC's properties.

Kalluri, Sreeramesh↗