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At least 19 records

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DOE OSTI2022

Multiphysics modeling of SOFC performance degradation caused by interface delamination and active layer cracking

In solid oxide device operation, delamination and cracking cause more catastrophic damage to cell life than other degradation mechanisms, leading to more rapid cell failure. The electrochemical performance degradation caused by electrode/electrolyte interface delamination and active layer cracking were investigated through in-house developed three-dimensional multiphysics simulations. Here the multiphysics simulations, fully calibrated against experimental datasets for button cells in a previous study, were extended to quantitatively investigate the effects of electrode/electrolyte interface delamination and active layer cracking. The simulated polarization curves and impedance behavior with various levels of delamination and cracking provided insights of the performance degradation. Furthermore, the local current distributions within the cell were analyzed for three different operating modes: constant voltage, constant current, and constant power. Finally, a practical strategy was proposed to mitigate the performance degradation in the realistic cell operations, extending overall cell lifetime.

08 HYDROGEN↗

NASA NTRS2006

Effect of Embedded Piezoelectric Sensors on Fracture Toughness and Fatigue Resistance of Composite Laminates Under Mode I Loading

Double-cantilevered beam (DCB) specimens of a glass/epoxy composite material with embedded piezoelectric sensors were tested both statically and under fatigue loading to determine the effect of the embedded material on the Mode I fracture toughness and fatigue resistance compared to baseline data without the embedded elements. A material known as LaRC-Macrofiber Composite (LaRC-MFC (TradeMark)), or MFC, was embedded at the midplane of the specimen during the layup. Specimens were manufactured with the embedded MFC material either at the loaded end of the specimen to simulate an initial delamination; or with the MFC material located at the delaminating interface, with a Teflon film at the loaded end to simulate an initial delamination. There were three types of specimens with the embedded material at the delaminating interface: co-cured with no added adhesive; cured with a paste adhesive applied to the embedded element; or cured with a film adhesive added to the embedded material. Tests were conducted with the sensors in both the passive and active states. Results were compared to baseline data for the same material without embedded elements. Interlaminar fracture toughness values (G(sub Ic)) for the passive condition showed little change when the MFC was at the insert end. Passive results varied when the MFC was at the delaminating interface. For the co-cured case and with the paste adhesive, G(sub Ic) decreased compared to the baseline toughness, whereas, for the film adhesive case, G(sub Ic) was significantly greater than the baseline toughness, but the failure was always catastrophic. When the MFC was in the active state, G(sub Ic) was generally lower compared to the passive results. Fatigue tests showed little effect of the embedded material whether it was active or passive compared to baseline values.

Murri, Gretchen B.↗

NASA NTRS1990

Strain energy release rate analysis of delamination in a tapered laminate subjected to tension load

A tapered composite laminate subjected to tension load was analyzed using the finite-element method. The glass/epoxy laminate has a (+ or - 45)sub 3 group of plies dropped in three distinct steps, each 20 ply-thicknesses apart, thus forming a taper angle of 5.71 degrees. Steep gradients of interlaminar normal and shear stress on a potential delamination interface suggest the existence of stress singularities at the points of material and geometric discontinuities created by the internal plydrops. The delamination was assumed to initiate at the thin end of the taper on a -45/+45 interface and the delamination growth was simulated in both directions, i.e., along the taper and into the thin region. The strain-energy-release rate for a delamination growing into the thin laminate consisted predominantly of mode I (opening) component. For a delamination growing along the tapered region, the strain-energy-release rate was initially all mode I, but the proportion of mode I decreased with increase in delamination size until eventually total G was all mode II. The total G for both delamination tips increased with increase in delamination size, indicating that a delamination initiating at the end of the taper will grow unstably along the taper and into the thin laminate simultaneously.

Salpekar, S. A.↗

NASA NTRS1986

Chemical Bonding Technology: Direct Investigation of Interfacial Bonds

This is the third Flat-Plate Solar Array (FSA) Project document reporting on chemical bonding technology for terrestrial photovoltaic (PV) modules. The impetus for this work originated in the late 1970s when PV modules employing silicone encapsulation materials were undergoing delamination during outdoor exposure. At that time, manufacturers were not employing adhesion promoters and, hence, module interfaces in common with the silicone materials were only in physical contact and therefore easily prone to separation if, for example, water were to penetrate to the interfaces. Delamination with silicone materials virtually vanished when adhesion promoters, recommended by silicone manufacturers, were used. The activities related to the direct investigation of chemically bonded interfaces are described.

Koenig, J. L.↗

NASA NTRS2020

Quasi-static and Fatigue Delamination at Tape/Fabric Interfaces

The relationship between quasi-static and fatigue delamination of a fabric/tape interface is examined experimentally and numerically.Mixed-mode bending tests were conducted using specimens in which a mid-plane delamination is bound between a ply of 0-degree unidirectional tape and a 0-degree fabric ply of the same material system. The experimental results indicate that delaminations tend to migrate towards the constraining ply that is on the compressive side of the laminate in bending, and that the fracture toughness for a fabric-constrained delamination is almost twice that of a tape-constrained delamination. A cohesive model based on superposition of bilinear laws was used to account for these differences in measured properties. Fatigue analyses were conducted with a cohesive damage model that uses an idealization of stress-life diagrams used in engineering design. The fatigue model is shown to be capable of predicting the steady-state rate of delamination propagation described by the Paris law, as well as the initial transients that depend on the quasi-static R-curve effects. The analysis results help quantify the effects of fracture toughness and R-curves on the rates of delamination propagation in fatigue.

Davila, Carlos G.↗

DOE OSTI2020

Locally developed electronic conduction in a yttria stabilized zirconia (YSZ) electrolyte for durable solid oxide fuel cells

In the present work, anode supported solid oxide fuel cells (SOFCs) based on a YSZ single layer electrolyte with locally developed electronic conduction near the anode side is fabricated to improve the cell durability under negative voltage conditions. A ceria added Ni/YSZ anode functional layer is utilized and co-sintered with the YSZ electrolyte at 1460 °C. Cerium ions are diffused into a limited region of the YSZ layer (~6 μm), establishing a ceria doped YSZ region. We successfully demonstrate that this YSZ single layer cell can operate stably for ~100 h without anode/electrolyte interface delamination, even under a negative voltage. The embedded probe technique and theoretical calculation reveal that the internal oxygen partial pressure (near the anode) is substantially reduced (stabilized) by means of local electronic conduction of ceria doped YSZ. Thus, we propose an SOFC electrolyte design comprising a YSZ single layer with a ceria added anode functional layer (locally formed ceria doped YSZ in the electrolyte) as a protection method against fuel cell stack degradation caused by negative voltage operation.

25 ENERGY STORAGE↗

DOE OSTI2022

Red-Ox Robust SOFC Stacks for Affordable, Reliable Distributed Generation Power Systems

While SOFC systems are expected to operate reliably and with limited degradation in steady state or transient performance, SOFC stacks may ultimately fail due to the loss of structural integrity of one or several of the cells as a result of the weakening of the materials and interfaces due to physico-chemical changes that occur during continuous operation as a result of plastic and creep deformations, modification of the temperature profile, and/or degradation of the electrochemical performance of the cells. Degradation mechanisms originating from the cell components include coarsening of the microstructure over time; decomposition of materials; chemical reaction of electrode materials with electrolyte at the interface; delamination from each other; and for the anode, coking and sulfur poisoning. Of all the reliability issues that may occur for SOFCs, the main limitation for Ni-based cermet anodes (e.g., NiO-YSZ) is the poor stability during reduction-oxidation (red-ox) cycling. This project was aimed at the development of ceramic anode SOFCs based on SFCM (SrFe0.2Co0.4Mo0.4O3), which is a conductive perovskite that is red-ox stable. Additionally, the project involved the development of a red-ox robust stack. Scale up of SFCM-based cells to a large format (10 cm by 10 cm) cell size was achieved as well as a maximum power density of 0.9 W/cm 2 at 600 °C (>0.6 W/cm 2 at 0.6 V). Up to a 10-cell stack was successfully assembled and demonstrated, and cells showed similar performance in reformed, pipeline natural gas as in hydrogen. Finally, a 3-cell stack was red-ox cycled without degradation for 40 cycles at ~600 °C.

03 NATURAL GAS↗

NASA NTRS1984

The characterization of Mode I delamination failure in non-woven, multidirectional laminates

The uniform double cantilever beam test and SEM are presently used for the characterization of Mode I delamination behavior in fiber-reinforced epoxy laminates. Delamination failure assumes forms that depend on ply orientation, test specimen geometry, and matrix toughness, but the calculated fracture energy is noted to be heavily dependent on fracture surface morphology. A material property concept that is independent of both test specimen geometry and the orientation of the plies constituting the delaminating interface is elucidated, through the definition of interlaminar fracture solely in terms of an interlaminar separation that includes no fiber breakage or pull-out. This value, which dissipates the lowest possible amount of energy during crack growth, is the controlling factor for laminate toughness.

Chai, H.↗

NASA NTRS1985

Two-dimensional modelling of compressive failure in delaminated laminates

An analytical model is developed to assess the compressive strength criticality of near-surface interlaminar defects in laminated composites. The delaminated region is elliptic in shape, separating a thick isotropic plate from a thin orthotropic layer whose material axes coincide with the ellipse axes. The growth conditions and growth behavior of this defect are studied by breaking the overall problem into an elastic stability problem and a fracture problem. Post-buckling solution for the elliptic section is obtained using the Rayleigh-Ritz method while an energy balance criterion based on a self-similar disbond growth governs the fracture. The parameters controlling the growth or arrest of the delamination damage are identified as the fracture energy, disbond depth and elastic properties of the materials from both sides of the delaminating interface. By varying the degree of material anisotropy relative to the loading axis a range in growth behavior was found including stable or unstable crack growth parallel to or normal to the loading axis.

Chai, H.↗

NASA NTRS1986

Sublaminate analysis of interlaminar fracture in composites

A simple analysis method based upon a transverse shear deformation theory and a sublaminate approach is utilized to analyze a mixed-mode edge delamination specimen. The analysis provides closed form expressions for the interlaminar shear stresses ahead of the crack, the total energy release rate, and the energy release rate components. The parameters controlling the behavior are identified. The effect of specimen stacking sequence and delamination interface on the strain energy release rate components is investigated. Results are compared with a finite element simulation for reference. The simple nature of the method makes it suitable for preliminary design analyses which require a large number of configurations to be evaluated quickly and economically.

Armanios, E. A.↗

NASA NTRS1986

Interlaminar analysis of laminated composites using a sublaminate approach

A simple analysis method based upon a transverse shear deformation theory and a sublaminate approach is utilized to analyze a Mixed-Mode edge delamination specimen. The analysis provides a closed form distribution of the interlaminar shear stresses ahead of the crack, and the parameters controlling the behavior are identified. The effect of specimen stacking sequence and delamination interface on the strain energy release rate components is investigated. Results are compared with a finite element simulation for reference. The simple nature of the method makes it suitable for preliminary design analyses which require a large number of configurations to be evaluated quickly and economically.

Armanios, E. A.↗

NASA NTRS1989

Sublaminate analysis of interlaminar fracture in composites. I - Analytical model

A simple analysis method based on a transverse shear-deformation theory and a sublaminate approach is utilized to analyze a mixed-mode edge delamination specimen. The analysis provides closed-form expressions for the interlaminar shear stresses ahead of the crack, the total strain-energy release rate, and the strain-energy release-rate components. The parameters controlling the behavior are identified. The effect of specimen stacking sequence and delamination interface on the strain energy release rate components is investigated. Results are compared with a finite-element simulation for reference. The simple nature of the method makes it suitable for preliminary design analyses which require a large number of configurations to be evaluated quickly and economically.

Armanios, Erian A.↗

NASA NTRS1998

Investigation of Thermal High Cycle and Low Cycle Fatigue Mechanisms of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal low cycle fatigue (LCF) and high cycle fatigue (HCF) during engine operation. In this paper, the mechanisms of fatigue crack initiation and propagation in a ZrO2-8wt.% Y2O3 thermal barrier coating, under simulated engine thermal LCF and HCF conditions, are investigated using a high power CO2 laser. Experiments showed that the combined LCF/HCF tests induced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. Lateral crack branching and the ceramic/bond coat interface delaminations were also facilitated by HCF thermal loads, even in the absence of severe interfacial oxidation. Fatigue damages at crack wake surfaces, due to such phenomena as asperity/debris contact induced cracking and splat pull-out bending during cycling, were observed especially for the combined LCF/HCF tests. It is found that the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. The failure associated with HCF process, however, is mainly associated with a surface wedging mechanism. The interaction between the LCF, HCF and ceramic coating creep, and the relative importance of LCF and HCF in crack propagation are also discussed based on the experimental evidence.

Zhu, Dongming↗

NASA NTRS1998

Investigation of Thermal High Cycle and Low Cycle Fatigue Mechanisms of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal low cycle fatigue (LCF) and high cycle fatigue (HCF) during engine operation. In this paper, the mechanisms of fatigue crack initiation and propagation in a ZrO2-8wt% Y2O3 thermal barrier coating, under simulated engine thermal LCF and HCF conditions, are investigated using a high power CO2 laser. Experiments showed that the combined LCF-HCF tests induced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. Lateral crack branching and the ceramic/bond coat interface delaminations were also facilitated by HCF thermal loads, even in the absence of severe interfacial oxidation. Fatigue damage at crack wake surfaces, due to such phenomena as asperity/debris contact induced cracking and splat pull-out bending during cycling, was observed especially for the combined LCF-HCF tests. It is found that the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. The failure associated with HCF process, however, is mainly associated with a surface wedging mechanism. The interaction between the LCF, HCF and ceramic coating creep, and the relative importance of LCF and HCF in crack propagation are also discussed based on the experimental evidence.

Zhu, Dongming↗

NASA NTRS2004

Sintering and Fracture Behavior of Plasma-sprayed Thermal Barrier Coatings

Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. There is a need to characterize the fundamental sintering and fracture behavior of the current ZrO2-(7 to 8)wt%Y2O3 coating, in order to fully take advantage of the coating capability. In addition, a thorough evaluation of the coating behavior and temperature limits will be useful for more accurately assessing the benefit gained from future advanced coating systems. In this study, the sintering behavior of plasma-sprayed ZrO2-8wt%Y2O3 coatings was systematically investigated as a function of temperature and time using a dilatometer in the temperature range of 1200-1500 C. The coating sintering kinetics obtained by dilatometry were compared with the coating thermal conductivity increase kinetics, determined by a steady-state laser heat-flux testing approach, under high temperature and thermal gradient sintering conditions. The mode I, mode II, and mixed mode I-mode II fracture behavior of as-processed and sintering-annealed coatings was determined in asymmetric flexure loading at ambient and elevated temperatures in order to evaluate the coating sintering effects on the fracture envelope of K(sub I) versus K(sub II). The coating thermal conductivity cyclic response associated with the interface delamination of the coating systems under simulated engine heat-flux conditions will be discussed in conjunction with the sintering and fracture testing results.

Zhu, Dongming↗

NASA NTRS1998

Thermal High- and Low-Cycle Fatigue Behavior of Thick Thermal Barrier Coating Systems

Ceramic thermal barrier coatings have received increasing attention for advanced gas turbine and diesel engine applications because of their ability to provide thermal insulation to engine components. However, the durability of these coatings under the severe thermal cycling conditions encountered in a diesel engine (ref. 1) still remains a major issue. In this research at the NASA Lewis Research Center, a high-power laser was used to investigate the thermal fatigue behavior of a yttria-stabilized zirconia coating system under simulated diesel engine conditions. The mechanisms of fatigue crack initiation and propagation, and of coating failure under complex thermal low-cycle fatigue (LCF, representing stop/start cycles) and thermal high-cycle fatigue (HCF, representing operation at 1300 rpm) are described. Continuous wave and pulse laser modes were used to simulate pure LCF and combined LCF/HCF, respectively (ref. 2). The LCF mechanism was found to be closely related to the coating sintering and creep at high temperatures. These creep strains in the ceramic coating led to a tensile stress state during cooling, thus providing the major driving force for crack growth under LCF conditions. The combined LCF/HCF tests induced more severe coating surface cracking, microspallation, and accelerated crack growth than did the pure LCF test. HCF thermal loads also facilitated lateral crack branching and ceramic/bond coat interface delaminations. HCF is associated with the cyclic stresses originating from the high-frequency temperature fluctuation at the ceramic coating surface. The HCF thermal loads act on the crack by a wedging mechanism (ref. 1), resulting in continuous crack growth at temperature. The HCF stress intensity factor amplitude increases with the interaction depth and temperature swing, and decreases with the crack depth. HCF damage also increases with the thermal expansion coefficient and the Young's modulus of the ceramic coating (refs. 1 and 3).

Miller, Robert A.↗

NASA NTRS1990

Surface Cracking and Interface Reaction Associated Delamination Failure of Thermal and Environmental Barrier

In this paper, surface cracking and interface reactions of a ZrO2-8wt%Y2O3 and mullite/BSAS/Si thermal and environmental barrier coating system on SiC/SiC ceramic matrix composites were characterized after long-term combined laser thermal gradient and furnace cyclic tests in a water vapor containing environment. The surface cracking was analyzed based on the coating thermal gradient sintering behavior and thermal expansion mismatch stress characteristics under the thermal cyclic conditions. The interface reactions that were largely enhanced by the coating surface cracking in the water vapor environment were investigated in detail, and the reaction phases were identified for the coating system after the long-term exposure. The accelerated coating delamination failure was attributed to the increased delamination driving force under the thermal gradient cyclic loading and the reduced interface adhesion due to the detrimental interface reactions. The coating design issues will also be discussed based on the observed failure mechanisms under the high-heat-flux test conditions.

Zhu, Dongming↗

NASA NTRS2003

Surface Cracking and Interface Reaction Associated Delamination Failure of Thermal and Environmental Barrier Coatings

In this paper, surface cracking and interface reactions of a BSAS coating and a multi-layer ZTO2-8wt%Y2O3 and mullite/BSAS/Si thermal and environmental barrier coating system on SiC/SiC ceramic matrix composites were characterized after long-term combined laser thermal gradient and furnace cyclic tests in a water vapor containing environment. The surface cracking was analyzed based on the coating thermal gradient sintering behavior and thermal expansion mismatch stress characteristics under the thermal cyclic conditions. The interface reactions, which were largely enhanced by the coating surface cracking in the water vapor environment, were investigated in detail, and the reaction phases were identified for the coating system after the long- term exposure. The accelerated coating delamination failure was attributed to the increased delamination driving force under the thermal gradient cyclic loading and the reduced interface adhesion due to the detrimental interface reactions.

Zhu, Dongming↗