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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

Open hole and postimpact compressive fatigue of stitched and unstitched carbon-epoxy composites

The performance is studied of a stitched uniweave fabric composite and that of a toughened tape composite. The effects of stitching on compression fatigue life are addressed. Post impact compression fatigue and open hole fatigue tests were run on an AS4/3501-6 uniweave with stitching and a toughened IM7/8551-7 tape without stitching. Stitching was found to increase the thickness and consequently the weight of the composite material. The two materials were compared on an equal carbon content basis as well as on an equal weight basis. The excess thickness in the stitched uniweave composite was responsible for the lower fatigue life, on an equal carbon basis, compared to the toughened resin tape composite. Comparison of fatigue lives on an equal carbon content basis indicated that puncture or crimp type damage from stitching has very little effect on compression failure. Post impact fatigue test showed that although the damage area in the stitched uniweave composite was twice that of the toughened tape composite, the fatigue lives of the stitched composite were significantly longer than those of the toughened composite. Thus, it appears that the increase in thickness from stitching is much more of a penalty than crimped fibers or puncture type damage from stitching.

Portanova, Marc A.↗

NASA NTRS1990

Intermetallic matrix composites; Proceedings of the MRS Symposium, San Francisco, CA, Apr. 18-20, 1990

The present volume on intermetallic matrix composites discusses the modeling, processing, microstructure/property relationships, and compatibility of intermetallic matrix composites. Attention is given to models for the strength of ductile matrix composites, innovative processing techniques for intermetallic matrix composites, ductile phase toughening of brittle intermetallics, and reactive synthesis of NbAl3 matrix composites. Topics addressed include solidification processing of NbCr2 alloys, Ta and Nb reinforced MoSi2, the microstructure and mechanical behavior of Ni3Al-matrix composites, and ductile-phase toughening of Cr3Si with chromium. Also discussed are dislocation morphologies in TiB2/NiAl, the development of highly impact resistant NiAl matrix composites, the effect of notches on the fatigue life of the SCS-6Ti3Al composite, and the chemical stability of fiber-metal matrix composites.

Anton, D. L.↗

NASA NTRS1993

An overview of the NASA textile composites program

The NASA Langley Research Center is conducting and sponsoring research to explore the benefits of textile reinforced composites for civil transport aircraft primary structures. The objective of this program is to develop and demonstrate the potential of affordable textile reinforced composite materials to meet design properties and damage tolerance requirements of advanced aircraft structures. In addition to in-house research, the program includes major participation by the aircraft industry and aerospace textile companies. The major program elements include development of textile preforms, processing science, mechanics of materials, experimental characterization of materials, and development and evaluation of textile reinforced composite structural elements and subcomponents. The NASA Langley in-house research is focused on science-based understanding of resin transfer molding (RTM), development of powder-coated towpreg processes, analysis methodology, and development of a performance database on textile reinforced composites. The focus of the textile industry participation is on development of multidirectional, damage-tolerant preforms, and the aircraft industry participation is in the areas of innovative design concepts, cost-effective fabrication, and testing of textile reinforced composite structural elements and subcomponents. Textile processes such as 3-D weaving, 2-D and 3-D braiding, and knitting/stitching are being compared with conventional laminated tape processes for improved damage tolerance. Through-the-thickness reinforcements offer significant damage tolerance improvements. However, these gains must be weighed against potential loss in in-plane properties such as strength and stiffness. Analytical trade studies are underway to establish design guidelines for the application of textile material forms to meet specific loading requirements. Fabrication and testing of large structural components are required to establish the full potential of textile reinforced composite materials. The goals of the NASA Langley-sponsored research program are to demonstrate technology readiness with subscale composite components by 1995 and to verify the performance of full-scale composite primary aircraft structural components by 1997. The status of textile reinforced composite structural elements under development by Boeing, Douglas, Lockheed, and Grumman are presented. Included are braided frames and woven/stitched wing and fuselage panels.

Dexter, H. Benson↗

NASA NTRS1992

Properties of Graphite Fiber Reinforced Copper Matrix Composites for Space Power Applications

The thermal and mechanical properties of pitch-based graphite fiber reinforced copper matrix (Gr/Cu) composites usable for space applications such as radiator fins were investigated. Thermal conductivity was measured as a function of fiber volume fraction and architecture. Results showed for unidirectional P-100 Gr/Cu composites, the longitudinal thermal conductivity was nearly independent of fiber volume fraction. Transverse thermal conductivities (perpendicular to the fibers) were strongly affected by the fiber volume fraction with higher volume fractions resulting in lower thermal conductivities. The effect of architecture on thermal conductivity followed the cosine squared law for simple architectures. Insufficient data are available currently to model more complex architectures, but adding fibers in the direction of the heat flow increases the thermal conductivity as low conductivity plies are supplemented by high conductivity plies. Thermal expansion tests were conducted on the Gr fibers and Gr/Cu composites. The results show a considerable thermal expansion mismatch between the fibers and the Cu matrix. The longitudinal thermal expansion showed a strong dependence on the architecture of the Gr/Cu composites. The composites also show a thermal expansion hysteresis. The hysteresis was eliminated by an engineered interface. Mechanical testing concentrated on the dynamic modulus and strength of the composites. The dynamic modulus of the Gr/Cu composites was 305 GPa up to 400 C, a value equivalent to Be. The strengths of the composites were less than expected, but this is attributed to the poor bond across the interface between the Gr fibers and Cu matrix. Testing of composites with an engineered interface is expected to yield strengths nearer the values predicted by the rule of mixtures.

Ellis, David L.↗

NASA NTRS1993

IPACS (Integrated Probabilistic Assessment of Composite Structures): Code development and applications

A methodology and attendant computer code have been developed and are described to computationally simulate the uncertain behavior of composite structures. The uncertain behavior includes buckling loads, stress concentration factors, displacements, stress/strain etc., which are the consequences of the inherent uncertainties (scatter) in the primitive (independent random) variables (constituent, ply, laminate and structural) that describe the composite structures. The computer code, IPACS (Integrated Probabilistic Assessment of Composite Structures), can handle both composite mechanics and composite structures. Application to probabilistic composite mechanics is illustrated by its uses to evaluate the uncertainties in the major Poisson's ratio and in laminate stiffness and strength. IPACS application to probabilistic structural analysis is illustrated by its use to evaluate the uncertainties in the buckling of a composite plate, in the stress concentration factor in a composite panel and in the vertical displacement and ply stress in a composite aircraft wing segment.

Chamis, C. C.↗

NASA NTRS1994

Fiber-matrix interphase characterization in composites using ultrasonic velocity data

A nondestructive method is introduced to determine the effective elastic of fiber-matrix interphases from measured composite moduli. The composite moduli are obtained by measuring the angular dependences of ultrasonic longitudinal and transverse phase velocities in planes along and perpendicular to the fibers. Three independent interphase effective moduli are found using micromechanical multiphase models which were applied after averaging composite transverse moduli to account for the composite orthotropy. Sensitivity analysis shows that errors in the calculated interphasial moduli are approximately ten times those in the composite moduli. Experiments are performed on Si3N4 ceramic and Ti-24Al-11Nb intermetallic matrix composites reinforced with carbon coated silicon carbide fibers. The experimental interphasial moduli for the intermetallic composites agree with literature data after accounting for the interphase microstructure. The interphasial moduli for ceramic composites are lower than those for the intermetallic composite due to imperfect mechanical contact between the interphase and the porous matrix. The use of the method to assess the interphase degradation is demonstrated for interphasial oxidation damage. The analysis helps to determine the morphology of the damaged interphase.

Chu, Y. C.↗

NASA NTRS1995

Tensile Behavior of Al2o3/feal + B and Al2o3/fecraly Composites

The feasibility of Al2O3/FeAl + B and Al2O3/FeCrAlY composites for high-temperature applications was assessed. The major emphasis was on tensile behavior of both the monolithics and composites from 298 to 1100 K. However, the study also included determining the chemical compatibility of the composites, measuring the interfacial shear strengths, and investigating the effect of processing on the strength of the single-crystal Al2O3 fibers. The interfacial shear strengths were low for Al203/FeAl + B and moderate to high for Al203/FeCrAlY. The difference in interfacial bond strengths between the two systems affected the tensile behavior of the composites. The strength of the Al203 fiber was significantly degraded after composite processing for both composite systems and resulted in poor composite tensile properties. The ultimate tensile strength (UTS) values of the composites could generally be predicted with either rule of mixtures (ROM) calculations or existing models when using the strength of the etched-out fiber. The Al2O3/FeAl + B composite system was determined to be unfeasible due to poor interfacial shear strengths and a large mismatch in coefficient of thermal expansion (CTE). Development of the Al2O3/FeCrAlY system would require an effective diffusion barrier to minimize the fiber strength degradation during processing and elevated temperature service.

Draper, S. L.↗

NASA NTRS1997

Analysis of Smart Composite Structures Including Debonding

Smart composite structures with distributed sensors and actuators have the capability to actively respond to a changing environment while offering significant weight savings and additional passive controllability through ply tailoring. Piezoelectric sensing and actuation of composite laminates is the most promising concept due to the static and dynamic control capabilities. Essential to the implementation of these smart composites are the development of accurate and efficient modeling techniques and experimental validation. This research addresses each of these important topics. A refined higher order theory is developed to model composite structures with surface bonded or embedded piezoelectric transducers. These transducers are used as both sensors and actuators for closed loop control. The theory accurately captures the transverse shear deformation through the thickness of the smart composite laminate while satisfying stress free boundary conditions on the free surfaces. The theory is extended to include the effect of debonding at the actuator-laminate interface. The developed analytical model is implemented using the finite element method utilizing an induced strain approach for computational efficiency. This allows general laminate geometries and boundary conditions to be analyzed. The state space control equations are developed to allow flexibility in the design of the control system. Circuit concepts are also discussed. Static and dynamic results of smart composite structures, obtained using the higher order theory, are correlated with available analytical data. Comparisons, including debonded laminates, are also made with a general purpose finite element code and available experimental data. Overall, very good agreement is observed. Convergence of the finite element implementation of the higher order theory is shown with exact solutions. Additional results demonstrate the utility of the developed theory to study piezoelectric actuation of composite laminates with pre-existing debonding. Significant changes in the modes shapes and reductions in the control authority result due to partially debonded actuators. An experimental investigation addresses practical issues, such as circuit design and implementation, associated with piezoelectric sensing and actuation of composite laminates. Composite specimens with piezoelectric transducers were designed, constructed and tested to validate the higher order theory. These specimens were tested with various stacking sequences, debonding lengths and gains for both open and closed loop cases. Frequency changes of 15% and damping on the order of more than 20% of critical damping, via closed loop control, was achieved. Correlation with the higher order theory is very good. Debonding is shown to adversely affect the open and closed loop frequencies, damping ratios, settling time and control authority.

Chattopadhyay, Aditi↗

NASA NTRS2001

Ultrasonic Resonance Spectroscopy of Composite Rings for Flywheel Rotors

Flywheel energy storage devices comprising multilayered composite rotor systems are being studied extensively for utilization in the International Space Station. These composite material systems were investigated with a recently developed ultrasonic resonance spectroscopy technique. The system employs a swept frequency approach and performs a fast Fourier transform on the frequency spectrum of the response signal. In addition. the system allows for equalization of the frequency spectrum, providing all frequencies with equal amounts of energy to excite higher order resonant harmonics. Interpretation of the second fast Fourier transform, along with equalization of the frequency spectrum, offers greater assurance in acquiring and analyzing the fundamental frequency, or spectrum resonance spacing. The range of frequencies swept in a pitch-catch mode was varied up to 8 MHz, depending on the material and geometry of the component. Single and multilayered material samples, with and without known defects, were evaluated to determine how the constituents of a composite material system affect the resonant frequency. Amplitude and frequency changes in the spectrum and spectrum resonance spacing domains were examined from ultrasonic responses of a flat composite coupon, thin composite rings, and thick composite rings. Also, the ultrasonic spectroscopy responses from areas with an intentional delamination and a foreign material insert, similar to defects that may occur during manufacturing malfunctions, were compared with those from defect-free areas in thin composite rings. A thick composite ring with varying thickness was tested to investigate the full-thickness resonant frequency and any possible bulk interfacial bond issues. Finally, the effect on the frequency response of naturally occurring single and clustered voids in a composite ring was established.

Harmon, Laura M.↗

NASA NTRS2002

The Velocity and Attenuation of Acoustic Emission Waves in SiC/SiC Composites Loaded in Tension

The behavior of acoustic waves produced by microfracture events and from pencil lead breaks was studied for two different silicon carbide fiber-reinforced silicon carbide matrix composites. The two composite systems both consisted of Hi-Nicalon (trademark) fibers and carbon interfaces but had different matrix compositions that led to considerable differences in damage accumulation and acoustic response. This behavior was primarily due to an order of magnitude difference in the interfacial shear stress for the two composite systems. Load/unload/reload tensile tests were performed and measurements were made over the entire stress range in order to determine the stress-dependence of acoustic activity for increasing damage states. It was found that using the extensional wave velocities from acoustic emission (AE) events produced from pencil lead breaks performed outside of the transducers enabled accurate measurements of the stiffness of the composite. The extensional wave velocities changed as a function of the damage state and the stress where the measurement was taken. Attenuation for AE waveforms from the pencil lead breaks occurred only for the composite possessing the lower interfacial shear stress and only at significantly high stresses. At zero stress after unloading from a peak stress, no attenuation occurred for this composite because of crack closure. For the high interfacial stress composite no attenuation was discernable at peak or zero stress over the entire stress-range of the composite. From these observations, it is believed that attenuation of AE waveforms is dependent on the magnitude of matrix crack opening.

Morscher, Gregory N.↗

NASA NTRS2002

Monitoring of Structural Integrity of Composite Structures by Embedded Optical Fiber Sensors

Real time monitoring of the mechanical integrity and stresses on key aerospace composite structures like aircraft wings, walls of pressure vessels and fuel tanks or any other structurally extended components and panels as in space telescopes is very important to NASA. Future military and commercial aircraft as well as NASA space systems such as Space Based Radar and International Space Station will incorporate a monitoring system to sense any degradation to the structure. In the extreme flight conditions of an aerospace vehicle it might be desirable to measure the strain every ten centimeters and thus fully map out the strain field of a composite component. A series of missions and vehicle health management requirements call for these measurements. At the moment thousands of people support a few vehicle launches per year. This number can be significantly reduced by implementing intelligent vehicles with integral nervous systems (smart structures). This would require maintenance to be performed only as needed. Military and commercial aircrafts have an equally compelling case. Maintenance yearly costs are currently reaching astronomical heights. Monitoring techniques are therefore required that allow for maintenance to be performed only when needed. This would allow improved safety by insuring that necessary tasks are performed while reducing costs by eliminating procedures that are costly and not needed. The advantages fiber optical sensors have over conventional electro-mechanical systems like strain gauges have been widely extolled in the research literature. These advantages include their small size, low weight, immunity to electrical resistance, corrosion resistance, compatibility with composite materials and process conditions, and multiplexing capabilities. One fiber optic device which is suitable for distributed sensing is the fiber Bragg grating (FBG). Researchers at NASA MSFC are currently developing techniques for using FBGs for monitoring the integrity of advanced structural materials expected to become the mainstay of the current and future generation space structures. Since carbon-epoxy composites are the materials of choice for the current space structures, the initial study is concentrated on this type of composite. The goals of this activity are to use embedded FBG sensors for measuring strain and temperature of composite structures, and to investigate the effects of various parameters such as composite fiber orientation with respect to the optical sensor, unidirectional fiber composite, fabrication process etc., on the optical performance of the sensor. This paper describes an experiment to demonstrate the use of an embedded FBG for measuring strain in a composite material. The performance of the fiber optic sensor is determined by direct comparison with results from more conventional instrumentation.

Albert J. Osei↗

NASA NTRS2002

Ultrasonic Resonance Spectroscopy of Composite Rims for Flywheel Rotors

Flywheel energy storage devices comprising multilayered composite rotor systems are being studied extensively for utilization in the International Space Station. These composite material systems were investigated with a recently developed ultrasonic resonance spectroscopy technique. The ultrasonic system employs a continuous swept-sine waveform and performs a fast Fourier transform (FFT) on the frequency response spectrum. In addition, the system is capable of equalizing the amount of energy at each frequency. Equalization of the frequency spectrum, along with interpretation of the second FFT, aids in the evaluation of the fundamental frequency. The frequency responses from multilayered material samples, with and without known defects, were analyzed to assess the capabilities and limitations of this nondestructive evaluation technique for material characterization and defect detection. Amplitude and frequency changes were studied from ultrasonic responses of thick composite rings and a multiring composite rim. A composite ring varying in thickness was evaluated to investigate the full thickness resonance. The frequency response characteristics from naturally occurring voids in a composite ring were investigated. Ultrasonic responses were compared from regions with and without machined voids in a composite ring and a multiring composite rim. Finally, ultrasonic responses from the multiring composite rim were compared before and after proof spin testing to 63,000 rpm.

Harmon, Laura M.↗

NASA NTRS2003

Investigation of Structural Properties of Carbon-Epoxy Composites Using Embedded Fiber-Optic Bragg Gratings

Real time monitoring of the mechanical integrity and stresses on key aerospace composite structures like aircraft wings, walls of pressure vessels and fuel tanks or any other structurally extended components and panels as in space telescopes is very important to NASA. Future military and commercial aircraft as well as NASA space systems such as Space Based Radar and International Space Station will incorporate a monitoring system to sense any degradation to the structure. In the extreme flight conditions of an aerospace vehicle it might be desirable to measure the strain every ten centimeters and thus fully map out the strain field of a composite component. A series of missions and vehicle health management requirements call for these measurements. At the moment thousands of people support a few vehicle launches per year. This number can be significantly reduced by implementing intelligent vehicles with integral nervous systems (smart structures). This would require maintenance to be performed only as needed. Military and commercial aircrafts have an equally compelling case. Annual maintenance costs are currently reaching astronomical heights. Monitoring techniques are therefore required that allow for maintenance to be performed only when needed. This would allow improved safety by insuring that necessary tasks are performed while reducing costs by eliminating procedures that are costly and not needed. The advantages fiber optical sensors have over conventional electro-mechanical systems like strain gauges have been widely extolled in the research literature. These advantages include their small size, low weight, immunity to electrical resistance, corrosion resistance, compatibility with composite materials and process conditions, and multiplexing capabilities. One fiber optic device which is suitable for distributed sensing is the fiber Bragg grating (FBG). This is a periodic perturbation in the refractive index of the fiber core. When a broadband light is coupled into the optical fiber sensor, a reflection peak will be obtained centered around a wavelength called Bragg-wavelength. The Bragg-wavelength depends on the refractive index and the period of the grating, which both change due to mechanical and thermal strain applied to the sensor. The shift in the Bragg-wavelength is directly proportional to the strain. Researchers at NASA MSFC are currently developing techniques for using FBGs for monitoring the integrity of advanced structural materials expected to become the mainstay of the current and future generation space structures. Since carbon-epoxy composites are the materials of choice for the current space structures, the initial study is concentrated on this type of composite. The goals of this activity are to use embedded FBG sensors for measuring strain and temperature of composite structures, and to investigate the effects of various parameters such as composite fiber orientation with respect to the optical sensor, unidirectional fiber composite, fabrication process etc., on the optical performance of the sensor. This paper describes an experiment to demonstrate the use of an embedded FBG for measuring strain in a composite material. The performance of the fiber optic sensor is determined by direct comparison with results from more conventional instrumentation.

Osei, Albert J.↗

NASA NTRS2004

Identification of Interplanetary Coronal Mass Ejections at 1 AU Using Multiple Solar Wind Plasma Composition Anomalies

We investigate the use of multiple simultaneous solar wind plasma compositional anomalies, relative to the composition of the ambient solar wind, for identifying interplanetary coronal mass ejection (ICME) plasma. We first summarize the characteristics of several solar wind plasma composition signatures (O(+7)/O(+6), Mg/O, Ne/O, Fe charge states, He/p) observed by the ACE and WIND spacecraft within the ICMEs during 1996 - 2002 identsed by Cane and Richardson. We then develop a set of simple criteria that may be used to identify such compositional anomalies, and hence potential ICMEs. To distinguish these anomalies from the normal variations seen in ambient solar wind composition, which depend on the wind speed, we compare observed compositional signatures with those 'expected' in ambient solar wind with the same solar wind speed. This method identifies anomalies more effectively than the use of fixed thresholds. The occurrence rates of individual composition anomalies within ICMEs range from approx. 70% for enhanced iron and oxygen charge states to approx. 30% for enhanced He/p (> 0.06) and Ne/O, and are generally higher in magnetic clouds than other ICMEs. Intervals of multiple anomalies are usually associated with ICMEs, and provide a basis for the identification of the majority of ICMEs. We estimate that Cane and Richardson, who did not refer to composition data, probably identitied approx. 90% of the ICMEs present. However, around 10% of their ICMEs have weak compositional anomalies, suggesting that the presence of such signatures does not provide a necessary requirement for an ICME. We note a remarkably similar correlation between the Mg/O and O(7)/O(6) ratios in hourly-averaged data both within ICMEs and the ambient solar wind. This 'universal' relationship suggests that a similar process (such as minor ion heating by waves inside coronal magnetic field loops) produces the first-ionization potential bias and ion freezing-in temperatures in the source regions of both ICMEs and the ambient solar wind.

Richardson, I. G.↗

NASA NTRS2005

Influence of Silicate Melt Composition on Metal/Silicate Partitioning of W, Ge, Ga and Ni

The depletion of the siderophile elements in the Earth's upper mantle relative to the chondritic meteorites is a geochemical imprint of core segregation. Therefore, metal/silicate partition coefficients (Dm/s) for siderophile elements are essential to investigations of core formation when used in conjunction with the pattern of elemental abundances in the Earth's mantle. The partitioning of siderophile elements is controlled by temperature, pressure, oxygen fugacity, and by the compositions of the metal and silicate phases. Several recent studies have shown the importance of silicate melt composition on the partitioning of siderophile elements between silicate and metallic liquids. It has been demonstrated that many elements display increased solubility in less polymerized (mafic) melts. However, the importance of silicate melt composition was believed to be minor compared to the influence of oxygen fugacity until studies showed that melt composition is an important factor at high pressures and temperatures. It was found that melt composition is also important for partitioning of high valency siderophile elements. Atmospheric experiments were conducted, varying only silicate melt composition, to assess the importance of silicate melt composition for the partitioning of W, Co and Ga and found that the valence of the dissolving species plays an important role in determining the effect of composition on solubility. In this study, we extend the data set to higher pressures and investigate the role of silicate melt composition on the partitioning of the siderophile elements W, Ge, Ga and Ni between metallic and silicate liquid.

Singletary, S. J.↗

NASA NTRS2001

Uncertainties in the Thermal and Mechanical Properties of Particulate Composites Quantified

Particle-reinforced composites are candidate materials for a wide variety of aerospace and nonaerospace applications. The high costs and technical difficulties involved with the use of many fiber-reinforced composites often limit their use in many applications. Consequently, particulate composites have emerged as viable alternatives to conventional fiber-reinforced composites. Particulate composites can be processed to near net shapepotentially reducing the manufacturing costs. They are candidate materials where shock or impact properties are important. For example, particle-reinforced metal matrix composites have shown great potential for many automotive applications. Typically, these materials are aluminum matrix reinforced with SiC or TiC particles. Reinforced concrete can also be thought of as a particle-reinforced composite. In situ ceramics can be modeled as particulate composites and are candidate materials for many high-temperature applications. The characterization of these materials is fundamental to their reliable use. It has been observed that the overall properties of these composites exhibit scatter because of the uncertainty in the constituent material properties, and fabrication-related parameters.

Murthy, Pappu L. N.↗

NASA NTRS2002

Lightweight, Actively Cooled Ceramic Matrix Composite Thrustcells Successfully Tested in Rocket Combustion Lab

In a joint effort between the NASA Glenn Research Center and the NASA Marshall Space Flight Center, regeneratively cooled ceramic matrix composite (CMC) thrustcells were developed and successfully tested in Glenn's Rocket Combustion Lab. Cooled CMC's offer the potential for substantial weight savings over more traditional metallic parts. Two CMC concepts were investigated. In the first of these concepts, an innovative processing approach utilized by Hyper-Therm, Inc., allowed woven CMC coolant containment tubes to be incorporated into the complex thruster design. In this unique design, the coolant passages had varying cross-sectional shapes but maintained a constant cross-sectional area along the length of the thruster. These thrusters were silicon carbide matrix composites reinforced with silicon carbide fibers. The second concept, which was supplied by Ceramic Composites, Inc., utilized copper cooling coils surrounding a carbon-fiber-reinforced carbon matrix composite. In this design, a protective gradient coating was applied to the inner thruster wall. Ceramic Composites, Inc.'s, method of incorporating the coating into the fiber and matrix eliminated the spallation problem often observed with thermal barrier coatings during hotfire testing. The focus of the testing effort was on screening the CMC material's capabilities as well as evaluating the performance of the thermal barrier or fiber-matrix interfacial coatings. Both concepts were hot-fire tested in gaseous O2/H2 environments. The test matrix included oxygen-to-fuel ratios ranging from 1.5 to 7 with chamber pressures to 400 psi. Steady-state internal wall temperatures in excess of 4300 F were measured in situ for successful 30-sec test runs. Photograph of actively cooled composite thrustcell fabricated by Hyper-Therm is shown. The thrustcell is a silicon-carbide-fiber-reinforced silicon carbide matrix composite with woven cooling channels. The matrix is formed via chemical vapor infiltration. Photograph of hot-fire test of an actively cooled carbon-fiber-reinforced carbon matrix composite thrustcell is also shown. This composite thrustcell, which was fabricated by CCI, Inc., was wound with copper cooling coils to contain the water coolant. The tests were run with oxygen fuel ratios up to seven with chamber pressures of 200 psia.

Jaskowiak, Martha H.↗