Engineering topics

Levine, Stanley R.

Publications and source records attributed to Levine, Stanley R..

At least 37 records · Page 2

NASA NTRS2003

UHTC for Sharp Leading Edges

Ultrahigh temperature ceramics have performed unreliably due to material flaws and attachment design. These deficiencies are brought to the fore by the low fracture toughness and thermal shock resistance of UHTCs. If these deficiencies are overcome, we are still faced with poor oxidation resistance as a limitation on UHTC applicability to reusable launch vehicles. We have been addressing the deficiencies of UHTCs for the past year via a small task at GRC that is part of the 3rd Gen TPS effort. Our focus is on composite constructions and functional grading to address the mechanical issues and on composition modification to address the oxidation issue. The approaches and progress will be reported.

Levine, Stanley R.↗

NASA NTRS2002

C/sic Life Prediction for Propulsion Applications

Accurate life prediction is critical to successful use of ceramic matrix composites (CMC). The tools to accomplish this are immature and not oriented toward the behavior of carbon fiber reinforced silicon carbide (C/SiC), the primary system of interest for many reusable and single mission launch vehicle propulsion and airframe applications. This paper describes an approach and process made to satisfy the need to develop an integrated life prediction system that addresses mechanical durability and environmental degradation of C/SiC. Issues such as oxidation, steam and hydrogen effects on material behavior are discussed. Preliminary tests indicate that steam will aggressively remove SiC seal coat and matrix in line with past experience. The kinetics of water vapor reaction with carbon fibers is negligible at 600 C, but comparable to air attack at 1200 C. The mitigating effect of steam observed in fiber oxidation studies has also been observed in stress rupture tests. Detailed microscopy of oxidized specimens is being carried out to develop the oxidation model. Carbon oxidation kinetics are reaction controlled at intermediate temperatures and diffusion controlled at high temperatures (approximately 1000 C). Activation energies for T-300 and interface pyrolytic carbon were determined as key inputs to the oxidation model. Crack opening as a function of temperature and stress was calculated. Mechanical property tests to develop and verify the probabilistic life model are very encouraging except for residual strength prediction. Gage width is a key variable governing edge oxidation of seal coated specimens. Future efforts will include architectural effects, enhanced coatings, biaxial tests, and LCF. Modeling will need to account for combined effects.

Levine, Stanley R.↗

NASA NTRS2002

C/SIC Life Prediction for Propulsion Applications

Accurate life prediction is critical to successful use of ceramic matrix composites (CMC). The tools to accomplish this are immature and not oriented toward the behavior of carbon fiber reinforced silicon carbide (C/SiC), the primary system of interest for many reusable and single mission launch vehicle propulsion and airframe applications. This paper describes an approach and progress made to satisfy the need to develop an integrated life prediction system that addresses mechanical durability and environmental degradation of C/SiC. Issues such as oxidation, steam and hydrogen effects on material behavior are discussed. Preliminary tests indicate that stream will aggressively remove SiC seal coat and matrix in line with past experience. The kinetics of water vapor reaction with carbon fibers is negligible at 600 C, but comparable to air attack at 1200 C. The mitigating effect of steam observed in fiber oxidation studies has also been observed in stress rupture tests. Detailed microscopy of oxidized specimens is being carried out to develop the oxidation model. Carbon oxidation kinetics are reaction controlled at intermediate temperatures and diffusion controlled at high temperatures (approx. 1000 C). Activation energies for T-300 and interface pyrolytic carbon were determined as key inputs to the oxidation model. Crack opening as a function of temperature and stress was calculated. Mechanical property tests to develop and verify the probabilistic life model are very encouraging except for residual strength prediction. Gage width is a key variable governing edge oxidation of seal coated specimens. Future efforts will include architectural effects, enhanced coatings, biaxial tests, and LCF. Modeling will need to account for combined effects.

Levine, Stanley R.↗

NASA NTRS2002

Evaluation of Ultra-High Temperature Ceramics for Propulsion Application

Ultra-high temperature ceramic (UHTC) materials consisting of zirconium diboride or hafnium diboride plus silicon carbide offer a combination of properties that make them candidates for airframe leading edges on sharp-bodied reentry vehicles. These UHTC perform well in the environment for such applications, i.e. low pressure air. The purpose of this study was to examine three of these materials under conditions more representative of a propulsion environment, i.e. higher oxygen and total pressure. Results of stren$h and fracture toughness measurements, furnace oxidation, and thermal shock exposures are presented. The poor oxidation resistance of UHTCs is the predominant factor limiting their applicability to propulsion.

Levine, Stanley R.↗

NASA NTRS2001

Evaluation of Ultra-High Temperature Ceramics for Aeropropulsion Use

Among the ultra-high temperature ceramics (UHTC) are a group of materials consisting of zirconium diboride or hafnium diboride plus silicon carbide, and in some instances, carbon. These materials offer a good combination of properties that make them candidates for airframe leading edges on sharp-bodied reentry vehicles. These UHTC perform well in the environment for such applications, i.e., air at low pressure. The purpose of this study was to examine three of these materials under conditions more representative of a propulsion environment, i.e., higher oxygen partial pressure and total pressure. Results of strength and fracture toughness measurements, furnace oxidation and high velocity thermal shock exposures are presented for ZrB2 plus 20 volume % SiC, ZrB2 plus 14 volume % SiC plus 30 volume % C, and SCS-9a SiC fiber reinforced ZrB2 plus 20 volume % SiC. The poor oxidation resistance of UHTCs is the predominant factor limiting their applicability to propulsion applications.

Levine, Stanley R.↗

NASA NTRS2000

Ceramic Matrix Composites (CMC) Life Prediction Method Development

Advanced launch systems (e.g., Reusable Launch Vehicle and other Shuttle Class concepts, Rocket-Based Combine Cycle, etc.), and interplanetary vehicles will very likely incorporate fiber reinforced ceramic matrix composites (CMC) in critical propulsion components. The use of CMC is highly desirable to save weight, to improve reuse capability, and to increase performance. CMC candidate applications are mission and cycle dependent and may include turbopump rotors, housings, combustors, nozzle injectors, exit cones or ramps, and throats. For reusable and single mission uses, accurate prediction of life is critical to mission success. The tools to accomplish life prediction are very immature and not oriented toward the behavior of carbon fiber reinforced silicon carbide (C/SiC), the primary system of interest for a variety of space propulsion applications. This paper describes an approach to satisfy the need to develop an integrated life prediction system for CMC that addresses mechanical durability due to cyclic and steady thermomechanical loads, and takes into account the impact of environmental degradation.

Levine, Stanley R.↗

NASA NTRS2000

Roles of Poly(propylene Glycol) During Solvent-Based Lamination of Ceramic Green Tapes

Solvent lamination for alumina green tapes is readily accomplished using a mixture of ethanol, toluene and poly(propylene glycol). After lamination, the PPG is clearly present as a discrete film at the interface between the laminated tapes. This condition, however, does not generate delamination during firing. Systematic sets of experiments are undertaken to determine the role of PPG in the lamination process and, specifically, the mechanism by which it is redistributed during subsequent processing. PPG slowly diffuses through the organic binder film at room temperature. The PPG diffusion rapidly increases as temperature is increased to 80 C. The key to the efficiency of adhesives during green-tape lamination is mutual solubility of the nonvolatile component of the glue and the base polymeric binder.

Suppakarn, Nitinat↗

NASA NTRS2000

Production Strategies for Production-Quality Parts for Aerospace Applications

A combination of rapid prototyping processes (3D Systems' stereolithography and Sanders Prototyping's ModelMaker) are combined with gelcasting to produce high quality silicon nitride components that were performance tested under simulated use conditions. Two types of aerospace components were produced, a low-force rocket thruster and a simulated airfoil section. The rocket was tested in a test stand using varying mixtures of H2 and O2, whereas the simulated airfoil was tested by subjecting it to a 0.3 Mach jet-fuel burner flame. Both parts performed successfully, demonstrating the usefulness of the rapid prototyping in efforts to effect materials substitution. In addition, the simulated airfoil was used to explore the possibility of applying thermal/environmental barrier coatings and providing for internal cooling of ceramic parts. It is concluded that this strategy for processing offers the ceramic engineer all the flexibility normally associated with investment casting of superalloys.

Cawley, J. D.↗

NASA NTRS2000

Environment Conscious Ceramics (Ecoceramics)

Environment conscious ceramics (Ecoceramics) are a new class of materials, which can be produced with renewable natural resources (wood) or wood wastes (wood sawdust). Silicon carbide-based ecoceramics have been fabricated by reactive infiltration of carbonaceous preforms by molten silicon or silicon-refractory metal alloys. These carbonaceous preforms have been fabricated by pyrolysis of solid wood bodies at 1000 C. The fabrication approach, microstructure, and mechanical properties of SiC-based ecoceramics are presented. Ecoceramics have tailorable properties and behave like ceramic materials manufactured by conventional approaches.

Singh, Mrityunjay↗

NASA NTRS2000

Coated Feedstock for Fabrication of Ceramic Parts by CAM-LEM

In laminated object manufacturing of ceramic components, lamination is one of the most important materials issues. Good lamination ensures monolithic component after firing. Otherwise, lamination defects that inevitably will occur in the parts will affect the properties of ceramic components. Adhesive (both liquid and non-liquid) lamination processes were developed for the cut-then-stack (CAM-LEM) procedure. The non-liquid adhesive lamination is discussed in detail.

Liu, Zhien↗

NASA NTRS2000

The Single-Crystal Elasticity of Yttria (Y2O3) to High Temperature

The single-crystal elastic moduli of yttria have been measured by Brillouin spectroscopy up to 1200 C. The room temperature values obtained are C11 = 223.6 +/- 0.6 GPa, C44 = 74.6 +/- 0.5 GPa, and C12 = 112.4 +/- 1.0 GPa. The resulting bulk and (Voigt-Reuss-Hill) shear moduli are K = 149.5 +/- 1.0 GPa and G(sub VRH) = 66.3 +/- 0.8 GPa, respectively. These agree much more closely with experimental values reported for polycrystalline samples than do previous single-crystal measurements. Linear least squares regressions to the variation of bulk and shear moduli with temperature result in derivatives of dK/dT = -17 +/- 2 MPa/degC and dG(sub VRH)/dT = -8 +/- 2 MPa/degC. Elastic anisotropy was found to remain essentially constant over the temperature range studied.

Kriven, Waltraud M.↗

NASA NTRS1999

Method for Forming Fiber Reinforced Composite Bodies with Graded Composition and Stress Zones

A near-net, complex shaped ceramic fiber reinforced silicon carbide based composite bodies with graded compositions and stress zones is disclosed. To provide the composite a fiber preform is first fabricated and an interphase is applied by chemical vapor infiltration, sol-gel or polymer processes. This first body is further infiltrated with a polymer mixture containing carbon, and/or silicon carbide, and additional oxide, carbide, or nitride phases forming a second body. One side of the second body is spray coated or infiltrated with slurries containing high thermal expansion and oxidation resistant. crack sealant phases and the other side of this second body is coated with low expansion phase materials to form a third body. This third body consisting of porous carbonaceous matrix surrounding the previously applied interphase materials, is then infiltrated with molten silicon or molten silicon-refractory metal alloys to form a fourth body. The resulting fourth body comprises dense composites consisting of fibers with the desired interphase which are surrounded by silicon carbide and other second phases materials at the outer and inner surfaces comprising material of silicon, germanium, refractory metal suicides, borides, carbides, oxides, and combinations thereof The resulting composite fourth body has different compositional patterns from one side to the other.

Singh, Mrityunjay↗

NASA NTRS1995

Effect of Stacking Faults on the X-Ray Diffraction Profiles of Beta-SiC Powders

X-ray diffraction patterns or beta-SiC (3C or the cubic polytype or sic) powders often exhibit an additional peak at d = 0.266 nm, high background intensity around the (111) peak, and relative intensities for peaks which differ from those predicted from the crystal structure. Computer simulations were used to show that all these features are due to stacking faults in the powders and not due to the presence of other polytypes in the powders. Such simulations allow diffraction patterns to be generated for different types, frequencies, and spatial distribution or faults. Comparison of the simulation results to the XRD data indicates that the B-SiC particles consist either of heavily faulted clusters distributed irregularly between regions that have only occasional faults or twins, or the powders consist of two types of particles with different populations of faults: those with a high density of faults and those with only twins or occasional faults. Additional information is necessary to determine which description is correct. However, the simulation results can be used to rule out certain fault configurations.

Pujar, Vijay V.↗

NASA NTRS1994

Composites research at NASA Lewis Research Center

Composites research at NASA Lewis is focused on their applications in aircraft propulsion, space propulsion, and space power, with the first being predominant. Research on polymer-, metal-, and ceramic-matrix composites is being carried out from an integrated materials and structures viewpoint. This paper outlines some of the topics being pursued from the standpoint of key technical issues, current status, and future directions.

Levine, Stanley R.↗

NASA NTRS1993

Sintering silicon nitride

Oxides having a composition of (Ba(1-x)Sr(x))O-Al2O3-2SiO2 are used as sintering aids for producing an improved silicon nitride ceramic material. The x must be greater than 0 to insure the formation of the stable monoclinic celsian glass phase.

Bansal, Narottam P.↗

NASA NTRS1992

Ceramics and ceramic matrix composites - Aerospace potential and status

Thermostructural ceramics and ceramic-matrix composites are attractive in numerous aerospace applications; the noncatastrophic fracture behavior and flaw-insensitivity of continuous fiber-reinforced CMCs renders them especially desirable. The present development status evaluation notes that, for most highly-loaded high-temperature applications, the requisite fiber-technology base is at present insufficient. In addition to materials processing techniques, the life prediction and NDE methods are immature and require a projection of 15-20 years for the maturity of CMC turbine rotors. More lightly loaded, moderate temperature aircraft engine applications are approaching maturity.

Levine, Stanley R.↗

NASA NTRS1992

Flight-vehicle materials, structures, and dynamics - Assessment and future directions. Vol. 3 - Ceramics and ceramic-matrix composites

The present volume discusses ceramics and ceramic-matrix composites in prospective aerospace systems, monolithic ceramics, transformation-toughened and whisker-reinforced ceramic composites, glass-ceramic matrix composites, reaction-bonded Si3N4 and SiC composites, and chemical vapor-infiltrated composites. Also discussed are the sol-gel-processing of ceramic composites, the fabrication and properties of fiber-reinforced ceramic composites with directed metal oxidation, the fracture behavior of ceramic-matrix composites (CMCs), the fatigue of fiber-reinforced CMCs, creep and rupture of CMCs, structural design methodologies for ceramic-based materials systems, the joining of ceramics and CMCs, and carbon-carbon composites.

Levine, Stanley R.↗

NASA NTRS1992

Ceramics and ceramic composites in future aeronautical and space systems

An account is given of the advantages of ceramics-based materials systems in thermostructural applications in aircraft propulsion, spacecraft propulsion and power systems, aerospace (transatmospheric) vehicles, and space structures. Prototype component applications are evaluated with a view to further technical requirements entailed by the implementation of such ceramic components. Typical near-term applications are the Space Shuttle's thermal protection system and high temperature aircraft thermal insulators; a major long-term development goal is that of integrally bladed turbine rotors in aircraft gas turbines. The fiber technology required for highly loaded/high temperature operations is not yet mature; use temperatures are restricted to 1100-1300 C.

Levine, Stanley R.↗