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At least 109 records · Page 6

High Temperature Tensile Properties and Fatigue Behavior of a Melt-Infiltrated SiC/SiC Composite

High temperature fatigue behavior of a woven, SiC/SiC ceramic matrix composite (CMC) was investigated in air at two temperatures. The reinforcement for the CMC consisted of 5HS Sylramic(Trademark) fabric with a [0deg/90deg]4s lay-up. The SiC matrix material was infiltrated into the fiber-preform with a slurry-cast, melt-infiltration process. Tensile and fatigue test specimens were machined from the CMC plates. Initially tensile tests were conducted to obtain the average values of tensile properties at 1038 and 1204 C. Subsequently, low-cycle fatigue (LCF) tests with zero and two-hour hold-times at the maximum stress were conducted at the same two temperatures. Fatigue life data generated in the LCF tests were used to determine the geometric mean fatigue lives. In this paper, the tensile behavior and the fatigue durability of the CMC determined under different loading conditions are documented. In addition, reductions observed in the cyclic lives of the composite due to the two hour hold-time at maximum tensile stress are discussed.

Kalluri, Sreeramesh↗

Delamination Mechanisms of Thermal and Environmental Barrier Coatings on SiC/SiC Ceramic Matrix Composites

Advanced ceramic thermal harrier coatings will play an increasingly important role In future gas turbine engines because of their ability to effectively protect the engine components and further raise engine temperatures. However, the coating durability issue remains a major concern with the ever-increasing temperature requirements. In this paper, thermal cyclic response and delamination failure modes of a ZrO2-8wt%Y2O3 and mullite/BSAS thermaVenvironmenta1 barrier coating system on SiC/SiC ceramic matrix composites were investigated using a laser high-heat-flux technique. The coating degradation and delamination processes were monitored in real time by measuring coating apparent conductivity changes during the cyclic tests under realistic engine temperature and stress gradients, utilizing the fact that delamination cracking causes an apparent decrease in the measured thermal conductivity. The ceramic coating crack initiation and propagation driving forces under the cyclic thermal loads, in conjunction with the mechanical testing results, will be discussed.

Zhu, Dongming↗

Delamination Mechanisms of Thermal and Environmental Barrier Coatings on SiC/SiC Ceramic Matrix Composites

Advanced ceramic thermal barrier coatings will play an increasingly important role in future gas turbine engines because of their ability to effectively protect the engine components and further raise engine temperatures. However, the coating durability issue remains a major concern with the ever-increasing temperature requirements. In this paper, thermal cyclic response and delamination failure modes of a ZrO2-8wt%Y2O3 and mullite/BSAS thermal/environmental barrier coating system on SiC/SiC ceramic matrix composites were investigated using a laser high-heat-flux technique. The coating degradation and delamination processes were monitored in real time by measuring coating apparent conductivity changes during the cyclic tests under realistic engine temperature and stress gradients, utilizing the fact that delamination cracking causes an apparent decrease in the measured thermal conductivity. The ceramic coating crack initiation and propagation driving forces under the cyclic thermal loads, in conjunction with the mechanical testing results, will be discussed.

Zhu, Dongming↗

Improved Benchmarking of Cohesive Elements in Abaqus Standard for Predicting Disbond and Delamination in Composite Structures

Traditional approaches for aircraft certification require the assumption of an initial flaw condition, either represented as barely visible impact damage (BVID) or through inclusion of a Teflon insert to serve as surrogate damage. Based on the initial composite damage state, the structure must be shown to demonstrate structural durability and damage tolerance (DaDT) according to the following criteria: a. Damage displays no detrimental growth under cyclic loading b. The structure is able to sustain design limit load (DLL) Currently, the only available manner for validating structural performance is through test. Since damage can occur over a wide variety of areas within a structure, this approach has proven to be increasingly expensive and time consuming for composite airframes and acreage structure within the design-test-certification building block. A further complicating factor is the requirement to accurately capture the most critical damage morphologies as a starting condition. To understand the severity of the damage, it is either required to experimentally determine the most critical areas at tremendous expense or rely on legacy data of similar structural testing, which limits design space expansion. A preferred solution is to use advanced analysis to provide improved understanding of load margins for critical locations based on a wide variety of potential starting damage conditions. The standard industry approach for DaDT certification adheres to the use of the traditional virtual crack closure technique (VCCT) method. VCCT is generally a preferred method because it conforms to the current certification principles of damage from a known flaw, and when used correctly, can be effective at predicting delamination propagation under static and cyclic loading. The VCCT method requires the inclusion of an initial flaw in the finite element (FE) model requiring a-priori knowledge of the flaw location. This in turn requires a plethora of analysis cases to be examined to cover a reasonable span of potential damage states. Additionally, the VCCT approach requires node-to-node connectivity rendering it incompatible with the best practices and approaches for using continuum damage mechanics (CDM) based progressive damage and failure analysis (PDFA) tools within a typical FE solver. Alternatives to VCCT have emerged in the form of cohesive elements which utilize the cohesive zone model (CZM). Unlike VCCT which models linear elastic fracture mechanics, cohesive elements couples continuum and fracture based responses through the use of bilinear traction separation laws. These laws are defined based on a penalty stiffness, a cohesive strength, and a strain energy release rate. The approach can be mesh regularized with native cohesive elements within many FE solvers such as Abaqus and LS-DYNA. In Phase I of the NASA Advanced Composites Consortium (ACC) post-buckled stiffened panel with BVID, Strength and Life [1], the performance of cohesive elements were benchmarked in comparison to VCCT and LEFM solutions and showed good agreement using Abaqus explicit [2]. To realize savings on current and future programs, it is still necessary to close technical gaps related to the use of cohesive elements with Abaqus Standard. Within a program environment, standard finite element analysis is the preferred analytical capability for quasi-static loading as it eliminates uncertainty due to oscillatory behavior commonly seen with explicit analysis. This oscillatory behavior creates difficulties in writing margins of safety based on the analysis. The use of negative tangent stiffness material models complicates convergence which typically requires the use of numerical controls such as viscous damping to overcome. To date, there has not been a comprehensive study on how to establish best practices for cohesive element convergence for predictive capability within the Abaqus implicit solver. In pursuit of these goals, under the NASA ACC program, several numerical benchmark problems were proposed including pure mode I (double cantilevered beam – DCB), pure mode II (end notch flexure – ENF), and symmetric/unsymmetric evolving mixed mode (single leg bend – SLB). This paper focuses on the use of cohesive elements to model the delamination through the use of CZM. Specifically, finite element models for the DCB, ENF, symmetric SLB, and unsymmetric SLB, are developed and various solution controls for convergence are studied to develop a best practice. Once the best practice has been developed, the predictive capability of the objective CZM model is used to analyze the hat pull-off strength of a standard hat stiffened configuration under various loading conditions.

Abaqus↗

Improved Benchmarking of Cohesive Elements in Abaqus Standard for Predicting Disbond and Delamination in Composite Structures

Traditional approaches for aircraft certification require the assumption of an initial flaw condition, either represented as barely visible impact damage (BVID) or through inclusion of a Teflon insert to serve as surrogate damage. Based on the initial composite damage state, the structure must be shown to demonstrate structural durability and damage tolerance (DaDT) according to the following criteria: a. Damage displays no detrimental growth under cyclic loading. The structure is able to sustain design limit load (DLL). Currently, the only available manner for validating structural performance is through test. Since damage can occur over a wide variety of areas within a structure, this approach has proven to be increasingly expensive and time consuming for composite airframes and acreage structure within the design-test-certification building block. A further complicating factor is the requirement to accurately capture the most critical damage morphologies as a starting condition. To understand the severity of the damage, it is either required to experimentally determine the most critical areas at tremendous expense or rely on legacy data of similar structural testing, which limits design space expansion. A preferred solution is to use advanced analysis to provide improved understanding of load margins for critical locations based on a wide variety of potential starting damage conditions.

Eric M. Roberts↗

Cyclic bend over sheave performance of a steel tension member belt for wave energy conversion

Rotary power take-offs (PTOs) promise many benefits for commercial wave energy converters (WECs), including longer power strokes/reduced end-stop concerns, deployment advantages, and controllability. However, these winch-type PTOs can impose millions of bending cycles on the belt or rope element every year, which may lead to a failure mode known as Cyclic Bend Over Sheave, or “CBOS”. Synthetic rope, though attractive due to its high strength, low elongation, and durability, suffers from comparatively poor CBOS performance and struggles to reach a million load cycles without failing. Using belts instead of ropes for winching elements should improve CBOS performance due to having a smaller thickness that undergoes bending. Unfortunately, belts have their own host of problems. Maintaining even tension across the width of a belt subject to twist or fleet angles is a challenge, especially for WECs which can move in all 6 degrees of freedom in the ocean. This study sought to quantify the CBOS performance of a belt constructed of steel tension members in a polyurethane matrix containing longitudinal profiles. Belt samples were tested to failure or up to two million bend-unbend cycles and subject to a range of fleet angles. This paper summarizes the utilized testing methodology and the resulting belt performance.

16 TIDAL AND WAVE POWER↗

Hygro-thermo-mechanical modeling of partially saturated air-entrained concrete containing dissolved salt and exposed to freeze-thaw cycles

Highlights: • A model for cyclic freezing of air-entrained concrete containing salt is proposed. • The freeze-thaw hysteresis, also including the effect of dissolved salt, is modeled. • The diffusive and convective flux of salt is coupled to the freeze-thaw processes. • The freeze-thaw response of air-entrained concrete containing salt is reproduced. • Liquid absorption from reservoirs increases with an increased concentration of salt. In cold regions, understanding the freeze-thaw behavior of air-entrained concrete is important for designing durable structures and assessing the remaining service life of existing structures. This study presents a hygro-thermo-mechanical multiphase model that describes the cyclic freeze-thaw behavior of partially saturated air-entrained concrete containing dissolved salt. An equilibrium and a non-equilibrium approach are adopted to model the ice formation, including the freeze-thaw hysteresis, inside the porous network. The model also considers the diffusive and convective transport of the dissolved salt coupled to the freeze-thaw processes. Two examples are presented to verify and highlight the capabilities of the model. The first example shows that the model is capable of reproducing the experimentally observed mechanical response of specimens containing NaC1-solutions of different concentrations. In the second example, a larger absorption of liquid from an external reservoir is obtained with an increasing salt concentration in the reservoir, which is consistent with experimental observations.

36 MATERIALS SCIENCE↗

Tests of NASA ceramic thermal barrier coating for gas-turbine engines

A two-layer thermal barrier coating system with a bond coating of nickel-chromium-aluminum-yttrium and a ceramic coating of yttria-stabilized zirconia was tested for corrosion protection, thermal protection and durability. Full-scale gas-turbine engine tests demonstrated that this coating eliminated burning, melting, and warping of uncoated parts. During cyclic corrosion resistance tests made in marine diesel fuel products of combustion in a burner rig, the ceramic cracked on some specimens. Metallographic examination showed no base metal deterioration.

Liebert, C. H.↗

High Temperature, Slow Strain Rate Forging of Advanced Disk Alloy ME3

The advanced disk alloy ME3 was designed in the HSR/EPM disk program to have extended durability at 1150 to 1250 F in large disks. This was achieved by designing a disk alloy and process producing balanced monotonic, cyclic, and time-dependent mechanical properties. combined with robust processing and manufacturing characteristics. The resulting baseline alloy, processing, and supersolvus heat treatment produces a uniform, relatively fine mean grain size of about ASTM 7, with as-large-as (ALA) grain size of about ASTM 3. There is a long term need for disks with higher rim temperature capabilities than 1250 F. This would allow higher compressor exit (T3) temperatures and allow the full utilization of advanced combustor and airfoil concepts under development. Several approaches are being studied that modify the processing and chemistry of ME3, to possibly improve high temperature properties. Promising approaches would be applied to subscale material, for screening the resulting mechanical properties at these high temperatures. n obvious path traditionally employed to improve the high temperature and time-dependent capabilities of disk alloys is to coarsen the grain size. A coarser grain size than ASTM 7 could potentially be achieved by varying the forging conditions and supersolvus heat treatment. The objective of this study was to perform forging and heat treatment experiments ("thermomechanical processing experiments") on small compression test specimens of the baseline ME3 composition, to identify a viable forging process allowing significantly coarser grain size targeted at ASTM 3-5, than that of the baseline, ASTM 7.

Gabb, Timothy P.↗

Deciphering Reaction Mechanisms of Molecular Proton Reduction Catalysts with Cyclic Voltammetry: Kinetic vs Thermodynamic Control

The kinetics and thermodynamics of elementary reaction steps involved in the catalytic reduction of protons to hydrogen define the reaction landscape for catalysis. The mechanisms can differ in the order of the elementary proton transfer, electron transfer, and bond-forming steps and can be further differentiated by the sites at which protons and electrons localize. Access to fully elucidated mechanistic, kinetic, and thermochemical details of molecular catalysts is crucial to facilitate the development of new catalysts that operate with optimal efficiency, selectivity, and durability. The mechanism by which a catalyst operates, as well as the kinetics and thermodynamics associated with the individual steps, can often be accessed through electroanalytical studies. Here, this Account details the application of cyclic voltammetry to interrogate reaction mechanisms and quantify the kinetics and thermodynamics of elementary reaction steps for a series of molecular catalysts that mediate electrochemical proton reduction. I distinguish the limiting scenarios wherein a catalyst operates under kinetic control vs thermodynamic control, with a focus on detecting how cyclic voltammetry features shift with proton source strength and concentration, as well as scan rate. For systems that operate under kinetic control, catalytic currents are observed at, or slightly positive toward, the formal potential for the redox process that triggers catalysis. Under thermodynamic control, catalytic responses shift as a function of the proton source pKa and effective pH of the solution. After drawing this distinction, we introduce the appropriate voltammetry experiments and accompanying analytical expressions for extracting key metrics from the data. To illustrate analytical strategies to quantify elementary reaction steps of catalysts operating under kinetic control, I describe our studies of proton reduction catalysts Co(dmgBF 2 ) 2 (CH 3 CN) 2 (dmgBF 2 = difluoroboryl-dimethylglyoxime) and [Ni(P 2 Ph N 2 Ph ) 2 ] 2+ (P 2 Ph N 2 Ph = 1,5-phenyl-3,7-phenyl-1,5-diaza-3,7-diphosphacyclooctane). Here, peak shift analysis, foot-of-the-wave analysis, and plateau current analysis are applied to data sets wherein voltammetric response are recorded as a function of catalyst concentration, proton source concentration, proton source strength, and scan rate to quantify rate constants for elementary proton transfer and bond-forming steps in a catalytic cycle. Further, the case study of [Ni(P 2 Ph N 2 Ph ) 2 ] 2+ illustrates how complementary spectroscopic methods can bolster the mechanistic assignment. Collectively, these two studies showcase how detailed mechanistic studies inform on rate-limiting elementary steps in catalysis and other key processes underpinning catalysis. Second, I present analytical strategies to interrogate catalysts operating under thermodynamic control, centered on the case study of [Ni II (P 2 Ph N 2 Bn ) 2 ] 2+ (P 2 Ph N 2 Bn = 1,5-dibenzyl-3,7-diphenyl-1,5-diaza-3,7-diphosphacyclooctane). Here, the application of nonaqueous Pourbaix theory to extract thermodynamic information is introduced, and the construction of a coupled Pourbaix diagram is detailed. This study identifies ligand-based protonation as the key process that places catalysis under thermodynamic control and influences the reaction mechanism. Together, the work detailed in this Account showcases the utility of electroanalytical methods to disentangle complex reaction mechanisms and extract key thermochemical and kinetic parameters for elementary steps of catalysis. Through detailed presentation of the key analytical expressions that underpin these analyses, this Account seeks to facilitate the adoption of cyclic voltammetry by the community to fully extract kinetic, thermochemical, and mechanistic information on electrochemical small-molecule activation.

catalysts↗

Assessment of Cementitious Composites for High-Temperature Geothermal Wells

High-temperature (HT) geothermal wells can provide green power 24 hours a day, 7 days a week. Under harsh environmental and operational conditions, the long-term durability requirements of such wells require special cementitious composites for well construction. This paper reports a comprehensive assessment of geothermal cement composites in cyclic pressure function laboratory tests and field exposures in an HT geothermal well (300–350 °C), as well as a numerical model to complement the experimental results. Performances of calcium–aluminate cement (CAC)-based composites and calcium-free cement were compared against the reference ordinary Portland cement (OPC)/silica blend. The stability and degradation of the tested materials were characterized by crystalline composition, thermo-gravimetric and elemental analyses, morphological studies, water-fillable porosity, and mechanical property measurements. All CAC-based formulations outperformed the reference blend both in the function and exposure tests. The reference OPC/silica lost its mechanical properties during the 9-month well exposure through extensive HT carbonation, while the properties of the CAC-based blends improved over that period. The Modified Cam-Clay (MCC) plasticity parameters of several HT cement formulations were extracted from triaxial and Brazilian tests and verified against the experimental results of function cyclic tests. These parameters can be used in well integrity models to predict the field-scale behavior of the cement sheath under geothermal well conditions.

15 GEOTHERMAL ENERGY↗

Fractographic and microstructural evaluation of 3500-hour durability specimens

Long term durability testing of candidate ceramic materials for advanced gas turbine applications was performed. Specimens of the materials were exposed to combustion atmospheres under temperature cyclic conditions for times up to 3500 hours and at peak temperatures of 1200 and 1370 C. The specimen strengths after exposure were measured at room temperature and at 1200 C. In addition, a number of physical measurements were taken; however, no microstructural examination of the specimens was performed. Materials examined include: sintered alpha silicon carbide, sintered silicon nitride, and reaction bonded silicon nitride. Sample preparation techniques were developed to provide high quality thin-section specimens which can be examined by transmitted light or thinned using an ion mill for subsequent transmission electron microscopic examination. Specimen preparation techniques and the results of optical and electron microscopic examination of the reaction interfaces of the selected specimens are presented.

Miller, A. D.↗

Development Status and Performance Comparisons of Environmental Barrier Coating Systems for SiCSiC Ceramic Matrix Composites

Environmental barrier coatings (EBC) and SiCSiC ceramic matrix composites (CMCs) will play a crucial role in future aircraft turbine engine systems, because of their ability to significantly increase engine operating temperatures, reduce engine weight and cooling requirements. This paper presents current NASA EBC-CMC development emphases including: the coating composition and processing improvements, laser high heat flux-thermal gradient thermo-mechanical fatigue - environmental testing methodology development, and property evaluations for next generation EBC-CMC systems. EBCs processed with various deposition techniques including Plasma Spray, Electron Beam - Physical Vapor Deposition, and Plasma Spray Physical Vapor Deposition (PS-PVD) will be particularly discussed. The testing results and demonstrations of advanced EBCs-CMCs in complex simulated engine thermal gradient cyclic fatigue, oxidizing-steam and CMAS environments will help provide insights into the coating development strategies to meet long-term engine component durability goals.

Processing and Properties↗

Combustor liner durability analysis

An 18 month combustor liner durability analysis program was conducted to evaluate the use of advanced three dimensional transient heat transfer and nonlinear stress-strain analyses for modeling the cyclic thermomechanical response of a simulated combustor liner specimen. Cyclic life prediction technology for creep/fatigue interaction is evaluated for a variety of state-of-the-art tools for crack initiation and propagation. The sensitivity of the initiation models to a change in the operating conditions is also assessed.

Moreno, V.↗

Probabilistic Fatigue: Computational Simulation

Fatigue is a primary consideration in the design of aerospace structures for long term durability and reliability. There are several types of fatigue that must be considered in the design. These include low cycle, high cycle, combined for different cyclic loading conditions - for example, mechanical, thermal, erosion, etc. The traditional approach to evaluate fatigue has been to conduct many tests in the various service-environment conditions that the component will be subjected to in a specific design. This approach is reasonable and robust for that specific design. However, it is time consuming, costly and needs to be repeated for designs in different operating conditions in general. Recent research has demonstrated that fatigue of structural components/structures can be evaluated by computational simulation based on a novel paradigm. Main features in this novel paradigm are progressive telescoping scale mechanics, progressive scale substructuring and progressive structural fracture, encompassed with probabilistic simulation. These generic features of this approach are to probabilistically telescope scale local material point damage all the way up to the structural component and to probabilistically scale decompose structural loads and boundary conditions all the way down to material point. Additional features include a multifactor interaction model that probabilistically describes material properties evolution, any changes due to various cyclic load and other mutually interacting effects. The objective of the proposed paper is to describe this novel paradigm of computational simulation and present typical fatigue results for structural components. Additionally, advantages, versatility and inclusiveness of computational simulation versus testing are discussed. Guidelines for complementing simulated results with strategic testing are outlined. Typical results are shown for computational simulation of fatigue in metallic composite structures to demonstrate the versatility of this novel paradigm in predicting a priori fatigue life.

Chamis, Christos C.↗

Stirling engine: Available tools for long-life assessment

A review is presented for the durability approaches applicable to long-time life assessment of Stirling engine hot-section components. The crucial elements are experimental techniques for generating long-time materials property data (both monotonic and cyclic flow and failure properties); analytic representations of slow strain rate material stress-strain response characteristics (monotonic and cyclic constitutive relations) at high temperatures and low stresses and strains; analytic creep-fatigue-environmental interaction life prediction methods applicable to long lifetimes at high temperatures and small stresses and strains; and experimental verification of life predictions. Long-lifetime design criteria for materials of interest are woefully lacking. Designing against failures due to creep, creep-rupture, fatigue, environmental attack, and creep-fatigue-environmental interaction will require considerable extrapolation. Viscoplastic constitutive models and time-temperature parameters will have to be calibrated for the hot-section materials of interest. Analysis combined with limited verification testing in a short-time regime will be required to build confidence in long-lifetime durability models.

Halford, Gary R.↗

Stirling engine - Available tools for long-life assessment

A review is presented for the durability approaches applicable to long-time life assessment of Stirling engine hot-section components. The crucial elements are experimental techniques for generating long-time materials property data (both monotonic and cyclic flow and failure properties); analytic representations of slow strain rate material stress-strain response characteristics (monotonic and cyclic constitutive relations) at high temperatures and low stresses and strains; analytic creep-fatigue-environmental interaction life prediction methods applicable to long lifetimes at high temperatures and small stresses and strains; and experimental verification of life predictions. Long-lifetime design criteria for materials of interest are woefully lacking. Designing against failures due to creep, creep-rupture, fatigue, environmental attack, and creep-failure-environmental interaction will require considerable extrapolation. Viscoplastic constitutive models and time-temperature parameters will have to be calibrated for the hot-section materials of interest. Analysis combined with limited verification testing in a short-time regime will be required to build confidence in long-lifetime durability models.

Halford, Gary R.↗

A survey of Kaufman thruster cathodes

A survey is presented of the various cathodes which were developed and used in the Kaufman ion thruster. The electron bombardment type ion source is briefly described. The general design, operating characteristics, and power requirements are shown for each type of cathode from the refractory metals used in 1960 to the plasma discharge hollow cathodes of today. A detailed discussion of the hollow cathode is given, including starting and cyclic operating characteristics as well as more fundamental design parameters. Tests to date show that the plasma hollow cathode is an efficient electron source with demonstrated durability over 10,000 hours.

Weigand, A. J.↗