Refractory metal fiber nickel base alloy composites for use at high temperatures
High temperature research on creep rupture strength of refractory metal fiber and nickel alloy composites
Petrasek, D. W.↗
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Understanding the interdiffusion behavior and determining the long term stability of tungsten fiber reinforced niobium-base matrix composite systems
The long term interdiffusional stability of tungsten fiber reinforced niobium alloy composites is addressed. The matrix alloy that is most promising for use as a high temperature structural material for reliable long-term space power generation is Nb1Zr. As an ancillary project to this program, efforts were made to assess the nature and kinetics of interphase reaction between selected beryllide intermetallics and nickel and iron aluminides.
Tien, John K.↗
Computed Performance of a Composite Engine Based on Experimental Data for a Single-cylinder Conventional Aircraft Engine Converted to Compression-ignition Operation
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Mccoy, J Arnold↗
MoSi2-Base Hybrid Composite Passed Engine Test
The intermetallics compound molybdenum disilicide (MoSi2) is an attractive high-temperature structural material for advanced engine applications. It has excellent oxidation resistance, a high melting point, relatively low density, and high thermal conductivity, and it is easily machined. Past research'at the NASA Lewis Research Center has resulted in the development of a hybrid composite consisting of a MoSi2 matrix reinforced with silicon nitride (Si3N4) Particulate and silicon carbide (SiC) fibers. This composite has demonstrated attractive strength, toughness, thermal fatigue, and oxidation resistance, including resistance to "pest" oxidation. These properties attracted the interest of the Office of Naval Research and Pratt & Whitney, and a joint NASA/Navy/Pratt & Whitney effort was developed to continue to mature the MoSi2 Composite technology. A turbine blade outer air seal, which was part of the Integrated High Performance Turbine Engine Technology (IHPTET) program, was chosen as a first component on which to focus. The first tasks of the materials development effort were to develop improved processing methods to reduce costs and to use fine-diameter fibers that enable the manufacturing of complex shapes. Tape-casting methods were developed to fully infiltrate the fine SiC fibers with matrix powders. The resulting composites were hot pressed to 100-percent density. Composites with cross-plied fiber architectures with 30 vol. % hi-nicalon SiC fibers and 30 vol. % nitride particles are now made routinely and demonstrate a good balance of properties. The next task entailed the measurement of a wide variety of mechanical properties to confirm the suitability of this composite in engines. In particular, participants in this effort demonstrated that composites made with Hi-Nicalon fibers had strength and toughness properties equal to or better than those of the composites made with the large-diameter fibers that had been used previously. Another critically important property measured was impact resistance. Aircraft engine components require sufficient toughness to resist manufacturing defects, assembly damage, stress concentrations at notches, and foreign object damage. Engine company designers indicated that impact resistance would have to be measured before they would seriously consider these types of composites. The Charpy V-notch test was chosen to assess impact resistance, and both monolithic and composite versions Of MOSi2 were tested from -300 to 1400 C. The results (see the following graphs) show that nitride-particulate-reinforced MoSi2 exhibited impact resistance higher than that of many monolithic ceramics and intermetallics, and that the fiber-reinforced composites had even higher values, approaching that of cast superalloys.
Keith, Theo G., Jr.↗
Performance of Nanotube-Based Ceramic Composites: Modeling and Experiment
The excellent mechanical properties of carbon-nanotubes are driving research into the creation of new strong, tough nanocomposite systems. In this program, our initial work presented the first evidence of toughening mechanisms operating in carbon-nanotube- reinforced ceramic composites using a highly-ordered array of parallel multiwall carbon-nanotubes (CNTs) in an alumina matrix. Nanoindentation introduced controlled cracks and the damage was examined by SEM. These nanocomposites exhibit the three hallmarks of toughening in micron-scale fiber composites: crack deflection at the CNT/matrix interface; crack bridging by CNTs; and CNT pullout on the fracture surfaces. Furthermore, for certain geometries a new mechanism of nanotube collapse in shear bands was found, suggesting that these materials can have multiaxial damage tolerance. The quantitative indentation data and computational models were used to determine the multiwall CNT axial Young's modulus as 200-570 GPa, depending on the nanotube geometry and quality.
Curtin, W. A.↗
MoSi2-Base Structural Composite Passed Engine Test
The intermetallic compound molybdenum disilicide (MoSi2) is an attractive high-temperature structural material for advanced engine applications. It has excellent oxidation resistance, a high melting point, relatively low density, and high thermal conductivity; and it is easily machined. Past research at the NASA Lewis Research Center has resulted in the development of a hybrid composite consisting of a MoSi2 matrix reinforced with silicon nitride (Si3N4) particulate and silicon carbide (SiC) fibers. This composite has demonstrated attractive strength, toughness, thermal fatigue, and oxidation resistance, including resistance to "pest" oxidation. These properties attracted the interest of the Office of Naval Research and Pratt & Whitney, and a joint NASA/Navy/Pratt & Whitney effort was developed to continue to mature the MoSi2 composite technology. A turbine blade outer air seal, which was part of the Integrated High Performance Turbine Engine Technology (IHPTET) program, was chosen as a first component on which to focus.
Nathal, Michael V.↗
Method of depositing a coating on Si-based ceramic composites
A process of depositing a coating system suitable for use as an environmental barrier coating on various substrate materials, particularly those containing silicon and intended for high temperature applications such as the hostile thermal environment of a gas turbine engine. The process comprises depositing a first coating layer containing mullite, and preferably a second coating layer of an alkaline earth aluminosilicate, such as barium-strontium-aluminosilicate (BSAS), by thermal spraying while maintaining the substrate at a temperature of 800.degree. C. or less, preferably 500.degree. C. or less, by which a substantially crack-free coating system is produced with desirable mechanical integrity.
Wang, Hongyu↗
X-ray Fluorescence Spectroscopy Study of Coating Thickness and Base Metal Composition
For electrical, electronic, and electromechanical (EEE) parts to be approved for space use, they must be able to meet safety standards approved by NASA. A fast, reliable, and precise method is needed to make sure these standards are met. Many EEE parts are coated in gold (Au) and nickel (Ni), and the thickness coating is crucial to a part s performance. A nondestructive method that is efficient in measuring coating thickness is x-ray fluorescence (XRF) spectroscopy. The XRF spectrometer is a machine designed to measure layer thickness and composition of single or multilayered samples. By understanding the limitations in the collection of the data by this method, accurate composition and thickness measurements can be obtained for samples with Au and Ni coatings. To understand the limitations of data found, measurements were taken with the XRF spectrometer and compared to true values of standard reference materials (SRM) that were National Institute of Standards and Technology (NIST) traceable. For every sample, six different parameters were varied to understand measurement error: coating/substrate combination, number of layers, counting interval, collimator size, coating thickness, and test area location. Each measurement was taken in accordance with standards set by the American Society for Testing and Materials (ASTM) International Standard B 568.
Rolin, T. D.↗
Carbon Cryogel and Carbon Paper-Based Silicon Composite Anode Materials for Lithium-Ion Batteries
A variety of materials are under investigation for use as anode materials in lithium-ion batteries, of which, the most promising are those containing silicon. 6 One such material is a composite formed via the dispersion of silicon in a resorcinol-formaldehyde (RF) gel followed by pyrolysis. Two silicon-carbon composite materials, carbon microspheres and nanofoams produced from nano-phase silicon impregnated RF gel precursors have been synthesized and investigated. Carbon microspheres are produced by forming the silicon-containing RF gel into microspheres whereas carbon nano-foams are produced by impregnating carbon fiber paper with the silicon containing RF gel to create a free standing electrode. 1-5 Both materials have demonstrated their ability to function as anodes and utilize the silicon present in the material. Stable reversible capacities above 400 mAh/g for the bulk material and above 1000 mAh/g of Si have been observed.
Woodworth, James↗
Facilitating Field Observations Based Atmospheric Composition Research via. SOOT
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Gao Chen↗
Static and dynamic strain energy release rates in toughened thermosetting composite laminates
In this work, the static and dynamic fracture properties of several thermosetting resin based composite laminates are presented. Two classes of materials are explored. These are homogeneous, thermosetting resins and toughened, multi-phase, thermosetting resin systems. Multi-phase resin materials have shown enhancement over homogenous materials with respect to damage resistance. The development of new dynamic tests are presented for composite laminates based on Width Tapered Double Cantilevered Beam (WTDCB) for Mode 1 fracture and the End Notched Flexure (ENF) specimen. The WTDCB sample was loaded via a low inertia, pneumatic cylinder to produce rapid cross-head displacements. A high rate, piezo-electric load cell and an accelerometer were mounted on the specimen. A digital oscilloscope was used for data acquisition. Typical static and dynamic load versus displacement plots are presented. The ENF specimen was impacted in three point bending with an instrumented impact tower. Fracture initiation and propagation energies under static and dynamic conditions were determined analytically and experimentally. The test results for Mode 1 fracture are relatively insensitive to strain rate effects for the laminates tested in this study. The test results from Mode 2 fracture indicate that the toughened systems provide superior fracture initiation and higher resistance to propagation under dynamic conditions. While the static fracture properties of the homogeneous systems may be relatively high, the apparent Mode 2 dynamic critical strain energy release rate drops significantly. The results indicate that static Mode 2 fracture testing is inadequate for determining the fracture performance of composite structures subjected to conditions such as low velocity impact. A good correlation between the basic Mode 2 dynamic fracture properties and the performance is a combined material/structural Compression After Impact (CAI) test is found. These results underscore the importance of examining rate-dependent behavior for determining the longevity of structures manufactured from composite materials.
Cairns, Douglas S.↗
A synthesis of lunar highlands compositional data
Based on compositions of lunar soils and endogeneous highland rocks and mineral phase relationships, a composition for the non-KREEP, mafic portion of the lunar highlands is determined through the use of a mixing model. It is found that the most common materials making up the surface highlands appear to be ferroan anorthosite (FAN) and a material of olivine norite composition (HON, highlands olivine norite) in roughly equal proportions. It is also found that the composition of HON is similar to that of the residual liquid from crystallization of FAN and that the proportion of FAN to HON at the lunar surface appears to be much higher than the phase relations allow for the extent of evolution of HON from a primitive plagioclase-saturated liquid. This is seen as implying an excess of FAN in the upper highlands.
Korotev, R. L.↗
Chemical Stability of the Fiber Coating/Matrix Interface in Silicon-Based Ceramic Matrix Composites
Carbon and boron nitride are used as fiber coatings in silicon-based composites. In order to assess the long-term stability of these materials, reactions of carbon/Si3N4 and BN/SiC were studied at high temperatures with Knudsen effusion, coupon tests, and microstructural examination. In the carbon/Si3N4 system, carbon reacted with Si3N4 to form gaseous N2 and SiC. The formation of SiC limited further reaction by physically separating the carbon and Si3N4. Consequently, the development of high p(N2) at the interface, predicted from thermochemical calculations, did not occur, thus limiting the potential deleterious effects of the reaction on the composite. Strong indications of a reaction between BN and SiC were shown by TEM and SIMS analysis of the BN/SiC interface. In long-term exposures, this reaction can lead to a depletion of a BN coating and/or an unfavorable change of the interfacial properties, limiting the beneficial effects of the coating.
Lee, Kang N.↗
Space environmental effects on polymers and composites
The response of polymers and polymer-based composites to the space environment is being investigated. A wide range of materials are covered in this study, including elastometer seals for Space Station Freedom, polymer films for thermal control, and composites for space structural elements. Space environmental agents of concern include atomic oxygen, thermal cycling, space debris impacts, UV, charged particles and other forms of high-energy radiation. This ambitious project is potentially a multi-year research effort and the success of such a project could be expected to have a profound impact on the design of future space-based structures. The research goal of this first Summer is to identify the priority areas of research and to carry out the initial phase task so that a collaborative research can proceed smoothly and fruitfully in the near future.
Jang, Bor Z.↗
Development of a Subcell Based Modeling Approach for Modeling the Architecturally Dependent Impact Response of Triaxially Braided Polymer Matrix Composites
Understanding the high velocity impact response of polymer matrix composites with complex architectures is critical to many aerospace applications, including engine fan blade containment systems where the structure must be able to completely contain fan blades in the event of a blade-out. Despite the benefits offered by these materials, the complex nature of textile composites presents a significant challenge for the prediction of deformation and damage under both quasi-static and impact loading conditions. The relatively large mesoscale repeating unit cell (in comparison to the size of structural components) causes the material to behave like a structure rather than a homogeneous material. Impact experiments conducted at NASA Glenn Research Center have shown the damage patterns to be a function of the underlying material architecture. Traditional computational techniques that involve modeling these materials using smeared homogeneous, orthotropic material properties at the macroscale result in simulated damage patterns that are a function of the structural geometry, but not the material architecture. In order to preserve heterogeneity at the highest length scale in a robust yet computationally efficient manner, and capture the architecturally dependent damage patterns, a previously-developed subcell modeling approach where the braided composite unit cell is approximated as a series of four adjacent laminated composites is utilized. This work discusses the implementation of the subcell methodology into the commercial transient dynamic finite element code LS-DYNA (Livermore Software Technology Corp.). Verification and validation studies are also presented, including simulation of the tensile response of straight-sided and notched quasi-static coupons composed of a T700/PR520 triaxially braided [0deg/60deg/-60deg] composite. Based on the results of the verification and validation studies, advantages and limitations of the methodology as well as plans for future work are discussed.
finite element method↗
Working group written presentation: Atomic oxygen
Earlier Shuttle flight experiments have shown NASA and SDIO spacecraft designed for operation in low-Earth orbit (LEO) must take into consideration the highly oxidative characteristics of the ambient flight environment. Materials most adversely affected by atomic oxygen interactions include organic films, advanced (carbon-based) composites, thermal control coatings, organic-based paints, optical coatings, and thermal control blankets commonly used in spacecraft applications. Earlier results of NASA flight experiments have shown prolonged exposure of sensitive spacecraft materials to the LEO environment will result in degraded systems performance or, more importantly, lead to requirements for excessive on-orbit maintenance, with both conditions contributing significantly to increased mission costs and reduced mission objectives. Flight data obtained from previous Space Shuttle missions and results of the Solar Max recovery mission are limited in terms of atomic oxygen exposure and accuracy of fluence estimates. The results of laboratory studies to investigate the long-term (15 to 30 yrs) effects of AO exposure on spacecraft surfaces are only recently available, and qualitative correlations of laboratory results with flight results have been obtained for only a limited number of materials. The working group recommended the most promising ground-based laboratories now under development be made operational as soon as possible to study the full-life effects of atomic oxygen exposure on spacecraft systems.
Leger, Lubert J.↗
Mechanical Testing of PMCs under Simulated Rapid Heat-Up Propulsion Environments: In-Plane Compressive Behavior - II
Carbon fiber thermoset polymer matrix composites (PMC) with high temperature polyimide based in-situ polymerized monomer reactant (PMR) resin has been used for some time in applications which can see temperatures up to 550 F. Currently, graphite fiber PMR based composites are used in several aircraft engine components including the outer bypass duct for the GE F-404, exit flaps for the P&W F-100-229, and the core cowl for the GE/Snecma CF6-80A3. Newer formulations, including PMR-II-50 are being investigated as potential weight reduction replacements of various metallic components in next generation high performance propulsion rocket engines that can see temperatures which exceed 550 F. Extensive FEM thermal modeling indicates that these components are exposed to rapid heat-up rates (up to -200 F/sec) and to a maximum temperature of around 600 F. Even though the predicted maximum part temperatures were within the capability of PW-II-50, the rapid heat-up causes significant through-thickness thermal gradients in the composite part and even more unstable states when combined with moisture. Designing composite parts for such extreme service environments will require accurate measurement of intrinsic and transient mechanical properties and the hygrothermal performance of these materials under more realistic use conditions. The mechanical properties of polymers degrade when exposed to elevated temperatures even in the absence of gaseous oxygen. Accurate mechanical characterization of the material is necessary in order to reduce system weight while providing sufficient factors of safety. Historically, the testing of PMCs at elevated temperatures has been plagued by the antagonism between two factors. First, moisture has been shown to profoundly affect the mechanical response of these materials at temperatures above their glass transition temperature while concurrently lowering the material's Tg. Moisture phenomena is due to one or a combination of three effects, i.e., plastization of polymeric material by water, the internal pressure generated by the volatilization of water at elevated temperatures, and hydrolytic chemical decomposition. However, moisture is lost from the material at increasing rates as temperature increases. Second, because PMCs are good thermal insulators, when they are externally heated at even mild rates large thermal gradients can develop within the material. At temperatures where a material property changes rapidly with temperature the presence of a large thermal gradient is unacceptable for intrinsic property characterization purposes. Therefore, long hold times are required to establish isothermal conditions. However, in the service environments high-heating-rates, high temperatures, high-loading rates are simultaneous present along with residual moisture. In order to capture the effects of moisture on the material, holding at- temperature until isothermal conditions are reached is unacceptable particularly in materials with small physical dimensions. Thus, the effects due to moisture on the composite's mechanical characteristics, ie., their so-called analog response, may be instructive. One approach employed in this program was rapid heat-up (approx. 200 F/sec.) and loading of both dry and wet in-plane compressive specimens to examine the effects of moisture on this resin dominated mechanical property of the material.
Stokes, Eric H.↗
Thermal-structural composites for aerospace applications.
Inorganic bonded refractory fiber-based composite materials evaluated for aerospace application
MATERIAL TESTING↗