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At least 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

Nondestructive Characterization Techniques Used for Ceramic Matrix Composite Life Determination

Recent results indicate that the specific damping capacity and resonant frequency measurements taken periodically during a component's lifetime is able to quantify the mechanical fatigue of CMCS. This gives hope for the potential of determining the actual and residual life of CMC materials using a combination of nondestructive techniques. If successful, then this new paradigm for life prediction of CMCs could revolutionize the approach for designing and servicing CMC components, thereby significantly reducing costs for design, development, health monitoring, and maintenance of CMC components and systems. The Nondestructive Characterization (NDC) life prediction approach would complement life prediction using micromechanics and continuum finite element models. This paper reports on the initial concept of NDC life prediction, a review of the C/SiC blisk damping data, and how changes in the specific damping capacity & ultrasonic elastic modulus data have established the concept as a possibility.

Effinger, Michael↗
NASA NTRS2001

The Oxidation Kinetics of Continuous Carbon Fibers in a Cracked Ceramic Matrix Composite

Experimental observations and results suggest two primary regimes as a function of temperature, i.e., diffusion and reaction controlled kinetics. Thermogravimetric analysis of carbon fiber in flowing oxygen gave an activation energy of 64.1 kJ/mol in the temperature range of 500 to 600 C and an apparent activation energy of 7.6 kJ/mol for temperatures from 600 to 1400 C. When C/SiC composite material was unstressed, matrix effects at temperatures from 900 to 1400 C protected the internal fibers. When under stress, self-protection was not observed. Increasing the stress from 10 to 25 ksi caused a 67 to 82 percent reduction in times to failure at temperatures from 750 to 1500 C. Based on experimental results, observation, and theory, a finite difference model was developed, which simulates the diffusion of oxygen into a matrix crack that is bridged by carbon fibers. The model allows the influence of important variables on oxidation kinetics to be studied systematically, i.e., temperature, reaction rate constant, diffusion coefficient, environment, and sample geometry.

Halbig, Michael C.↗
NASA NTRS2001

Development of Reliability Based Life Prediction Methods for Thermal and Environmental Barrier Coatings in Ceramic Matrix Composites

Literature survey related to the EBC/TBC (environmental barrier coating/thermal barrier coating) fife models, failure mechanisms in EBC/TBC and the initial work plan for the proposed EBC/TBC life prediction methods development was developed as well as the finite element model for the thermal/stress analysis of the GRC-developed EBC system was prepared. Technical report for these activities is given in the subsequent sections.

Shah, Ashwin↗
NASA NTRS2001

Life Prediction Issues in Thermal/Environmental Barrier Coatings in Ceramic Matrix Composites

Issues and design requirements for the environmental barrier coating (EBC)/thermal barrier coating (TBC) life that are general and those specific to the NASA Ultra-Efficient Engine Technology (UEET) development program have been described. The current state and trend of the research, methods in vogue related to the failure analysis, and long-term behavior and life prediction of EBCITBC systems are reported. Also, the perceived failure mechanisms, variables, and related uncertainties governing the EBCITBC system life are summarized. A combined heat transfer and structural analysis approach based on the oxidation kinetics using the Arrhenius theory is proposed to develop a life prediction model for the EBC/TBC systems. Stochastic process-based reliability approach that includes the physical variables such as gas pressure, temperature, velocity, moisture content, crack density, oxygen content, etc., is suggested. Benefits of the reliability-based approach are also discussed in the report.

Shah, Ashwin R.↗
NASA NTRS2002

Effect of Environment on Fatigue Behavior of a Nicalon(TM)/Si-N-C Ceramic Matrix Composite

The effect of environmental exposure on the fatigue life of Nicalon(TM) /Si-N-C composite was investigated in this study. Test specimens with arrays of 1.8 mm diameter holes and two different open areas, 25 and 35%, were machined. Three environmental conditions were studied: 1) continuous fatigue cycling in air, 2) fatigue cycling in air alternating with humidity exposure, and 3) fatigue cycling in air alternating with exposure to a salt-fog environment. All fatigue testing on specimens with holes was performed with a load ratio, R = 0.05, and at a temperature of 910 C. In general, fatigue lives were shortest for specimens subjected to salt-fog exposure and longest for specimens subjected to continuous fatigue cycling in air. The fatigue data generated on the specimens with holes were compared with fatigue data generated in air on specimens with no holes. Fatigue strength reduction factors for different environmental conditions and open areas investigated in the study were calculated for the Nicalon(TM) /Si-N-C composite.

Kalluri, Sreeramesh↗
NASA NTRS2003

Influence Of Holes On The In-Plane Tensile Strength And Fatigue Durability Of A NICALON(Trademark)/Si-N-C Ceramic Matrix Composite

Effects of different sizes of holes as well as different percentages of open areas on the in-plane tensile strength and fatigue durability of the SiC/Si-N-C composite were investigated in this study. Test specimens with no holes, four different diameters of holes (1.0 to 3.2 mm), and four different open areas (20 to 35%) were machined. All mechanical testing was performed in air at a temperature of 910 C. Fatigue tests were conducted with a load ratio, R = 0.05, and a frequency of 0.33 Hz. In general, both the in-plane tensile strength of the composite and its fatigue durability decreased with an increase in the size of the hole and percentage of the open area. Reductions in the in-plane tensile strength and cyclic fatigue life of the composite were described by empirical equations with the diameter of the hole and the percent open area as the independent variables. The validity of these two empirical equations was verified with additional tensile and fatigue test data generated on the composite specimens.

Kalluri, Sreeramesh↗
NASA NTRS2002

Effect of Environment on Stress-Rupture Behavior of a Carbon Fiber-Reinforced Silicon Carbide (C/SiC) Ceramic Matrix Composite

Stress-rupture tests were conducted in air, vacuum, and steam-containing environments to identify the failure modes and degradation mechanisms of a carbon fiber-reinforced silicon carbide (C/SiC) composite at two temperatures, 600 and 1200 C. Stress-rupture lives in air and steam containing environments (50 - 80% steam with argon) are similar for a composite stress of 69 MPa at 1200 C. Lives of specimens tested in a 20% steam/argon environment were about twice as long. For tests conducted at 600 C, composite life in 20% steam/argon was 20 times longer than life in air. Thermogravimetric analysis of the carbon fibers was conducted under similar conditions to the stress-rupture tests. The oxidation rate of the fibers in the various environments correlated with the composite stress-rupture lives. Examination of the failed specimens indicated that oxidation of the carbon fibers was the primary damage mode for specimens tested in air and steam environments at both temperatures.

Verrilli, Michael J.↗
NASA NTRS2003

Dependency of Shear Strength on Test Rate in SiC/BSAS Ceramic Matrix Composite at Elevated Temperature

Both interlaminar and in-plane shear strengths of a unidirectional Hi-Nicalon(TM) fiber-reinforced barium strontium aluminosilicate (SiC/BSAS) composite were determined at 1100 C in air as a function of test rate using double notch shear test specimens. The composite exhibited a significant effect of test rate on shear strength, regardless of orientation which was either in interlaminar or in in-plane direction, resulting in an appreciable shear-strength degradation of about 50 percent as test rate decreased from 3.3 10(exp -1) mm/s to 3.3 10(exp -5) mm/s. The rate dependency of composite's shear strength was very similar to that of ultimate tensile strength at 1100 C observed in a similar composite (2-D SiC/BSAS) in which tensile strength decreased by about 60 percent when test rate varied from the highest (5 MPa/s) to the lowest (0.005 MPa/s). A phenomenological, power-law slow crack growth formulation was proposed and formulated to account for the rate dependency of shear strength of the composite.

Choi, Sung R.↗
NASA NTRS2004

Development of Ceramic Matrix Composites For High Temperature Applications

The microstructure and mechanical properties of carbon fiber reinforced silicon carbide (C/SiC) composites that incorporated molecular-level oxidation inhibitors designed to increase the material s high temperature durability were characterized. The viability of a fiber-level inhibitor incorporated as part of a layered interface system as well as a molecularly-integrated matrix-level oxidation inhibitor that is co-deposited with the SiC matrix during Chemical Vapor Infiltration (CVI) was determined. It was expected that the inhibitor would act as a glass former that will getter the oxygen and form a crack sealant to reduce further ingress of oxygen into the composite. Three composites were examined. Composite A was a baseline C(sub f)/SiC(sub m) composite that incorporated a approx. 0.4 micron pyrolytic carbon (PyC) fiber coating to promote strength and toughness, and a CVI-derived SiC matrix. Composite B was a C(sub f)/SiC(sub m) composite incorporating a approx 0.4 micron pyrolytic carbon (PyC) fiber coating to promote strength and toughness, a approx. 0.6 micron B4C fiber-level oxidation barrier coating, and a CVI-derived SiC matrix. Composite C was a C(sub f) /SiC(sub m) composite that incorporated a approx. 0.4 micron pyrolytic carbon (PyC) fiber coating to promote strength and toughness, a approx. 0.6 micron B4C fiber-level oxidation barrier coating, and a BxC-SiC oxidation-inhibited matrix produced by CVI co-deposition. All composites were reinforced with 10 plies of T-300 balanced plain weave carbon fabric with 3K tows at 12.5 ends per inch.

Heimann, Paula↗
NASA NTRS2003

Oxidation Kinetics and Strength Degradation of Carbon Fibers in a Cracked Ceramic Matrix Composite

Experimental results and oxidation modeling will be presented to discuss carbon fiber susceptibility to oxidation, the oxidation kinetics regimes and composite strength degradation and failure due to oxidation. Thermogravimetric Analysis (TGA) was used to study the oxidation rates of carbon fiber and of a pyro-carbon interphase. The analysis was used to separately obtain activation energies for the carbon constituents within a C/SiC composite. TGA was also conducted on C/SiC composite material to study carbon oxidation and crack closure as a function of temperature. In order to more closely match applications conditions C/SiC tensile coupons were also tested under stressed oxidation conditions. The stressed oxidation tests show that C/SiC is much more susceptible to oxidation when the material is under an applied load where the cracks are open and allow for oxygen ingress. The results help correlate carbon oxidation with composite strength reduction and failure.

Halbig, Michael C.↗
NASA NTRS2004

Ceramic Matrix Composite Vane Subelement Testing in a Gas Turbine Environment

Vane subelements were fabricated from a silicon carbide fiber reinforced silicon carbide matrix (SiC/SiC) composite and were coated with an environmental barrier coating (EBC). A test configuration for the vanes in a gas turbine environment was designed and fabricated. Prior to testing, finite element analyses were performed to predict the temperatures and stress conditions present in vane during rig testing. This paper discusses the test configuration, the finite element analysis predictions, and results of the vane testing.

Verrilli, Michael↗
NASA NTRS2004

Probabilistic Analysis of a SiC/SiC Ceramic Matrix Composite Turbine Vane

To demonstrate the advanced composite materials technology under development within the Ultra-Efficient Engine Technology (UEET) Program, it was planned to fabricate, test, and analyze a turbine vane made entirely of silicon carbide-fiber-reinforced silicon carbide matrix composite (SiC/SiC CMC) material. The objective was to utilize a five-harness satin weave melt-infiltrated (MI) SiC/SiC composite material developed under this program to design and fabricate a stator vane that can endure 1000 hours of engine service conditions. The vane was designed such that the expected maximum stresses were kept within the proportional limit strength of the material. Any violation of this design requirement was considered as the failure. This report presents results of a probabilistic analysis and reliability assessment of the vane. Probability of failure to meet the design requirements was computed. In the analysis, material properties, strength, and pressure loading were considered as random variables. The pressure loads were considered normally distributed with a nominal variation. A temperature profile on the vane was obtained by performing a computational fluid dynamics (CFD) analysis and was assumed to be deterministic. The results suggest that for the current vane design, the chance of not meeting design requirements is about 1.6 percent.

Murthy, Pappu L. N.↗
NASA NTRS1997

Stress Intensity Factor Solutions for Multiple Edge Cracks in Ceramic Matrix Composites

NASA Lewis Research Center conducted a study to determine the stress intensity factor solutions for periodic arrays of bridged cracks for various crack spacings and crack lengths. Initially, the stress intensity factor of an array of unbridged multiple edge cracks was determined under constant global displacement as well as at a point load along the crack wake. These solutions are expected to contribute toward the development of a damage-based life-prediction methodology for CMC engine components.

Ghosn, Louis↗
NASA NTRS1998

Attachment of Free Filament Thermocouples for Temperature Measurements on Ceramic Matrix Composites

At the NASA Lewis Research Center, a new installation technique utilizing convoluted wire thermocouples (TC's) was developed and proven to produce very good adhesion on CMC's, even in a burner rig environment. Because of their unique convoluted design, such TC's of various types and sizes adhere to flat or curved CMC specimens with no sign of delamination, open circuits, or interactions-even after testing in a Mach 0.3 burner rig to 1200 C (2200 F) for several thermal cycles and at several hours at high temperatures. Large differences in thermal expansion between metal thermocouples and low-expansion materials, such as CMC's, normally generate large stresses in the wires. These stresses cause straight wires to detach, but convoluted wires that are bonded with strips of coating allow bending in the unbonded portion to relieve these expansion stresses.

Lei, Jih-Fen↗
NASA NTRS2004

Characterization of Ceramic Matrix Composite Vane Subelements Subjected to Rig Testing in a Gas Turbine Environment

Vane subelements were fabricated from a silicon carbide fiber-reinforced silicon carbide matrix (SiC/SiC) composite. A cross-sectional slice of an aircraft engine metal vane was the basis of the vane subelement geometry. To fabricate the small radius of the vane's trailing edge using stiff Sylramic SiC fibers, a unique SiC fiber architecture was developed. A test configuration for the vanes in a high pressure gas turbine environment was designed and fabricated. Testing was conducted using a pressure of 6 atm and combustion flow rate of 0.5 kg/sec, and consisted of fifty hours of steady state operation followed by 102 2-minute thermal cycles. A surface temperature of 1320 C was obtained for the EBC-coated SiC/SiC vane subelement. This paper will briefly discuss the vane fabrication, test configuration, and results of the vane testing. The emphasis of the paper is on characterization of the post-test condition of the vanes.

Verrilli, Michael↗
NASA NTRS2004

Actively Cooled Ceramic Matrix Composite Concepts for High Heat Flux Applications

High temperature composite heat exchangers are an enabling technology for a number of aeropropulsion applications. They offer the potential for mass reductions of greater than fifty percent over traditional metallics designs and enable vehicle and engine designs. Since they offer the ability to operate at significantly higher operating temperatures, they facilitate operation at reduced coolant flows and make possible temporary uncooled operation in temperature regimes, such as experienced during vehicle reentry, where traditional heat exchangers require coolant flow. This reduction in coolant requirements can translate into enhanced range or system payload. A brief review of the approaches, challenges and test results are presented, along with a status of recent government-funded projects.

Eckel, Andrew J.↗
NASA NTRS2001

Environmental Barrier Coatings (EBC) for Ceramic Matrix Composite (CMC) Materials

The upper use temperature of current Environmental Barrier Coatings (EBC's) based on mullite and BSAS (EPM EBC's) is limited to -255 F due to silica volatility, chemical reactions, and high thermal conductivity. Therefore, new EBC s having low CTE, good chemical compatibility, and high melting point (greater than 2700 F ) are being investigated. Sinter-resistant, low thermal conductivity EBC s are strongly desired to achieve the UEET EBC goal of 270 F EBC surface temperature and 30 F AT over long exposures (greater than 1000 hr). Key areas affecting the upper temperature limit of current EBC s as well as the ongoing efforts to develop next generation EBC s in the UEET Program will be discussed.

Lee,Kang↗