The practical engineering use of filament reinforced metal matrix composites
Engineering use of filament reinforced metal matrix composites dependent on fabrication cost reduction, consistent properties and form flexibility
Alexander, J. A.↗
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Ceramic Matrix Composites for Rotorcraft Engines
Ceramic matrix composite (CMC) components are being developed for turbine engine applications. Compared to metallic components, the CMC components offer benefits of higher temperature capability and less cooling requirements which correlates to improved efficiency and reduced emissions. This presentation discusses a technology develop effort for overcoming challenges in fabricating a CMC vane for the high pressure turbine. The areas of technology development include small component fabrication, ceramic joining and integration, material and component testing and characterization, and design and analysis of concept components.
Halbig, Michael C.↗
Formulations for engineered ceramic matrix composites for high temperature applications
An engineered ceramic matrix is provided to blunt and self-heal matrix cracks to reduce oxygen ingress into a fiber reinforced composite.
36 MATERIALS SCIENCE↗
Development and Characterization of Hot-Pressed Matrices for Engineered Ceramic Matrix Composites (E-CMCs)
The present research effort was undertaken to develop a new generation of SiC fiber-reinforced engineered ceramic matrix composites (E-CMCs). In contrast to traditional CMCs with a brittle SiC matrix, an E-CMC is designed to consist of a matrix engineered to possess sufficient high temperature plasticity to minimize crack propagation, relatively high fracture toughness, and self-healing capabilities to prevent oxygen ingress to the BN-coated fibers through surface-connected cracks. The present paper discusses the bend strength, isothermal oxidation, microstructures and self-healing properties of several silicide-behaved engineered matrices. Based on the oxidation tests, where it was observed that some of the matrices exhibited either catastrophic oxidation ("pesting") or spalling of the oxide scale, two engineered matrices, CrSi2/SiC/Si3N4 and CrMoSi/SiC/Si3N4, were down-selected for further investigation. Four-point bend tests were conducted on these two engineered matrices between room temperature and 1698 degrees Kelvin. Although these matrices were brittle at low temperatures, it was observed that the bend strengths and bend ductility increased at high temperatures as the silicide particles became more ductile, which was qualitatively consistent with the theoretically expected behavior that crack blunting at these particles should increase the matrix strength. Additional studies were conducted to study the effects of different additives on the self-healing properties of the engineered matrices, which helped to identify the most effective additives.
Composite Materials↗
Development of Ceramic Matrix Composite Turbine Blisks for Rocket Engines
Ceramic matrix composite (CMC) integrally bladed turbine disks (blisks) are being considered for use in various advanced propulsion systems for space vehicles. The successful development of this technology can significantly impact National Aeronautics and Space Administration (NASA) space transportation missions, by enabling new efficient systems that can operate at higher temperatures, while reducing costs. Composite blisks comprised of carbon (C) fibers and a silicon carbide (SiC) ceramic matrix were designed, fabricated, characterized, and tested by a multidisciplinary team involving materials, design, structural analysis, turbomachinery, and nondestructive evaluation representatives from government, academia, and industry during a 4.5 year effort led by the NASA Marshall Space Flight Center (MSFC). The testing of several of these blisks, which were developed in the Simplex Turbopump CMC Blisk ]Program for use in rocket engine turbopumps, was recently completed. CMC blisks offer potential advantages in rocket engine turbopumps including increased safety resulting from increased operating temperature margins and greater pump reliability, and decreased costs resulting from improved turbopump performance. The progress that was achieved in that development effort is reviewed, and some of the technology that could be applied to other advanced space transportation propulsion systems is discussed.
Effinger, Mike↗
Thermal Expansion Behavior of Hot-Pressed Engineered Matrices
Advanced engineered matrix composites (EMCs) require that the coefficient of thermal expansion (CTE) of the engineered matrix (EM) matches those of the fiber reinforcements as closely as possible in order to reduce thermal compatibility strains during heating and cooling of the composites. The present paper proposes a general concept for designing suitable matrices for long fiber reinforced composites using a rule of mixtures (ROM) approach to minimize the global differences in the thermal expansion mismatches between the fibers and the engineered matrix. Proof-of-concept studies were conducted to demonstrate the validity of the concept.
engineered matrix↗
Ceramic matrix composite turbine engine vane
A vane has an airfoil shell and a spar within the shell. The vane has an outboard shroud at an outboard end of the shell and an inboard platform at an inboard end of the shell. The spar has a first chamber essentially along the suction side and a second chamber along the pressure side opposite the first chamber.
Shi, Jun↗
Ceramic matrix composite turbine engine vane
A vane has an airfoil shell and a spar within the shell. The vane has an outboard shroud at an outboard end of the shell and an inboard platform at an inboard end of the shell. The shell includes a region having a depth-wise coefficient of thermal expansion and a second coefficient of thermal expansion transverse thereto, the depth-wise coefficient of thermal expansion being greater than the second coefficient of thermal expansion.
Prill, Lisa A.↗
Ceramic matrix composite turbine engine vane
A vane has an airfoil shell and a spar within the shell. The vane has an outboard shroud at an outboard end of the shell and an inboard platform at an inboard end of the shell. The shell includes a region having a coefficient of thermal expansion (CTE) varying with depth.
Schaff, Jeffery R.↗
Advanced Environmental Carrier Coating Development and Validation for SiC/SiC Ceramic Matrix Composite Turbine Engine Components
No abstract available
Zhu, Dongming↗
High Temperature Lightweight Self-Healing Ceramic Composites for Aircraft Engine Applications
The present research effort was undertaken to develop a new generation of SiC fiber- reinforced engineered matrix composites (EMCs) with sufficient high temperature plasticity to reduce crack propagation and self-healing capabilities to fill surface-connected cracks to prevent the oxygen ingress to the fibers. A matrix engineered with these capabilities is expected to increase the load bearing capabilities of SiCSiC CMCs at high temperatures. Several matrix compositions were designed to match the coefficient of thermal expansion (CTE) of the SiC fibers using a rule of mixture (ROM) approach. The CTE values of these matrices were determined and it was demonstrated that they were generally in good agreement with that of monolithic SiC between room temperature and 1525 K. The parameters to hot press the powders were optimized, and specimens were fabricated for determining bend strength, CTE, oxidation and microstructural characteristics of the engineered matrices. The oxidation tests revealed that some of the matrices exhibited catastrophic oxidation, and therefore, these were eliminated from further consideration. Two promising compositions were down selected based on these results for further development. Four-point bend tests were conducted on these two promising matrices between room temperature and 1698 K. Although theses matrices were brittle and failed at low stresses at room temperature, they exhibited high temperature ductility and higher stresses at the higher temperatures. The effects of different additives on the self-healing capabilities of these matrices were investigated. The results of preliminary studies conducted to slurry and melt infiltration trials with CrSi2 are described.
Silicides↗
Orthorhombic Titanium Matrix Composite Subjected to Simulated Engine Mission Cycles
Titanium matrix composites (TMC's) are commonly made up of a titanium alloy matrix reinforced by silicon carbide fibers that are oriented parallel to the loading axis. These composites can provide high strength at lower densities than monolithic titanium alloys and superalloys in selected gas turbine engine applications. The use of TMC rings with unidirectional SiC fibers as reinforcing rings within compressor rotors could significantly reduce the weight of these components. In service, these TMC reinforcing rings would be subjected to complex service mission loading cycles, including fatigue and dwell excursions. Orthorhombic titanium aluminide alloys are of particular interest for such TMC applications because their tensile and creep strengths are high in comparison to those of other titanium alloys. The objective of this investigation was to assess, in simulated mission tests at the NASA Lewis Research Center, the durability of a SiC (SCS-6)/Ti-22Al-23Nb (at.%) TMC for compressor ring applications, in cooperation with the Allison Engine Company.
Gabb, Timothy P.↗
Metal Matrix Composites for Rocket Engine Applications
This document is from a presentation about the applications of Metal Matrix Composites (MMC) in rocket engines. Both NASA and the Air Force have goals which would reduce the costs and the weight of launching spacecraft. Charts show the engine weight distribution for both reuseable and expendable engine components. The presentation reviews the operating requirements for several components of the rocket engines. The next slide reviews the potential benefits of MMCs in general and in use as materials for Advanced Pressure Casting. The next slide reviews the drawbacks of MMCs. The reusable turbopump housing is selected to review for potential MMC application. The presentation reviews solutions for reusable turbopump materials, pointing out some of the issues. It also reviews the development of some of the materials.
McDonald, Kathleen R.↗
Ceramic matrix composites for rocket engine turbine applications
A program to establish the potential for introducing fiber reinforced ceramic matrix composites (FRCMC) in future rocket engine turbopumps was instituted in 1987. A brief summary of the overall program (both contract and in-house research) is presented. Tests at NASA Lewis include thermal upshocks in a hydrogen/oxygen test rig capable of generating heating rates up to 2500 C/sec. Post thermal upshock exposure evaluation includes the measurement of residual strength and failure analysis. Test results for monolithic ceramics and several FRCMC are presented. Hydrogen compatibility was assessed by isothermal exposure of monolithic ceramics in high temperature gaseous hydrogen plus water vapor.
Herbell, Thomas P.↗
Continuous fiber ceramic matrix composites for heat engine components
High strength at elevated temperatures, low density, resistance to wear, and abundance of nonstrategic raw materials make structural ceramics attractive for advanced heat engine applications. Unfortunately, ceramics have a low fracture toughness and fail catastrophically because of overload, impact, and contact stresses. Ceramic matrix composites provide the means to achieve improved fracture toughness while retaining desirable characteristics, such as high strength and low density. Materials scientists and engineers are trying to develop the ideal fibers and matrices to achieve the optimum ceramic matrix composite properties. A need exists for the development of failure models for the design of ceramic matrix composite heat engine components. Phenomenological failure models are currently the most frequently used in industry, but they are deterministic and do not adequately describe ceramic matrix composite behavior. Semi-empirical models were proposed, which relate the failure of notched composite laminates to the stress a characteristic distance away from the notch. Shear lag models describe composite failure modes at the micromechanics level. The enhanced matrix cracking stress occurs at the same applied stress level predicted by the two models of steady state cracking. Finally, statistical models take into consideration the distribution in composite failure strength. The intent is to develop these models into computer algorithms for the failure analysis of ceramic matrix composites under monotonically increasing loads. The algorithms will be included in a postprocessor to general purpose finite element programs.
Tripp, David E.↗
Phase Transformation Pathway of DyPO4 to 21.5 GPa
Interest in the deformation behavior and phase transformations of rare earth orthophosphates (REPO4s) spans several fields of science—from geological impact analysis to ceramic matrix composite engineering. In this study, the phase behavior of polycrystalline, xenotime DyPO4 is studied up to 21.5(16) GPa at ambient temperature using in situ diamond anvil cell synchrotron X-ray diffraction. This experiment reveals a large xenotime–monazite phase coexistence pressure range of 7.6(15) GPa and evidence for the onset of a post-monazite transformation at 13.9(10) GPa to scheelite. The identification of scheelite as the post-monazite phase of DyPO4, though not definitive, is consistent with REPO4 phase transformation pathways reported in both the experimental and the computational literature.
Sharma, Jai (ORCID:0000000339034534)↗
Ceramic Composites Used in High-Speed Turbines for Rocket Engines
Ceramic matrix composite (CMC) technology offers many benefits for liquid-fueled rocket engines. Analyses show that components made from fiber-reinforced ceramic matrix composites (FRCMC's) offer the opportunity for revolutionary gains in turbomachinery performance. In addition, they offer reduced weight and the potential for longer life and lower operating costs. A NASA-sponsored turbopump development effort, conducted at Rocketdyne with parallel material characterization at the NASA Lewis Research Center, confirmed the potential to use FRCMC's for complex turbomachinery components.
Source record↗