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At least 379 records · Page 21

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NASA NTRS2004

Advanced Control Surface Seal Development for Future Space Vehicles

NASA s Glenn Research Center (GRC) has been developing advanced high temperature structural seals since the late 1980's and is currently developing seals for future space vehicles as part of the Next Generation Launch Technology (NGLT) program. This includes control surface seals that seal the edges and hinge lines of movable flaps and elevons on future reentry vehicles. In these applications, the seals must operate at temperatures above 2000 F in an oxidizing environment, limit hot gas leakage to protect underlying structures, endure high temperature scrubbing against rough surfaces, and remain flexible and resilient enough to stay in contact with sealing surfaces for multiple heating and loading cycles. For this study, three seal designs were compared against the baseline spring tube seal through a series of compression tests at room temperature and 2000 F and flow tests at room temperature. In addition, canted coil springs were tested as preloaders behind the seals at room temperature to assess their potential for improving resiliency. Addition of these preloader elements resulted in significant increases in resiliency compared to the seals by themselves and surpassed the performance of the baseline seal at room temperature. Flow tests demonstrated that the seal candidates with engineered cores had lower leakage rates than the baseline spring tube design. However, when the seals were placed on the preloader elements, the flow rates were higher as the seals were not compressed as much and therefore were not able to fill the groove as well. High temperature tests were also conducted to asses the compatibility of seal fabrics against ceramic matrix composite (CMC) panels anticipated for use in next generation launch vehicles. These evaluations demonstrated potential bonding issues between the Nextel fabrics and CMC candidates.

DeMange, J. J.↗

NASA NTRS2008

Assessment of Proper Bonding Methods and Mechanical Characterization FPGA CQFPs

This presentation discusses fractured leads on field-programmable gate array (FPGA) during flight vibration. Actions taken to determine root cause and resolution of the failure include finite element analysis (FEA) and vibration testing and scanning electron microscopy (with X-ray microanalysis) and energy dispersive spectrometry (SEM/EDS) failure assessment. Bonding methods for surface mount parts is assessed, including critical analysis and assessment of random fatigue damage. Regarding ceramic quad flat pack (CQFP) lead fracture, after disassembling the attitude control electronics (ACE) configuration, photographs showed six leads cracked on FPGA RTSX72SU-1 CQ208B package located on the RWIC card. An identical package (FPGA RTSX32SU-1 CQ208B) mounted on the RWIC did not results in cracked pins due to vibration. FPGA lead failure theories include workmanship issues in the lead-forming, material defect in the leads of the FPGA packages, and the insecure mounting of the board in the card guides, among other theories. Studies were conducted using simple calculations to determine the response and fatigue life of the package. Shorter packages exhibited more response when loaded by out-of-plane displacement of PCB while taller packages exhibit more response when loaded by in-plane acceleration of PCB. Additionally, under-fill did not contribute to reducing stress in leads due to out-of-plane PCB loading or from component twisting, as much as corner bonding. The combination of corner bond and under-fill is best to address mechanical and thermal S/C environment. Test results of bonded parts showed reduced (dampened) amplitude and slightly shifted peaks at the un-bonded natural frequency and an additional response at the bonded frequency. Stress due to PCBB out-of-plane loading was decreased on in the corners when only a corner bond was used. Future work may address CQFP fatigue assessment, including the investigation of discrepancy in predicted fatigue damage, as well as comparing fatigue life and fatigue damage cycle ration computed using FEA and Miner's rule to results from a fatigue assessment software program.

Davis, Milton C.↗

DOE OSTI2022

Nanoscale chemistry and ion segregation in zirconia-based ceramic at grain boundaries by atom probe tomography

In this work nanoscale features that are of importance in the stability of yttria-stabilized tetragonal zirconia (Y-TZP) are quantified through atom probe tomography. In-depth analysis of grain boundary chemistry revealed preferential segregation of lighter and smaller ions towards specific grain boundaries. The relationship between elemental segregation and the local atomistic structure is investigated at the sub-nanometer level to gain insights on nanoscale features associated with the tetragonal-monoclinic phase transformation in Y-TZP through grain boundary characterization. Furthermore, principal component analysis was implemented to reveal any potential biases from varied field evaporation across stabilizer-rich grain boundaries. The observed variations in ion density across different grains suggested a variation in field which was attributed to potential variations in grain crystal orientation. In order to reveal the subtle depletion of oxygen atoms within grain boundaries a new methodology to map oxygen vacancies is proposed, utilizing the relative neighborhood chemistry of individual yttrium atoms.

36 MATERIALS SCIENCE↗

DOE OSTI2025

A high-temperature heat flux sensor using the transverse Seebeck effect in elemental rhenium

Heat flux sensors compatible with hot environments are critical to advance aerospace, materials, and energy generation technologies that cope with extreme thermal conditions. In this work, we report on the development and characterization of a high-temperature heat flux sensor using the transverse Seebeck effect in rhenium single crystals. The sensor leverages refractory alloys and ceramics compatible with temperatures exceeding 1000 °C. The heat flux sensor was characterized from room temperature to 500 °C using a temperature-controlled calibration facility. At constant temperature, the sensor’s voltage output is linear with respect to the absorbed heat flux. The responsivity of the sensor varies with temperature, from 1.3 μV/(W/cm 2 ) at room temperature to −3.2 μV/(W/cm 2 ) at 500 °C, increasing monotonically in magnitude after changing sign from positive to negative at approximately 300 °C. The experimental results are in good agreement with analytical predictions of the sensor’s temperature-dependent responsivity, which suggest a further increase in magnitude up to −7.4 μV/(W/cm 2 ) at 1000 °C. These results highlight the unique characteristics of rhenium as a TSE transducer. The design offers compatibility with a wide range of operating temperatures and yields a measurement sensitivity that increases as the environmental conditions become more challenging.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2023

High-entropy materials: fundamentals and applications

Metallic high-entropy materials (HEMs), also known as high-entropy alloys (HEAs), are an exotic class of materials that possess desirable properties, such as exceptional strength and ductility, high wear resistance, and corrosion resistance. Due to these positive attributes, HEAs have been proposed for use in the automotive and aerospace industries, nuclear reactor technology, and the biomedical field. In terms of composition, HEAs contain five or more elements in amounts ranging from 5 to 35 atomic percent (at.%) each, resulting in a vast compositional space that is still mainly unexplored to this day. More recently, the field of HEMs has broadened to include materials such as polymers and ceramics.

36 MATERIALS SCIENCE↗

NASA NTRS1981

Thermal and stress analysis of thermal barrier coatings

An analysis has been performed that predicts the thermomechanical behavior of thermal barrier coated specimens. The analysis predicts the behavior during both plasma spray coating application and burner rig testing conditions simulating engine operation. The analysis was accomplished through utilization of one-dimensional through thickness and two-dimensional finite element calculations. The results of these calculations showed that specimens with a substrate control temperature between 300 F and 600 F would be optimum. Controlling substrate temperature was found to have a more dominant effect on the mechanical strains than the ceramic or substrate thicknesses. The predicted stresses and mechanical strains at the bond-coating interface are large enough to cause cracks in this region where post-test observations have determined coating failures originate.

Cassenti, B. N.↗

NASA NTRS1999

Single Axis Piezoceramic Gimbal

This paper describes the fabrication, testing, and analysis of a single axis piezoceramic gimbal. The fabrication process consist of pre-stressing a piezoceramic wafer using a high-temperature thermoplastic polyimide and a metal foil. The differential thermal expansion between the ceramic and metal induces a curvature. The pre-stressed, curved piezoceramic is mounted on a support mechanism and a mirror is attached to the piezoceramic. A plot of gimbal angle versus applied voltage to the piezoceramic is presented. A finite element analysis of the piezoceramic gimbal is described. The predicted gimbal angle versus applied voltage is compared to experimental results.

Horner, Garnett C.↗

NASA NTRS2001

Single Axis Piezoceramic Gimbal

This paper describes the fabrication, testing, and analysis of a single axis piezoceramic gimbal. The fabrication process consists of pre-stressing a piezoceramic wafer using a high-temperature thermoplastic polyimide and a metal foil. The differential thermal expansion between the ceramic and metal induces a curvature. The pre-stressed, curved piezoceramic is mounted on a support mechanism and a mirror is attached to the piezoceramic. A plot of gimbal angle versus applied voltage to the piezoceramic is presented. A finite element analysis of the piezoceramic gimbal is described. The predicted gimbal angle versus applied voltage is compared to experimental results.

Horner, Garnett↗

DOE OSTI2023

Carbide-based fuel assembly for thermal propulsion applications

Carbide-based fuel assembly includes outer structural member of ceramic matrix composite material, the interior surface of which is lined in higher temperature regions with an insulation layer of porous refractory ceramic material. Continuous insulation layer extends the length of the fuel assembly or separate insulation layer sections have a thickness increasing step-wise along the length of the fuel assembly from upper (inlet) section towards bottom (outlet) section. A fuel element positioned inward of the insulation layer and between support meshes has a fuel composition including HALEU and the form of a plurality of individual elongated fuel bodies or one or more fuel monolith bodies containing coolant flow channels. Fuel assemblies are distributively arranged in a moderator block, with upper end of the outer structural member attached to an inlet for propellant and lower end of the outer structural member operatively interfaced with a nozzle forming a nuclear thermal propulsion reactor.

Barringer, Eric A.↗

DOE OSTI2022

System and method for engineered ceramic packages for use in fluid treatment technologies

The present disclosure relates to a modular fluid modification system having an outer container configured to permit a fluid flow there into at a first location, and to allow the fluid flow to exit the container at a second location spaced apart from the first location. A plurality of fluid contacting elements is housed in the outer container. The fluid contacting elements each form an independent filtering or reactor element. Each fluid contacting element includes a plurality of openings formed in a grid or lattice-like pattern.

Kelly, James Patrick↗

DOE OSTI2024

Effects of irradiation damage on the elastic properties and hardness of complex transition metal diborides

Multi-principal component transition metal (TM) diborides represent a class of high-entropy ceramics (HECs) that have received considerable interest in recent years owing to their promising properties for extreme environment applications that include thermal/ environmental barriers, hypersonic vehicles, turbine engines, and next-generation nuclear reactors. While the addition of chemical disorder through the random distribution of TM elements on the cation sublattice has offered opportunities to tailor elastic stiffness and hardness, the effects of irradiationinduced structural damage on the physical properties of these complex materials have remained largely unexplored. To this end, changes in the hardness and elastic moduli of a high-entropy TM diboride (Hf0.2Nb0.2Ta0.2Ti0.2Zr0.2)B2 and three of its quaternary subsets following irradiation with 10 MeV gold (Au) ions to fluences of up to 6 × 10^15 Au cm-2 are investigated at the micrometer and sub-micrometer length-scales via the dispersion of laser-generated surface acoustic waves (SAW) and nanoindentation, respectively. The nanoindentation measurements show that the TM diborides exhibit an initial increase in hardness following irradiation with energetic Au ions, with a subsequent decrease in hardness following further irradiation. One quaternary composition, (Hf1/3Ta1/3Ti1/3)B2, exhibits a notable exception to the trend and continues to exhibit an increase in hardness with ion irradiation fluence. Although differences in the absolute values of the effective elastic moduli obtained from the measured SAW dispersion and nanoindentation are observed (and attributed to microstructural variations at the measurement length-scale), both techniques yield similar trends in the form of an initial reduction and subsequent saturation in the elastic modulus with increasing ion irradiation fluence. The quaternary TM diboride (Hf1/3Ta1/3Ti1/3)B2 again exhibits a departure from this trend. The high-entropy TM diboride (Hf0.2Nb0.2Ta0.2Ti0.2Zr0.2)B2 exhibits the greatest recovery in hardness and modulus when irradiated to high ion fluences following initial changes at low fluence, indicating superior resistance to radiation-induced damage over its quaternary counterparts. Opportunities for designing HECs with superior hardness and modulus for enhanced radiation resistance (compared to their single constituent counterparts) by tailoring chemical disorder and bond character in the lattice are discussed.

36 - MATERIALS SCIENCE↗

NASA NTRS1971

Development of a High Temperature Heater using an Yttria Stabilized Zirconia Cored Brick Matrix

The Ames pilot heater is a ceramic regenerative heater that provides high temperature air for aerodynamic and combustion experiments. The development of this heater to provide a heat storage bed with temperature capability of about 4600 R is described. A bed was designed and installed having cored brick elements of yttria-stabilized zirconia. The bed dimensions were 14 inches in diameter by 10 feet high. The thermal stress limitations of the bed were studied and maximum air flow rates based upon these limits were established. A combustion reheat system was designed and installed to provide the necessary control over the bed temperature distribution. The revised heater system was successfully operated at a maximum bed temperature of 4600 R. The successful operation demonstrated that yttria-stabilized zirconia cored brick can satisfy the high temperature-long duration requirement for storage heater applications.

Smith, K. W.↗

DOE OSTI2021

Stochastic microstructural analysis of ceramic matrix composites using a high-fidelity multiscale framework

This paper presents a high-fidelity multiscale framework to simulate the mechanical behavior of ceramic matrix composites (CMCs), accounting for the complex micromorphology captured using detailed material characterization. First, high-resolution micrographs are obtained for the specific carbon fiber silicon-carbide-nitride matrix (C/SiNC) CMC to characterize the variability of the architectural features and manufacturing-induced defects at the microscale. An image processing algorithm is then used to precisely estimate the size and distribution of all subscale features and defects from the micrographs. The information is then used to generate a three-dimensional stochastic representative volume element (SRVE) to reconstruct microscale constituents accounting for the variability. As a result, the generated SRVEs are simulated using the high-fidelity generalized method of cells (HFGMC) micromechanics theory to investigate the effects of defects on the elastic properties of C/SiNC CMCs.

Ceramic Matrix Composites↗

DOE OSTI2024

Effects of irradiation damage on the hardness and elastic properties of quaternary and high entropy transition metal diborides

Multi-principal component transition metal (TM) diborides represent a class of high-entropy ceramics (HECs) that have received considerable interest in recent years owing to their promising properties for extreme environment applications that include thermal/ environmental barriers, hypersonic vehicles, turbine engines, and next-generation nuclear reactors. While the addition of chemical disorder through the random distribution of TM elements on the cation sublattice has offered opportunities to tailor elastic stiffness and hardness, the effects of irradiation-induced structural damage on the physical properties of these complex materials have remained largely unexplored. To this end, changes in the hardness and elastic moduli of a high-entropy TM diboride (Hf 0.2 Nb 0.2 Ta 0.2 Ti 0.2 Zr 0.2 )B 2 and three of its quaternary subsets following irradiation with 10 MeV gold (Au) ions to fluences of up to 6 × 10 15 Au cm -2 are investigated at the micrometer and sub-micrometer length-scales via the dispersion of laser-generated surface acoustic waves (SAW) and nanoindentation, respectively. The nanoindentation measurements show that the TM diborides exhibit an initial increase in hardness following irradiation with energetic Au ions, with a subsequent decrease in hardness following further irradiation. One quaternary composition, (Hf 1/3 Ta 1/3 Ti 1/3 )B 2 , exhibits a notable exception to the trend and continues to exhibit an increase in hardness with ion irradiation fluence. Although differences in the absolute values of the effective elastic moduli obtained from the measured SAW dispersion and nanoindentation are observed (and attributed to microstructural variations at the measurement length-scale), both techniques yield similar trends in the form of an initial reduction and subsequent saturation in the elastic modulus with increasing ion irradiation fluence. The quaternary TM diboride (Hf 1/3 Ta 1/3 Ti 1/3 )B 2 again exhibits a departure from this trend. The high-entropy TM diboride (Hf 0.2 Nb 0.2 Ta 0.2 Ti 0.2 Zr 0.2 )B 2 exhibits the greatest recovery in hardness and modulus when irradiated to high ion fluences following initial changes at low fluence, indicating superior resistance to radiation-induced damage over its quaternary counterparts. Opportunities for designing HECs with superior hardness and modulus for enhanced radiation resistance (compared to their single constituent counterparts) by tailoring chemical disorder and bond character in the lattice are discussed.

36 MATERIALS SCIENCE↗

NASA NTRS1989

Ceramic valve development for heavy-duty low heat rejection diesel engines

Monolithic ceramic valves can be successfully operated in a heavy-duty diesel engine, even under extreme low heat rejection operating conditions. This paper describes the development of a silicon nitride valve from the initial design stage to actual engine testing. Supplier involvement, finite element analysis, and preliminary proof of concept demonstration testing played a significant role in this project's success.

Weber, K. E.↗

NASA NTRS2006

Design Parameters Influencing Reliability of CCGA Assembly: A Sensitivity Analysis

Area Array microelectronic packages with small pitch and large I/O counts are now widely used in microelectronics packaging. The impact of various package design and materials/process parameters on reliability has been studied through extensive literature review. Reliability of Ceramic Column Grid Array (CCGA) package assemblies has been evaluated using JPL thermal cycle test results (-50(deg)/75(deg)C, -55(deg)/100(deg)C, and -55(deg)/125(deg)C), as well as those reported by other investigators. A sensitivity analysis has been performed using the literature da to study the impact of design parameters and global/local stress conditions on assembly reliability. The applicability of various life-prediction models for CCGA design has been investigated by comparing model's predictions with the experimental thermal cycling data. Finite Element Method (FEM) analysis has been conducted to assess the state of the stress/strain in CCGA assembly under different thermal cycling, and to explain the different failure modes and locations observed in JPL test assemblies.

reliability↗

DOE OSTI2024

Advanced thermal/environmental barrier coatings of high-entropy rare earth disilicates tuned by strong anharmonicity of Eu 2 Si 2 O 7

Advancing thermal/environmental barrier coating (TEBC) materials with integrated thermal-mechanical functions is paramount for safeguarding SiC-based ceramic matrix composites (CMCs) in high-efficiency gas turbines. Herein, we employ a synergistic approach, combining density functional theory (DFT) methods and combinatorial chemistry techniques, to design high-performance and low-cost RE 2 Si 2 O 7 (RE = rare earth elements) TEBC materials tailored for enhanced compatibility with SiC-based CMCs. Expanding on phase stability of alloying pure RE 2 Si 2 O 7 , the investigation extends to the mechanical and thermal properties of solid solution systems, including Er 1/2 Y 3/4 Yb 3/4 Si 2 O 7 , Gd 1/4 Er 1/4 Y 3/4 Yb 3/4 Si 2 O 7 , and Eu 1/4 Er 1/4 Y 3/4 Yb 3/4 Si 2 O 7 . The solid solution systems exhibit a major reduction in lattice thermal conductivity relative to their pure counterparts, achieving ultralow values of 0.25 to 0.39 W m −1 K −1 at 1500 K. Furthermore, the coefficients of thermal expansion (CTE) of these solid solutions are precisely tuned within the desired range for SiC (4.4 to 5.5 × 10 −6 K −1 ), while maintaining good mechanical properties. Here, in particular, the addition of Eu 2 Si 2 O 7 demonstrates to be an important variable to the tuning of CTE and lattice thermal conductivity by leveraging its strong anharmonicity, presenting a pioneering avenue for fine-tuning material properties. In summary, this research not only identifies promising TEBC materials with superior thermal properties, but also introduces a valuable computational material design methodology for the rapid discovery of complex materials for harsh environments.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Effect of sintering temperature on adhesion of spray-on piezoelectric transducers

Conventionally sol-gel spray-on transducers require a high-temperature (> 700 ◦C) sintering process; however, this process can affect the microstructure of the substrate material. For mechanical elbows and valves utilized for fluid transport in the energy sector, the components are designed to have a specific microstructure, and deviations from these specifications can create weak points in the system. For this reason it is important to investigate how the temperature of the deposition process affects the substrate. This paper investigates the effect of high-temperature and low-temperature (< 150 ◦C) processing conditions on the surface composition of the substrate. Furthermore, the resultant transducers from high- and low-temperature fabrication processes are compared to determine if a low-temperature processing method is feasible. For these studies a sol-gel spray-on process is employed to deposit piezoelectric ceramics onto a stainless-steel 316L substrate. Energy-dispersive X-ray spectroscopy is utilized to determine the composition of the substrate surface before and after transducer deposition. Results indicate that the high-temperature processing conditions may alter the surface composition of the metal due to a diffusion of the metal into the ceramic, which results in a metal surface that is bonded to the ceramic. Furthermore, it is shown that low-temperature processing of spray-on transducers is a viable method for transducer fabrication where the resultant transducers meet the industry minimum requirement of 30 dB signalto-noise ratio. In parallel simulation calculations, finite-element method (FEM) studies were performed to model the adhesive strength of the low-temperature processed transducer to the substrate surface. Comparisons between the simulations and experiments suggest that the bond strength is much greater than the commercial gel bonds and closer to hardened epoxy glue bonds. These results indicate that spray-on transducers fabricated under lowtemperature processing conditions are a viable solution for leave-in-place monitoring of structures.

M. Sinding, Kyle↗