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At least 127 records · Page 7

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NASA NTRS2001

Affordable, Robust Ceramic Joining Technology (ARCJoint) Developed

Affordable, Robust Ceramic Joining Technology (ARCJoint) is a method for joining high temperature- resistant ceramic pieces together, establishing joints that are strong, and allowing joining to be done in the field. This new way of joining allows complex shapes to be formed by joining together geometrically simple shapes. The joining technology at NASA is one of the enabling technologies for the application of silicon-carbide-based ceramic and composite components in demanding and high-temperature applications. The technology is being developed and tested for high-temperature propulsion parts for aerospace use. Commercially, it can be used for joining ceramic pieces used for high temperature applications in the power-generating and chemical industries, as well as in the microelectronics industry. This innovation could yield big payoffs for not only the power-generating industry but also the Silicon Valley chipmakers. This technology, which was developed at the NASA Glenn Research Center by Dr. Mrityunjay Singh, is a two-step process involving first using a paste to join together ceramic pieces and bonding them by heating the joint to 110 to 120 C for between 10 and 20 min. This makes the joint strong enough to be handled for the final joining. Then, a silicon-based substance is applied to the joint and heated to 1400 C for 10 to 15 min. The resulting joint is as strong as the original ceramic material and can withstand the same high temperatures.

Steele, Gynelle C.↗

NASA NTRS2015

Oxide_Oxide Ceramic Matrix Composite (CMC) Exhaust Mixer Development in the NASA Environmentally Responsible Aviation (ERA) Project

Rolls-Royce North American Technologies, Inc. (LibertyWorksLW) began considering the development of CMC exhaust forced mixers in 2008, as a means of obtaining reduced weight and hotter operating temperature capability, while minimizing shape distortion during operation, which would improve mixing efficiency and reduce fuel burn. Increased component durability, enhanced ability to fabricate complex-shaped components, and engine noise reduction are other potential advantages of CMC mixers (compared to metallic mixers). In 2010, NASA was pursuing the reduction of NOx emissions, fuel burn, and noise from turbine engines in Phase I of the Environmentally Responsible Aviation (ERA) Project. ERA subtasks, including those focused on CMC components, were formulated with the goal of maturing technology from proof of concept validation (TRL 3) to a systemsubsystem or prototype demonstration in a relevant environment (TRL 6). In April 2010, the NASA Glenn Research Center (GRC) and LibertyWorks jointly initiated a CMC Exhaust System Validation Program within the ERA Project, teaming on CMC exhaust mixer development for subsonic jet engines capable of operating with increased performance. Our initial focus was on designing, fabricating, and characterizing the thrust and acoustic performance of a roughly quarter-scale 16-lobe oxide oxide CMC mixer and tail cone along with a conventional low bypass exhaust nozzle. Support Services, LLC (Allendale, MI) and ATK COI Ceramics, Inc. (COIC, in San Diego, CA) supported the design of a subscale nozzle assembly that consisted of an oxide oxide CMC mixer and center body, with each component mounted on a metallic attachment ring. That design was based upon the operating conditions a mixer would experience in a turbofan engine. Validation of the aerodynamic and acoustic performance of the subscale mixer via testing and the achievement of TRL 4 encouraged the NASALWCOIC team to move to the next phase where a full scale CMC mixer sized for a RR AE3007 engine and a compatible attachment flange were designed, followed by CMC component fabrication by COIC, and vibration testing at GRC under conditions simulating the structural and dynamic environment encountered during engine operation. AFRL (WPAFB) supported this testing by performing 3D laser vibrometry to identify the mixer mode shapes and modal frequencies. The successful fabrication and testing of such a component has been achieved. The CMC mixer demonstrated good durability during vibration testing at room and elevated temperature (TRL5). This has cleared the article for a ground-based test on a Rolls-Royce AE3007 engine, where the performance and benefits of the component can be further assessed.

exhaust nozzles↗

DOE OSTI2022

Scalable, Infiltration-Free Ceramic Matrix Composite (SIF-CMC) manufacturing for Molten Salt Receiver: Investigation of particle-loaded preceramic resin

Due to their unique combination of high temperature, corrosion resistance, and toughness, Ceramic Matrix Composites (CMC) are the optimal materials to be used in the next generation of Concentrated Solar Power (CSP), which will operate at working temperatures up to 800 °C. However, today, CMC is too costly to be used in CSP applications due to its complex manufacturing process based on repeated infiltration-pyrolysis cycles. To solve this issue, PARC is developing a scalable, infiltration-free method (SIF) to manufacture CMC, which can reduce the production cost, increase batch consistency, and leverage all of the intrinsic advantages of current CMCs. The key to the SIF method is using a flowable preceramic resin with high loading of functional components. The formulation impregnates the fiber during curing and leads to high-density, low-shrinkage parts upon pyrolysis. In this paper, we demonstrate a proof-of-concept of the SIF process and report the relationships between key process parameters in the manufacturing process: functional material loading in the resin vs. resin’s flowability and morphology changes upon pyrolysis.

ceramic matrix composite, concentrated solar power↗

NASA NTRS2016

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↗

DOE OSTI2022

Woven ceramic matrix composite surrogate model based on physics-informed recurrent neural network

A recurrent neural network (RNN) based surrogate model is developed to emulate the nonlinear constitutive behavior of woven ceramic matrix composites (CMCs) driven by matrix damage at multiple length scales. Physics-informed constraints are introduced into the surrogate model through regularization to ground the prediction in physics and improve its predictive capabilities. Training data is generated using the multiscale generalized method of cells (MSGMC) approach coupled with a matrix damage model. This coupling permits simulating the nonlinear behavior of woven CMCs based on constituent response at the micro-, meso-, and macroscales. The multiscale repeating unit cell is loaded under non-monotonic conditions including multiple load / unload cycles and tension / compression. The fiber volume fraction as well as the intra- and intertow void volume fractions are also varied in the generation of training data. Therefore, the RNN-based surrogate model is tasked with predicting, as a function of variable input strain sequence and fiber and void volume fractions, the resulting stress versus strain response while satisfying physical constraints such as positive semi-definiteness of the tangent stiffness matrix and linear elastic unloading. Further, the trained surrogate model effectively matches the stress versus strain response and successfully predicts the tangent modulus throughout the loading regime. Neural network based surrogate models can offer efficient alternatives to running computationally intensive multiscale material models to simulate the nonlinear response of large structural models. Therefore the presented work provides evidence towards the feasibility of developing, training, and running such models for CMCs with complex architectures, nonlinear multiaxial material response, and under non-monotonic loading conditions.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRSDate not supplied

The Effect of Trailing Edge Grid Resolution in Large-Eddy Simulations

Ceramic Matrix Composite (CMC) with environmental barrier coating can tolerate significantly higher temperatures compared with the conventional metal alloy blades and thus can help achieve higher thermal efficiency in gas turbine engines. Due to the complex fabrication process of CMC blades, larger blade trailing edge thicknesses and larger leading-edge radii of curvature are expected. These features significantly alter aerodynamic performance especially near the trailing edge and thus the loss profile. In previous studies, the authors used the large eddy simulation (LES) as well as the Reynolds Averaged Navier-Stokes (RANS) coupled with an intermittency function-based transition model to simulate an aerodynamics performance of three different CMC blades and compared the predictions against the data acquired at NASA Glenn Transonic Turbine Blade Cascade Rig. Although we were able to successfully predict different characteristics of aerodynamic performance among three different blades (e.g., pressure loading and integrated losses), LES consistently predicted a small recirculation bubble at the end of the suction side. This was not inconsistent with the physics of the flow, but the pressure loading, locally, near the trailing edge, and as a result, the measured wake profiles did not match the experimental data. To delve further into these issues, a new LES grid with a much finer mesh near the trailing edge was generated where the spanwise extent of the grid was increased by 50%. An LES simulation for the CMC blade with the largest trailing edge thicknesses at the high-freestream turbulence (Tu=13%) condition showed that using such a mesh is necessary for LES to accurately capture the transition phenomena on the suction side. The resulting total pressure coefficient profile and the shift of the wake profile were greatly improved.

CMC↗

NASA NTRSDate not supplied

The Effect of Trailing Edge Grid Resolution in Large-Eddy Simulations

LES↗

DOE OSTI2020

Functional materials and devices by self-assembly

The field of self-assembly has moved far beyond early work, where the focus was primarily the resultant beautiful two- and three-dimensional structures, to a focus on forming materials and devices with important properties either otherwise not available, or only available at great cost. Over the last few years, materials with unprecedented electronic, photonic, energy-storage, and chemical separation functionalities were created with self-assembly, while at the same time, the ability to form even more complex structures in two and three dimensions has only continued to advance. Self-assembly crosscuts all areas of materials. Functional structures have now been realized in polymer, ceramic, metallic, and semiconducting systems, as well as composites containing multiple classes of materials. Finally, as the field of self-assembly continues to advance, the number of highly functional systems will only continue to grow and make increasingly greater impacts in both the consumer and industrial space.

Materials for Devices↗

NASA NTRS2012

Marshall Space Flight Center Materials and Processes Laboratory

Marshall?s Materials and Processes Laboratory has been a core capability for NASA for over fifty years. MSFC has a proven heritage and recognized expertise in materials and manufacturing that are essential to enable and sustain space exploration. Marshall provides a "systems-wise" capability for applied research, flight hardware development, and sustaining engineering. Our history of leadership and achievements in materials, manufacturing, and flight experiments includes Apollo, Skylab, Mir, Spacelab, Shuttle (Space Shuttle Main Engine, External Tank, Reusable Solid Rocket Motor, and Solid Rocket Booster), Hubble, Chandra, and the International Space Station. MSFC?s National Center for Advanced Manufacturing, NCAM, facilitates major M&P advanced manufacturing partnership activities with academia, industry and other local, state and federal government agencies. The Materials and Processes Laborato ry has principal competencies in metals, composites, ceramics, additive manufacturing, materials and process modeling and simulation, space environmental effects, non-destructive evaluation, and fracture and failure analysis provide products ranging from materials research in space to fully integrated solutions for large complex systems challenges. Marshall?s materials research, development and manufacturing capabilities assure that NASA and National missions have access to cutting-edge, cost-effective engineering design and production options that are frugal in using design margins and are verified as safe and reliable. These are all critical factors in both future mission success and affordability.

Tramel, Terri L.↗

NASA NTRS2002

Advancements in Binder Systems for Solid Freeform Fabrication

Paper will present recent developments in advanced material binder systems for solid freeform fabrication (SFF) technologies. The advantage of SFF is the capability to custom fabricate complex geometries directly from computer aided design data in layer- by-layer fashion, eliminated the need for traditional fixturing and tooling. Binders allow for the low temperature processing of 'green' structural materials, either metal, ceramic or composite, in traditional rapid prototyping machines. The greatest obstacle comes when green parts must then go through a sintering or burnout process to remove the binders and fully densify the parent material, without damaging or distorting the original part geometry. Critical issues and up-to-date assessments will be delivered on various material systems.

Cooper, Ken↗

NASA NTRS2015

Durability and CMAS Resistance of Advanced Environmental Barrier Coatings Systems for SiC/SiC Ceramic Matrix Composites

Environmental barrier coatings (EBCs) and SiCSiC ceramic matrix composites (CMCs) systems will play a crucial role in next generation turbine engines for hot-section component applications because of their ability to significantly increase engine operating temperatures with improved efficiency, reduce engine weight and cooling requirements. This paper will emphasize advanced environmental barrier coating developments for SiCSiC turbine airfoil components, by using advanced coating compositions and processing, in conjunction with mechanical and environment testing and durability validations. The coating-CMC degradations and durability in the laboratory simulated engine fatigue-creep and complex operating environments are being addressed. The effects of Calcium-Magnesium-Alumino-Silicate (CMAS) from road sand or volcano-ash deposits on the degradation mechanisms of the environmental barrier coating systems will be discussed. The results help understand the advanced EBC-CMC system performance, aiming at the durability improvements of more robust, prime-reliant environmental barrier coatings for successful applications of the component technologies and lifing methodologies.

Ceramic Matrix Composites↗

NASA NTRS2003

Analytical Failure Prediction Method Developed for Woven and Braided Composites

Historically, advances in aerospace engine performance and durability have been linked to improvements in materials. Recent developments in ceramic matrix composites (CMCs) have led to increased interest in CMCs to achieve revolutionary gains in engine performance. The use of CMCs promises many advantages for advanced turbomachinery engine development and may be especially beneficial for aerospace engines. The most beneficial aspects of CMC material may be its ability to maintain its strength to over 2500 F, its internal material damping, and its relatively low density. Ceramic matrix composites reinforced with two-dimensional woven and braided fabric preforms are being considered for NASA s next-generation reusable rocket turbomachinery applications (for example, see the preceding figure). However, the architecture of a textile composite is complex, and therefore, the parameters controlling its strength properties are numerous. This necessitates the development of engineering approaches that combine analytical methods with limited testing to provide effective, validated design analyses for the textile composite structures development.

Min, James B.↗

NASA NTRS1990

Development of polysilsesquioxane composites

Polymer composites are increasingly being required to operate for prolonged durations at higher temperatures than in the past. Hence there have been increased efforts devoted to synthesizing and characterizing polymers capable of withstanding temperatures greater than 300 C for long periods. Several such organic polymers have been investigated in recent times. This research effort seeks to enquire if inorganic polymers can be utilized to provide the same result. Ceramics have long been recognized as providing superior thermal properties for demanding applications. However, the extremely high softening temperatures preclude their being shaped into complex shapes through melt processing techniques common to organic polymers. One approach towards solving this problem has been through the development of preceramic polymers. These are capable of being processed in the polymeric state with ease, and subsequently being pyrolyzed to ceramic structures. This experimental study is aimed at studying the feasibility of using preceramic polymers (that have not been subject to the pyrolysis step) as high performance composite matrices for high temperature applications. A preliminary study of this nature is not geared towards optimizing mechanical properties suitable for such composites. Rather, this study attempts to process such resins in composite form and suitably characterize their properties.

Srinivasan, K.↗

NASA NTRS1991

Synthesis of high performance ceramic fibers by chemical vapor deposition for advanced metallics reinforcing

The chemical vapor deposition (CVD) synthesis of fibers capable of effectively reinforcing intermetallic matrices at elevated temperatures which can be used for potential applications in high temperature composite materials is described. This process was used due to its advantage over other fiber synthesis processes. It is extremely important to produce these fibers with good reproducible and controlled growth rates. However, the complex interplay of mass and energy transfer, blended with the fluid dynamics makes this a formidable task. The design and development of CVD reactor assembly and system to synthesize TiB2, CrB, B4C, and TiC fibers was performed. Residual thermal analysis for estimating stresses arising form thermal expansion mismatch were determined. Various techniques to improve the mechanical properties were also performed. Various techniques for improving the fiber properties were elaborated. The crystal structure and its orientation for TiB2 fiber is discussed. An overall view of the CVD process to develop CrB2, TiB2, and other high performance ceramic fibers is presented.

Revankar, Vithal↗

DOE OSTI2022

Quantification of gas concentrations in NO/NO 2 /C 3 H 8 /NH 3 mixtures using machine learning

We employ machine learning to decode the composition of unknown gas mixtures from the output of an array of four electrochemical sensors. The sensors use metal oxide electrodes paired with a ceramic electrolyte, yttria-stabilized zirconia (YSZ), to produce voltage responses to the presence of gases in complex mixtures. The voltages from the sensor array serve as inputs to a machine learning pipeline which first carries out multi-class classification of mixtures into types based on which gases are present at non-zero concentrations, and subsequently predicts gas concentrations given the mixture type. Thus, our model is able to take a single reading from the sensor array in response to gas mixtures involving NO, NO 2 , C 3 H 8 , and NH 3 , and output a highly accurate prediction of which gases are present in the mixture, along with the concentrations of each constituent gas. Of note, our computational framework can be easily expanded to include additional gases and additional mixture types, allowing it to be used in numerous automotive, industrial and environmental monitoring settings.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Direct Ink-Write Printing of Ceramic Clay with an Embedded Wireless Temperature and Relative Humidity Sensor

This research presents a simple method to additively manufacture Cone 5 porcelain clay ceramics by using the direct ink-write (DIW) printing technique. DIW has allowed the application of extruding highly viscous ceramic materials with relatively high-quality and good mechanical properties, which additionally allows a freedom of design and the capability of manufacturing complex geometrical shapes. Clay particles were mixed with deionized (DI) water at different ratios, where the most suitable composition for 3D printing was observed at a 1:5 w/c ratio (16.2 wt.%. of DI water). Differential geometrical designs were printed to demonstrate the printing capabilities of the paste. In addition, a clay structure was fabricated with an embedded wireless temperature and relative humidity (RH) sensor during the 3D printing process. The embedded sensor read up to 65% RH and temperatures of up to 85 °F from a maximum distance of 141.7 m. The structural integrity of the selected 3D printed geometries was confirmed through the compressive strength of fired and non-fired clay samples, with strengths of 70 MPa and 90 MPa, respectively. This research demonstrates the feasibility of using the DIW printing of porcelain clay with embedded sensors, with fully functional temperature- and humidity-sensing capabilities.

42 ENGINEERING↗

NASA NTRS1990

Ultrasonic and radiographic evaluation of advanced aerospace materials: Ceramic composites

Two conventional nondestructive evaluation techniques were used to evaluate advanced ceramic composite materials. It was shown that neither ultrasonic C-scan nor radiographic imaging can individually provide sufficient data for an accurate nondestructive evaluation. Both ultrasonic C-scan and conventional radiographic imaging are required for preliminary evaluation of these complex systems. The material variations that were identified by these two techniques are porosity, delaminations, bond quality between laminae, fiber alignment, fiber registration, fiber parallelism, and processing density flaws. The degree of bonding between fiber and matrix cannot be determined by either of these methods. An alternative ultrasonic technique, angular power spectrum scanning (APSS) is recommended for quantification of this interfacial bond.

Generazio, Edward R.↗

NASA NTRS1989

Crystallization of a barium-aluminosilicate glass

The crystallization of a celsian glass composition was investigated as a possible high-temperature ceramic matrix material. Heat treatments invariably resulted in crystallization of the hexaclesian phase unless a flux, such as lithia, was added or a nucleating agent used (e.g., celsian seeds). TEM analysis revealed complex microstructures. Glasses with Mo additions contained hexacelsian, mullite, and an Mo-rich glass. Li2O additions stabilized celsian but mullite and Mo-rich glass were still present.

Drummond, C. H., III↗