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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 NTRS2015

NASA NDE Program

The current activities in the National Aeronautics and Space Administration Nondestructive Evaluation (NDE) Program are presented. The topics covered include organizational communications, orbital weld inspection, electric field imaging, fracture critical probability of detection validation, monitoring of thermal protection systems, physical and document standards, image quality indicators, integrity of composite pressure vessels, and NDE for additively manufactured components.

Generazio, Ed↗

NASA NTRS1993

Effects of thermal and mechanical fatigue on the flexural strength of G40-600/PMR-15 cross-ply laminates

The effects of thermal and mechanical fatigue on the flexural strength of G40-600/PMR-15 cross-ply laminates with ply orientation of (0(2),90(2))2S and (90(2),0(2))2S are examined. The relative importance of shear and tensile stresses is examined by varying the span-to-depth ratios of flexural test specimens from 8 to 45. Acoustic emission signals are measured during the flexural tests in order to monitor the initiation and growth of damage. Optical microscopy is used to examine specimens for resin cracking, delamination, and fiber breaks after testing. Transverse matrix cracks and delaminations occur in all specimens, regardless of ply orientation, span-to-depth ratio, or previous exposure of specimens to thermal and mechanical fatigue. A small amount of fiber tensile fracture occurs in the outer 0 deg ply of specimens with high span-to-depth ratios. Because of the complex failure modes, the flexural test results represent the 'apparent' strengths rather than the true flexural or shear strengths for these cross-ply laminates. Thermal cycling of specimens prior to flexural testing does not reduce the apparent flexural strength or change the mode of failure. However, fewer acoustic events are recorded at all strains during flexural testing of specimens exposed to prior thermal cycling. High temperature thermal cycling (32 to 260 C, 100 cycles) causes a greater reduction in acoustic events than low temperature thermal cycling (-85 to +85 C, 500 cycles). Mechanical cycling (0 to 50 percent of the flexural strength, 100 cycles) has a similar effect, except that acoustic events are reduced only at strains less than the maximum strain applied during flexural fatigue.

Roberts, Gary D.↗

NASA NTRS2005

Micromechanics, Fracture Mechanics and Gas Permeability of Composite Laminates for Cryogenic Storage Systems

A micromechanics method is developed to investigate microcrack propagation in a liquid hydrogen composite tank at cryogenic temperature. The unit cell is modeled using square and hexagonal shapes depends on fiber and matrix layout from microscopic images of composite laminates. Periodic boundary conditions are applied to the unit cell. The temperature dependent properties are taken into account in the analysis. The laminate properties estimated by the micromechanics method are compared with empirical solutions using constituent properties. The micro stresses in the fiber and matrix phases based on boundary conditions in laminate level are calculated to predict the formation of microcracks in the matrix. The method is applied to an actual liquid hydrogen storage system. The analysis predicts micro stresses in the matrix phase are large enough to cause microcracks in the composite. Stress singularity of a transverse crack normal to a ply-interface is investigated to predict the fracture behavior at cryogenic conditions using analytical and finite element analysis. When a transverse crack touches a ply-interface of a composite layer with same fiber orientation, the stress singularity is equal to 1/2. When the transverse crack propagates to a stiffer layer normal to the ply-direction, the singularity becomes less than 1/2 and vice versa. Finite element analysis is performed to predict the fracture toughness of a laminated beam subjected to fracture loads measured by four-point bending tests at room and cryogenic temperatures. As results, the fracture load at cryogenic temperature is significantly lower than that at room temperature. However, when thermal stresses are taken into consideration, for both cases of room and cryogenic temperatures, the difference of the fracture toughness becomes insignificant. The result indicates fracture toughness is a characteristic property, which is independent to temperature changes. The experimental analysis is performed to investigate the effect of cryogenic cycling on permeability for various composite material systems. Textile composites have lower permeability than laminated composites even with increasing number of cryogenic cycle. Nano-particles dispersed in laminated composites do not show improvement on permeability. The optical inspection is performed to investigate the microcrack propagation and void content in laminated composites and compared the microscopic results before and after cryogenic cycling.

Choi, Sukjoo↗

NASA NTRS1995

A Petrographic History of Martian Meteorite ALH84001: Two Shocks and an Ancient Age

ALH84001 is an igneous meteorite, an orthopyroxenite of martian origin. It contains petrographic evidence of two shock metamorphic events, separated by thermal and chemical events. The evidence for two shock events suggests that ALH84001 is ancient and perhaps a sample of the martian highlands. From petrography and mineral chemistry, the history of ALH84001 must include: crystallization from magma, a first shock (impact) metamorphism, thermal metamorphism, low-temperature chemical alteration, and a second shock (impact) metamorphism. Originally, ALH84001 was igneous, an orthopyroxene-chromite cumulate. In the first shock event, the igneous rock was cut by melt-breccia or cataclastic veinlets, now bands of equigranular fine-grained pyroxene and other minerals (crush zones). Intact fragments of the cumulate were fractured and strained (now converted to polygonized zones). The subsequent thermal metamorphism (possibly related to the first shock) annealed the melt-breccia or cataclastic veinlets to their present granoblastic texture and permitted chemical homogenization of all mineral species present. The temperature of metamorphism was at least 875 C, based on mineral thermometers. Next, Mg-Fe-Ca carbonates and pyrite replaced plagioclase in both clasts and granular bands, producing ellipsoidal carbonate globules with sub-micron scale compositional stratigraphy, repeated identically in all globules, The second shock event produced microfault offsets of carbonate stratigraphy and other mineral contacts, radial fractures around chromite and maskelynite, and strain birefringence in pyroxene. Maskelynite could not have been preserved from the first shock event, because it would have crystallized back to plagioclase. The martian source area for ALH84001 must permit this complex, multiple impact history. Very few craters on young igneous surfaces are on or near earlier impact features. It is more likely that ALH84001 was ejected from an old igneous unit (Hesperian or Noachian age), pocked by numerous impact craters over its long exposure at the martian surface.

Treiman, Allan H.↗

NASA NTRS2014

Properties of Desert Sand and CMAS Glass

As-received desert sand from a Middle East country has been characterized for its phase composition and thermal stability. X-ray diffraction analysis showed the presence of quartz (SiO2), calcite (CaCO3), gypsum (CaSO4.2H2O), and NaAlSi3O8 phases in as-received desert sand and showed weight loss of approx. 35 percent due to decomposition of CaCO3 and CaSO4.2H2O when heated to 1400 C. A batch of as-received desert sand was melted into calcium magnesium aluminosilicate (CMAS) glass at approx. 1500 C. From inductively coupled plasma-atomic emission spectrometry, chemical composition of the CMAS glass was analyzed to be 27.8CaO-4MgO-5Al2O3-61.6SiO2-0.6Fe2O3-1K2O (mole percent). Various physical, thermal and mechanical properties of the glass have been evaluated. Bulk density of CMAS glass was 2.69 g/cc, Young's modulus 92 GPa, Shear modulus 36 GPa, Poisson's ratio 0.28, dilatometric glass transition temperature (T (sub g)) 706 C, softening point (T (sub d)) 764 C, Vickers microhardness 6.3 +/- 0.4 GPa, indentation fracture toughness 0.75 +/- 0.15 MPa.m (sup 1/2), and coefficient of thermal expansion (CTE) 9.8 x 10 (exp -6)/degC in the temperature range 25 to 700 C. Temperature dependence of viscosity has also been estimated from various reference points of the CMAS glass using the Vogel-Fulcher-Tamman (VFT) equation. The glass remained amorphous after heat treating at 850 C for 10 hr but crystallized into CaSiO3 and Ca-Mg-Al silicate phases at 900 C or higher temperatures. Crystallization kinetics of the CMAS glass has also been investigated by differential thermal analysis (DTA). Activation energies for the crystallization of two different phases in the glass were calculated to be 403 and 483 kJ/mol, respectively.

Desert sand↗

NASA NTRS1988

Status of Gr/glass composites technology at UTOS

The TSC (Thermally Stable Composite) refers to a family of graphite reinforced glass matrix composite materials developed by UTOS. This fiber matrix combination exhibits low coefficients of thermal expansion (CTE), exceptional dimensional stability, high specific strength and stiffness, adequate fracture toughness, and space environment compatibility. The dimensional stability of a TSC mirror structure was experimentally characterized at the Steward Observatory. Preliminary results indicate that TSC is significantly more thermally stable than most current structural composite materials. In addition, the use of lower CTE glass matrix materials, such as 96 percent silica glass, have the potential for producing graphite/glass panels with expansion rates and stability comparable to that of fused silica.

Mayor, Ramon A.↗

NASA NTRS2005

Lifetime Reliability Prediction of Ceramic Structures Under Transient Thermomechanical Loads

An analytical methodology is developed to predict the probability of survival (reliability) of ceramic components subjected to harsh thermomechanical loads that can vary with time (transient reliability analysis). This capability enables more accurate prediction of ceramic component integrity against fracture in situations such as turbine startup and shutdown, operational vibrations, atmospheric reentry, or other rapid heating or cooling situations (thermal shock). The transient reliability analysis methodology developed herein incorporates the following features: fast-fracture transient analysis (reliability analysis without slow crack growth, SCG); transient analysis with SCG (reliability analysis with time-dependent damage due to SCG); a computationally efficient algorithm to compute the reliability for components subjected to repeated transient loading (block loading); cyclic fatigue modeling using a combined SCG and Walker fatigue law; proof testing for transient loads; and Weibull and fatigue parameters that are allowed to vary with temperature or time. Component-to-component variation in strength (stochastic strength response) is accounted for with the Weibull distribution, and either the principle of independent action or the Batdorf theory is used to predict the effect of multiaxial stresses on reliability. The reliability analysis can be performed either as a function of the component surface (for surface-distributed flaws) or component volume (for volume-distributed flaws). The transient reliability analysis capability has been added to the NASA CARES/ Life (Ceramic Analysis and Reliability Evaluation of Structures/Life) code. CARES/Life was also updated to interface with commercially available finite element analysis software, such as ANSYS, when used to model the effects of transient load histories. Examples are provided to demonstrate the features of the methodology as implemented in the CARES/Life program.

Nemeth, Noel N.↗

NASA NTRS1982

Advanced ceramic coating development for industrial/utility gas turbine applications

The effects of ceramic coatings on the lifetimes of metal turbine components and on the performance of a utility turbine, as well as of the turbine operational cycle on the ceramic coatings were determined. When operating the turbine under conditions of constant cooling flow, the first row blades run 55K cooler, and as a result, have 10 times the creep rupture life, 10 times the low cycle fatigue life and twice the corrosion life with only slight decreases in both specific power and efficiency. When operating the turbine at constant metal temperature and reduced cooling flow, both specific power and efficiency increases, with no change in component lifetime. The most severe thermal transient of the turbine causes the coating bond stresses to approach 60% of the bond strengths. Ceramic coating failures was studied. Analytic models based on fracture mechanics theories, combined with measured properties quantitatively assessed both single and multiple thermal cycle failures which allowed the prediction of coating lifetime. Qualitative models for corrosion failures are also presented.

Andersson, C. A.↗

NASA NTRS2015

Opportunity In Situ Geologic Context of Aqueous Alteration Along Offsets in the Rim of Endeavour Crater

Mars Exploration Rover Opportunity traversed 7.9 km and 27 degrees of arc along the rim of the 22 km-diameter Noachian "Endeavour" impact crater since its arrival 1200 sols ago. Areas of aqueous and low-grade thermal alteration, and changes in structure, attitude, and macroscopic texture of outcrops are notable across several discontinuities between segments of the crater rim. The discontinuities and other post-impact joints and fractures coincide with sites of apparent deep fluid circulation processes responsible for thermal and chemical alteration of local outcrops.

Crumpler, L. S.↗

NASA NTRS1989

Observations of winter polynyas and fractures using NOAA AVHRR TIR images and Nimbus-7 SMMR sea ice concentration charts

The validity of the daily sea ice concentration charts obtained from Nimbus-7 SMMR data is tested against thermal IR NOAA AVHRR-4 images with a 1.1 x 1.1 km resolution. Polynyas and fractures recorded in both data sets are compared for the same times over the same areas. Although the coarser resolution of SMMR data leads to a loss of detail, it is found that the ice concentration charts provide valuable data on openings in the ice. The SMMR data on the location, orientation, and size of polynyas and fractures are shown to be in good agreement with the AVHRR data. Also, the results suggest that the location and orientation of plynyas and fractures are related to the direction of surface winds.

Dey, B.↗

NASA NTRS1992

Glasses, ceramics, and composites from lunar materials

A variety of useful silicate materials can be synthesized from lunar rocks and soils. The simplest to manufacture are glasses and glass-ceramics. Glass fibers can be drawn from a variety of basaltic glasses. Glass articles formed from titania-rich basalts are capable of fine-grained internal crystallization, with resulting strength and abrasion resistance allowing their wide application in construction. Specialty glass-ceramics and fiber-reinforced composites would rely on chemical separation of magnesium silicates and aluminosilicates as well as oxides titania and alumina. Polycrystalline enstatite with induced lamellar twinning has high fracture toughness, while cordierite glass-ceramics combine excellent thermal shock resistance with high flexural strengths. If sapphire or rutile whiskers can be made, composites of even better mechanical properties are envisioned.

Beall, George H.↗

NASA NTRS2016

Investigation of Desiccants and CO2 Sorbents for Advanced Exploration Systems 2015-2016

Design of advanced carbon dioxide removal systems begins with the study of sorbents. Specifically, new CO2 sorbents and desiccants need to be studied to enable greater productivity from existing and future spaceflight systems. This presentation will discuss the studies used as input for selecting future CO2 sorbent materials. Also, the adjoining issues of understanding the effects of water co-adsorption and material selection for desiccant beds will be discussed. Current sorbents for CO2 removal are based on 5A zeolites, but a transition to sorbents derived from 13X will be necessary as CO2 levels in cabin air become leaner. Unfortunately, these 13X zeolites are more susceptible to long-term performance loss due to water co-adsorption than 5A due at achievable regeneration temperatures. A study on how impactful the presence of trace water will be to the cyclic operation of small-scale beds will be discussed. Also, methods to recover the performance of beds in a space environment after a major moisture adsorption event will be discussed. The information obtained from the water co-adsorption studies will play a major part in selecting a CO2 sorbent for advanced removal systems. Pellet structural properties play another major role in the selection process. One factor for long-term, hands-off operation of a system is pellet integrity. Maintaining integrity means preventing pellet fracture and the generation of fines due to various thermal and mechanical means which would eventually clog filters or damage downstream systems. Either of these problems require significant shutdowns and maintenance operations and must be avoided. Therefore, study of high-integrity pellets and design of new pellets will be discussed.

Knox, James C.↗

NASA NTRSDate not supplied

Operating and Maintaining the JWST Cleanroom attached to JSC's Chamber A during preparations for the OTIS Cryogenic Thermal Vacuum Test

In order to maintain cleanliness during preparations for JWST’s OTIS (Optical Telescope Element-Integrated Science Instrument Module) Cryogenic Thermal Vacuum Test, a cleanroom was built that attached directly to the 60-year-old Chamber A. The cleanroom and chamber were outfitted with independent environmental control systems each providing ISO Class 71 air cleanliness. To maintain balanced, positive pressure in both the cleanroom and chamber volumes, a special control protocol was developed and successfully implemented. Dual back-up environmental control units (one each for the chamber and cleanroom) were installed just outside the building to provide environmental control redundancy due to a single source chilled water supply and weather threats. In addition, lack of a dedicated cleanroom airlock facilitating clean ingress and egress made it necessary to perform additional cleaning and packaging, as well as augment the uncontrolled truck lock space with small clean tents for pre-cleaning. Special procedures were developed to allow ingress of extra-large support equipment required for load testing of the cleanroom crane, installation of optical equipment in Chamber A and accommodation of the OTIS shipping container. A thorough bake-out and cleaning of Chamber A was also necessary to reduce volatiles from the shroud’s black thermal paint and to reduce particle fallout. Acrylic adhesive fracture discovered during early cryo-testing represented a significant challenge that was successfully mitigated prior to OTIS testing. A dedicated team of Contamination Control (CC) Technicians was specifically trained to clean support equipment and screen materials entering the cleanroom and chamber to ensure cleanliness and vacuum compatibility.

Optics↗

NASA NTRSDate not supplied

Operating and Maintaining the JWST Cleanroom attached to JSC's Chamber A during preparations for the OTIS Cryogenic Thermal Vacuum Test

James Webb Space Telescope↗

NASA NTRS1978

Thermal shock and erosion resistant tantalum carbide ceramic material

Ceramic tantalum carbide artifacts with high thermal shock and mechanical erosion resistance are provided by incorporating tungsten-rhenium and carbon particles in a tantalum carbide matrix. The mix is sintered by hot pressing to form the ceramic article which has a high fracture strength relative to its elastic modulus and thus has an improved thermal shock and mechanical erosion resistance. The tantalum carbide is preferable less than minus 100 mesh, the carbon particles are preferable less than minus 100 mesh, and the tungsten-rhenium particles are preferable elongate, having a length to thickness ratio of at least 2/1. Tungsten-rhenium wire pieces are suitable as well as graphite particles.

Honeycutt, L., III↗

NASA NTRS1982

Tensile properties of SiC/aluminum filamentary composites - Thermal degradation effects

Aluminium metal matrix composites with a low cost fiber, e.g. SiC, provide for an attractive combination of high elastic modulus and longitudinal strengths coupled with a low density. SiC (volume fraction 0.55)-aluminum (6061) systems have been studied in order to optimize fiber composite strength and processing parameters. A comparison of two SiC/aluminum composites produced by AVCO and DWA is provided. Fiber properties are shown to alter composite tensile properties and fracture morphology. The room temperature tensile strengths appear to be insensitive to thermal exposures at 500 C up to 150 h. The elastic modulus of the composites also appears to be stable up to 400 C, however variations in the loss modulus are apparent. The fracture morphology reflects the quality of the interfacial bond, fiber strengths and fiber processing.

Skinner, A.↗

NASA NTRS1993

NASA-UVA Light Aerospace Alloy and Structures Technology Program (LA2ST)

The NASA-UVA Light Aerospace Alloy and Structures Technology (LA2ST) Program continues a high level of activity. Progress achieved between 1 Jan. and 30 Jun. 1993 is reported. The objective of the LA2ST Program is to conduct interdisciplinary graduate student research on the performance of next generation, light weight aerospace alloys, composites, and thermal gradient structures in collaboration with NASA-Langley researchers. The following projects are addressed: environmental fatigue of Al-Li-Cu alloys; mechanisms of localized corrosion and environmental fracture in Al-Cu-Li-Mg-Ag alloy X2095 and compositional variations; the effect of zinc additions on the precipitation and stress corrosion cracking behavior of alloy 8090; hydrogen interactions with Al-Li-Cu alloy 2090 and model alloys; metastable pitting of aluminum alloys; cryogenic fracture toughness of Al-Cu-Li + In alloys; the fracture toughness of Weldalite (TM); elevated temperature cracking of advanced I/M aluminum alloys; response of Ti-1100/SCS-6 composites to thermal exposure; superplastic forming of Weldalite (TM); research to incorporate environmental effects into fracture mechanics fatigue life prediction codes such as NASA FLAGRO; and thermoviscoplastic behavior.

Gangloff, Richard P.↗