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NASA NTRS1993

Theoretical considerations for Reaction-Formed Silicon Carbide (RFSC) formation by molten silicon infiltration into slurry-derived preforms

For reaction-formed silicon carbide (RFSC) ceramics produced by silicon melt infiltration of porous carbon preforms, equations are developed to relate the amount of residual silicon to the initial carbon density. Also, for a slurry derived preform containing both carbon and silicon powder, equations are derived which relate the amount of residual silicon in the RFSC to the relative density of the carbon in the preform and to the amount of silicon powder added to the slurry. For a porous carbon preform that does not have enough porosity to prevent choking-off of the silicon infiltration, these results show that complete silicon infiltration can occur by adding silicon powder to the slurry mixture used to produce these preforms.

Behrendt, D. R.↗

NASA NTRS1993

A study of metal-ceramic wettability in SiC-Al using dynamic melt infiltration of SiC

Pressure-assisted infiltration with a 2014 Al alloy of plain and Cu-coated single crystal platelets of alpha silicon carbide was used to study particulate wettability under dynamic conditions relevant to pressure casting of metal-matrix composites. The total penetration length of infiltrant metal in porous compacts was measured at the conclusion of solidification as a function of pressure, infiltration time, and SiC size for both plain and Cu-coated SiC. The experimental data were analyzed to obtain a threshold pressure for the effect of melt intrusion through SiC compacts. The threshold pressure was taken either directly as a measure of wettability or converted to an effective wetting angle using the Young-Laplace capillary equation. Cu coating resulted in partial but beneficial improvements in wettability as a result of its dissolution in the melt, compared to uncoated SiC.

Asthana, R.↗

NASA NTRS2000

Parametric Study of Reactive Melt Infiltration

Reactive melt infiltration is viewed as a promising means of achieving near-net shape manufacturing with quick processing time and at low cost. Since the reactants and products are, in general, of varying density, overall conservation of mass dictates that there is a force related to chemical conversion which can directly influence infiltration behavior. In effect, the driving pressure forces may compete with the forces from chemical conversion, affecting the advancement of the front. We have developed a two-dimensional numerical code to examine these effects, using reaction-formed silicon carbide as a model system for this process. We have examined a range of initial porosities, pore radii, and reaction rates in order to investigate their effects on infiltration dynamics.

Nelson, Emily S.↗

NASA NTRS1995

(abstract) A Polarimetric Model for Effects of Brine Infiltrated Snow Cover and Frost Flowers on Sea Ice Backscatter

A polarimetric scattering model is developed to study effects of snow cover and frost flowers with brine infiltration on thin sea ice. Leads containing thin sea ice in the Artic icepack are important to heat exchange with the atmosphere and salt flux into the upper ocean. Surface characteristics of thin sea ice in leads are dominated by the formation of frost flowers with high salinity. In many cases, the thin sea ice layer is covered by snow, which wicks up brine from sea ice due to capillary force. Snow and frost flowers have a significant impact on polarimetric signatures of thin ice, which needs to be studied for accessing the retrieval of geophysical parameters such as ice thickness. Frost flowers or snow layer is modeled with a heterogeneous mixture consisting of randomly oriented ellipsoids and brine infiltration in an air background. Ice crystals are characterized with three different axial lengths to depict the nonspherical shape. Under the covering multispecies medium, the columinar sea-ice layer is an inhomogeneous anisotropic medium composed of ellipsoidal brine inclusions preferentially oriented in the vertical direction in an ice background. The underlying medium is homogeneous sea water. This configuration is described with layered inhomogeneous media containing multiple species of scatterers. The species are allowed to have different size, shape, and permittivity. The strong permittivity fluctuation theory is extended to account for the multispecies in the derivation of effective permittivities with distributions of scatterer orientations characterized by Eulerian rotation angles. Polarimetric backscattering coefficients are obtained consistently with the same physical description used in the effective permittivity calculation. The mulitspecies model allows the inclusion of high-permittivity species to study effects of brine infiltrated snow cover and frost flowers on thin ice. The results suggest that the frost cover with a rough interface significantly increases the backscatter from thin saline ice and the polarimetric signature becomes closer to the isotropic characteristics. The snow cover also modifies polarimetric signatures of thin sea ice depending on the snow mixture and the interface condition.

thin sea ice radar backscatter frost flowers snow ↗

NASA NTRS2014

Calcium-Magnesium-Aluminosilicate (CMAS) Infiltration and Cyclic Degradations of Thermal and Environmental Barrier Coatings in Thermal Gradients

In a continuing effort to develop higher temperature capable turbine thermal barrier and environmental barrier coating systems, Calcium-Magnesium-Aluminosilicate (CMAS) resistance of the advanced coating systems needs to be evaluated and improved. This paper highlights some of NASA past high heat flux testing approaches for turbine thermal and environmental barrier coatings assessments in CMAS environments. One of our current emphases has been focused on the thermal barrier - environmental barrier coating composition and testing developments. The effort has included the CMAS infiltrations in high temperature and high heat flux turbine engine like conditions using advanced laser high heat flux rigs, and subsequently degradation studies in laser heat flux thermal gradient cyclic and isothermal furnace cyclic testing conditions. These heat flux CMAS infiltration and related coating durability testing are essential where appropriate CMAS melting, infiltration and coating-substrate temperature exposure temperature controls can be achieved, thus helping quantify the CMAS-coating interaction and degradation mechanisms. The CMAS work is also playing a critical role in advanced coating developments, by developing laboratory coating durability assessment methodologies in simulated turbine engine conditions and helping establish CMAS test standards in laboratory environments.

Thermal Barrier Coatings↗

NASA NTRS2016

Temperature Dependence of Electrical Resistance of Woven Melt-Infiltrated SiCf/SiC Ceramic Matrix Composites

Recent studies have successfully shown the use of electrical resistance (ER)measurements to monitor room temperature damage accumulation in SiC fiber reinforced SiC matrix composites (SiCf/SiC) Ceramic Matrix Composites (CMCs). In order to determine the feasibility of resistance monitoring at elevated temperatures, the present work investigates the temperature dependent electrical response of various MI (Melt Infiltrated)-CVI (Chemical Vapor Infiltrated) SiC/SiC composites containing Hi-Nicalon Type S, Tyranno ZMI and SA reinforcing fibers. Test were conducted using a commercially available isothermal testing apparatus as well as a novel, laser-based heating approach developed to more accurately simulate thermomechanical testing of CMCs. Secondly, a post-test inspection technique is demonstrated to show the effect of high-temperature exposure on electrical properties. Analysis was performed to determine the respective contribution of the fiber and matrix to the overall composite conductivity at elevated temperatures. It was concluded that because the silicon-rich matrix material dominates the electrical response at high temperature, ER monitoring would continue to be a feasible method for monitoring stress dependent matrix cracking of melt-infiltrated SiC/SiC composites under high temperature mechanical testing conditions. Finally, the effect of thermal gradients generated during localized heating of tensile coupons on overall electrical response of the composite is determined.

Ceramic Matrix Composites↗

NASA NTRS2020

Contribution of Infiltration Process Uncertainty on the Simulation of Terrestrial Water and Energy Budgets

The infiltration step is the major forking point of precipitation partition in land surface models, which plays a more significant role than canopy interception for simulating water and energy budgets.In this study, we found significant differences in water and energy-related outputs amount JULES, Noah, Noah-MP, and VIC. The differences are directly or indirectly related to the infiltration components in the models. Those differences add uncertainties to the applications of land surface models. Thorough evaluations are needed to determine the reliability of infiltration schemes used in these models.

Wang, Shugong↗

NASA NTRS1991

Modeling of chemical vapor infiltration for ceramic composites reinforced with layered, woven fabrics

A homogeneous model is developed for the chemical vapor infiltration by one-dimensional diffusion into a system of layered plies consisting of woven tows containing bundles of filaments. The model predictions of the amount of deposition and the porosity of the sample as a function of time are compared with the predictions of a recent nonhomogeneous model with aligned holes formed by the weave. The nonhomogeneous model allows for diffusion through the aligned holes, into the spaces between plies, and into the gaps around filaments; i.e., three diffusion equations apply. Relative to the nonhomogeneous results, the homogeneous model underestimates the amount of deposition, since the absence of holes and spaces allows earlier occlusion of gaps around filaments and restricts the vapor infiltration.

Chung, Gui-Yung↗

NASA NTRS1999

Snowmelt and Infiltration Deficiencies of SSiB and Their Resolution with a New Snow-Physics Scheme

A two-year 1987-1988 integration of SSiB forced with ISLSCP Initiative I surface data (as part of the Global Soil Wetness Project, GSWP, evaluation and intercomparison) produced generally realistic land surface fluxes and hydrology. Nevertheless, the evaluation also helped to identify some of the deficiencies of the current version of the Simplified Simple Biosphere (SSiB) model. The simulated snowmelt was delayed in most regions, along with excessive runoff and lack of an spring soil moisture recharge. The SSIB model had previously been noted to have a problem producing accurate soil moisture as compared to observations in the Russian snowmelt region. Similarly, various GSWP implementations of SSIB found deficiencies in this region of the simulated soil moisture and runoff as compared to other non-SSiB land-surface models (LSMs). The origin of these deficiencies was: 1) excessive cooling of the snow and ground, and 2) deep frozen soil disallowing snowmelt infiltration. The problem was most severe in regions that experience very cold winters. In SSiB, snow was treated as a unified layer with the first soil layer, causing soil and snow to cool together in the winter months, as opposed to snow cover acting as an insulator. In the spring season, a large amount of heat was required to thaw a hard frozen snow plus deep soil layers, delaying snowmelt and causing meltwater to become runoff over the frozen soil rather than infiltrate into it.

Sud, Y. C.↗

NASA NTRS1997

Passive Microwave Observation of Soil Water Infiltration

Infiltration is a time varying process of water entry into soil. Experiments were conducted here using truck based microwave radiometers to observe small plots during and following sprinkler irrigation. Experiments were conducted on a sandy loam soil in 1994 and a silt loam in 1995. Sandy loam soils typically have higher infiltration capabilities than clays. For the sandy loam the observed brightness temperature (TB) quickly reached a nominally constant value during irrigation. When the irrigation was stopped the TB began to increase as drainage took place. The irrigation rates in 1995 with the silt loam soil exceeded the saturated conductivity of the soil. During irrigation the TB values exhibited a pattern that suggests the occurrence of coherent reflection, a rarely observed phenomena under natural conditions. These results suggested the existence of a sharp dielectric boundary (wet over dry soil) that was increasing in depth with time.

Jackson, Thomas J.↗

NASA NTRS2000

Processing and Properties of SiC/MoSi2-SiC Composites Fabricated by Melt Infiltration

Hi-Nicalon SiC fiber reinforced MoSi2-SiC matrix composites (SiC/MoSi2-SiC) have been fabricated by the melt infiltration approach. The composite consists of approximately 60 vol%, 2-D woven BN/SiC coated Hi-Nicalon SiC fibers and approximately 40 vol% MoSi2-SiC matrix. The room temperature tensile properties and thermal conductivity of the SiC/MoSi2-SiC composites were measured and compared with those of the melt infiltrated SiC/SiC composites. The influence oi fiber architecture on tensile properties was also evaluated. Results indicate that the primary modulus, stress corresponding to deviation from linearity, and transverse thermal conductivity values for the SiC/MoSi2-SiC composites are significantly lower than those for the SiC/SiC composites. Microcracking of the matrix due to the large difference in thermal expansion between MoSi2 and SiC appears to be the reason for the lower matrix dominated properties of SiC/MoSi2-SiC composites.

Bhatt, Ramakrishna T.↗

NASA NTRS1997

Application of Modular Modeling System to Predict Evaporation, Infiltration, Air Temperature, and Soil Moisture

Models are used for numerous application including hydrology. The Modular Modeling System (MMS) is one of the few that can simulate a hydrology process. MMS was tested and used to compare infiltration, soil moisture, daily temperature, and potential and actual evaporation for the Elinsboro sandy loam soil and the Mattapex silty loam soil in the Microwave Radiometer Experiment of Soil Moisture Sensing at Beltsville Agriculture Research Test Site in Maryland. An input file for each location was created to nut the model. Graphs were plotted, and it was observed that the model gave a good representation for evaporation for both plots. In comparing the two plots, it was noted that infiltration and soil moisture tend to peak around the same time, temperature peaks in July and August and the peak evaporation was observed on September 15 and July 4 for the Elinsboro Mattapex plot respectively. MMS can be used successfully to predict hydrological processes as long as the proper input parameters are available.

Boggs, Johnny↗

NASA NTRS2001

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and fibers) Aluminum MMC. To this end, a revolutionary tool-less pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part, properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub-element tests will be presented.

Shah, Sandeep↗

NASA NTRS2001

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and Fibers) Aluminum MMC. To this end, a revolutionary tool-less pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub element tests will be presented.

Shah, Sandeep↗

NASA NTRS2002

High Temperature Tensile Properties and Fatigue Behavior of a Melt-Infiltrated SiC/SiC Composite

High temperature fatigue behavior of a woven, SiC/SiC ceramic matrix composite (CMC) was investigated in air at two temperatures. The reinforcement for the CMC consisted of 5HS Sylramic(Trademark) fabric with a [0deg/90deg]4s lay-up. The SiC matrix material was infiltrated into the fiber-preform with a slurry-cast, melt-infiltration process. Tensile and fatigue test specimens were machined from the CMC plates. Initially tensile tests were conducted to obtain the average values of tensile properties at 1038 and 1204 C. Subsequently, low-cycle fatigue (LCF) tests with zero and two-hour hold-times at the maximum stress were conducted at the same two temperatures. Fatigue life data generated in the LCF tests were used to determine the geometric mean fatigue lives. In this paper, the tensile behavior and the fatigue durability of the CMC determined under different loading conditions are documented. In addition, reductions observed in the cyclic lives of the composite due to the two hour hold-time at maximum tensile stress are discussed.

Kalluri, Sreeramesh↗

NASA NTRS2002

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

This presentation provides an overview of the effort by Metal Matrix Cast Composites, Inc. to redesign turbopump housing joints using metal matrix composite material and a toolless net-shape pressure infiltration casting technology. Topics covered include: advantage of metal matrix composites for propulsion components, baseline pump design and analysis, advanced toolless pressure infiltration casting process, subscale pump housing, preform splicing and joining for large components, and fullscale pump housing redesign.

Shah, Sandeep↗

NASA NTRS2002

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-less Net-Shape Pressure Infiltration Casting Technology

Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and fibers) Aluminum MMC. To this end, a revolutionary toolless pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part, properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub-element tests will be presented.

Shah, Sandeep↗

NASA NTRS2003

Metal Matrix Composite LOX Turbopump Housing via Novel Tool-less Net-Shape Pressure Infiltration Casting Technology

Metal matrix composites for propulsion components offer high performance and affordability, resulting in low weight and cost. The following sections in this viewgraph presentation describe the pressure infiltration casting of a metal matrix composite LOX turbopump housing: 1) Baseline Pump Design and Stress Analysis; 2) Tool-less Advanced Pressure Infiltration Casting Process; 3) Preform Splicing and Joining for Large Components such as Pump Housing; 4) Fullscale Pump Housing Redesign.

Shah, Sandeep↗