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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
NASA NTRS1986

Experimental study of a metal-matrix composite

A metal-matrix specimen was investigated using moire interferometry with 2400 lines/m (60,960 l/in.). The specimen was a 6-ply (0/ + or - 45)s boron-aluminum tensile coupon with a central slot. The unequal deformations in fibers and matrix were evident. Special attention was given to a plastic slip zone in the matrix. Normal and shear strains were calculated in the slip zone; the shear-strain concentration factor rose dramatically with the onset of plastic slip and continued to rise gradually with load to 95 percent of the failure load. The precipitous change from maximum tensile strain in one fiber to zero tensile strain in the neighboring fiber was accommodated by the very high shear strains of the matrix in the slip zone. Experimental considerations are discussed: shear strains are independent of rigid-body rotations; simplified strain calculations are justified; averaging across the narrow slip region and the influence of finite thickness of the specimen grating contribute to underestimation of peak strains.

Post, D.↗
NASA NTRS2004

Probabilistic Residual Strength Model Developed for Life Prediction of Ceramic Matrix Composites

For the next generation of reusable launch vehicles, NASA is investigating introducing ceramic matrix composites (CMCs) in place of current superalloys for structural propulsion applications (e.g., nozzles, vanes, combustors, and heat exchangers). The higher use temperatures of CMCs will reduce vehicle weight by eliminating and/or reducing cooling system requirements. The increased strength-to-weight ratio of CMCs relative to superalloys further enhances their weight savings potential. However, in order to provide safe designs for components made of these new materials, a comprehensive life prediction methodology for CMC structures needs to be developed. A robust methodology for lifing composite structures has yet to be adopted by the engineering community. Current industry design practice continues to utilize deterministic empirically based models borrowed from metals design for predicting material life capabilities. The deterministic nature of these models inadequately addresses the stochastic character of brittle composites, and their empirical reliance makes predictions beyond the experimental test conditions a risky extrapolation. A team of engineers at the NASA Glenn Research Center has been developing a new life prediction engineering model. The Probabilistic Residual Strength (PRS) model uses the residual strength of the composite as its damage metric. Expected life and material strength are both considered probabilistically to account for the observed stochastic material response. Extensive experimental testing has been carried out on C/SiC (a candidate aerospace CMC material system) in a controlled 1000 ppm O2/argon environment at elevated temperatures of 800 and 1200 C. The test matrix was established to allow observation of the material behavior, characterization of the model, and validation of the model's predictive capabilities. Sample results of the validation study are illustrated in the graphs.

Thomas, David J.↗
NASA NTRS2024

Tensile Behavior and High-Cycle Fatigue Durability of a SiC/SiC Ceramic-Matrix Composite Without and With Simulated Cooling Holes

High-cycle fatigue (HCF) behavior of a melt-infiltrated, prepreg SiC/SiC composite was investigated using specimens without and with simulated cooling holes at 816 and 1,316 °C. The ceramic-matrix composite (CMC) material used for this study was fabricated by GE Aviation and had a ply configuration of [0/90/0] 3 . HCF tests were conducted with an R-ratio of 0.6 and a cyclic frequency of 30 Hz. Maximum tensile gross-section stresses used in the HCF tests ranged from 152 to 359 MPa. Runout in HCF was defined as 30 million cycles (278 h) at both temperatures. Monotonic tensile tests were conducted at room temperature (RT) on as-received CMC specimens and on HCF runout specimens without and with holes to determine residual tensile strengths. Digital image correlation (DIC) and acoustic emission (AE) techniques were used to monitor progression of damage in RT tensile tests on specimens without and with holes. Fractography was performed on a limited number of specimens without and with holes to determine morphology of fracture surfaces. Representative RT stress-strain behavior, elevated temperature HCF behavior at the two temperatures, and RT residual tensile strengths of HCF runout specimens are documented in this report. Select examples of DIC and AE data from RT tensile tests on specimens without and with holes and typical features observed on fracture surfaces of specimens tested under tensile and HCF conditions are also discussed.

Ceramic matrix composite↗
NASA NTRS2004

Particulate Titanium Matrix Composites Tested--Show Promise for Space Propulsion Applications

Uniformly distributed particle-strengthened titanium matrix composites (TMCs) can be manufactured at lower cost than many types of continuous-fiber composites. The innovative manufacturing technology combines cold and hot isostatic pressing procedures to produce near-final-shape components. Material stiffness is increased up to 26-percent greater than that of components made with conventional titanium materials at no significant increase in the weight. The improved mechanical performance and low-cost manufacturing capability motivated an independent review to assess the improved properties of ceramic titanium carbide (TiC) particulate-reinforced titanium at elevated temperature. Researchers at the NASA Glenn Research Center creatively designed and executed deformation and durability tests to reveal operating regimes where these materials could lower the cost and weight of space propulsion systems. The program compares the elevated-temperature performance of titanium alloy Ti-6Al-4V matrix material to an alloy containing 10 wt% of TiC particles. Initial experiments showed that at these relatively low particle concentrations the material stiffness of the TMC was improved 20 percent over that of the plain Ti-6Al-4V alloy when tested at 427 C. The proportional limit and ultimate strength of the composite in tension are 21- and 14-percent greater than those of the plain alloy. Compression tests showed that the proportional limit is about 30 percent greater for TMC than for the plain alloy. The enhanced deformation resistance of the TMC was also evident in a series of tensile and compressive stress relaxation tests that were made. Specimens were subjected to tensile or compressive strain amplitudes of 0.75 percent for 24 hr followed by a return to zero strain imposed for 24 hr. The stress relaxation data were normalized with respect to the maximum stress for each case and plotted as a function of time in the following graph. Tensile stresses relaxed 19 percent for the TMC and 25 percent for the plain Ti-6Al-4V alloy. Compressive stresses relaxed 25 percent for the TMC and 39 percent for the plain Ti-6Al-4V alloy. The superior deformation resistance of the TMC extends to a creep rate that is 28-percent slower for the TMC when it is loaded to stress levels that are 26-percent higher than for the plain Ti-6Al-4V alloy.

Lerch, Bradley A.↗
DOE OSTI2024

Tribological behavior of hybrid Aluminum-TiB 2 metal matrix composites for brake rotor applications

Here, this research investigates the feasibility of hybrid aluminum metal matrix composites (MMC) incorporating TiB 2 particles for brake rotor applications. The composites were produced by incorporating both in-situ, submicron-sized TiB 2 particles and regular micron-sized TiB 2 powders via stir and squeeze casting techniques into A206 aluminum alloy matrix. Systematic adjustments in the fractions of in-situ and ex-situ TiB 2 particles were conducted to evaluate their impact on wear behavior and mechanisms. Combination of both particle types allowed composites with up to 10 vol% of reinforcements. Composites with higher proportions of ex-situ particles demonstrated increased wear resistance compared to those solely composed of in-situ particles, control specimens without TiB 2 , and conventional cast iron counterparts. The lowest wear rate for the hybrid composites sliding against phenolic brake pads was 1.1 × 10 -5 mm 3 /Nm, signifying a 3-fold reduction relative to cast iron sliding against the same pads. Wear analysis elucidated distinctive mechanisms within the hybrid composites, characterized by mild fragmented abrasive wear, adhesive wear, and plastic deformation, accompanied by the formation of an intermixed tribo-oxide layer.

42 ENGINEERING↗
DOE OSTI2022

Scalable, Infiltration-Free Ceramic Matrix Composite (SIF-CMC) manufacturing for Molten Salt Receiver: Investigation of particle-loaded preceramic resin

Due to their unique combination of high temperature, corrosion resistance, and toughness, Ceramic Matrix Composites (CMC) are the optimal materials to be used in the next generation of Concentrated Solar Power (CSP), which will operate at working temperatures up to 800 °C. However, today, CMC is too costly to be used in CSP applications due to its complex manufacturing process based on repeated infiltration-pyrolysis cycles. To solve this issue, PARC is developing a scalable, infiltration-free method (SIF) to manufacture CMC, which can reduce the production cost, increase batch consistency, and leverage all of the intrinsic advantages of current CMCs. The key to the SIF method is using a flowable preceramic resin with high loading of functional components. The formulation impregnates the fiber during curing and leads to high-density, low-shrinkage parts upon pyrolysis. In this paper, we demonstrate a proof-of-concept of the SIF process and report the relationships between key process parameters in the manufacturing process: functional material loading in the resin vs. resin’s flowability and morphology changes upon pyrolysis.

ceramic matrix composite, concentrated solar power↗
DOE OSTI2021

Copper-Tantalum Metal Matrix Composites Consolidated from Powder Blends by Severe Plastic Deformation

We investigated the effectiveness of severe plastic deformation by equal channel angular extrusion (ECAE) for consolidation of metal powders into metal matrix composites. Equal volumes of copper (Cu) and tantalum (Ta) powders were consolidated at ambient temperature via different ECAE routes. Composites processed by ECAE routes 4E and 4Bc were also processed at 300 °C. The resulting materials were characterized by scanning electron microscopy (SEM) and compression testing. Processing by route 4Bc at 300 °C resulted in the highest compressive strength, lowest anisotropy, and least strain rate sensitivity. We conclude that the superior properties achieved by this route arise from mechanical bonding due to interlocking Cu and Ta phases as well as enhanced metallurgical bonds from contact of pristine metal surfaces when the material is sheared along orthogonal planes.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Modeling creep behavior in ceramic matrix composites

Here, in this work, a three-dimensional viscoplasticity formulation with progressive damage is developed and used to investigate the complex time-dependent constituent load transfer and progressive damage behavior in ceramic matrix composites (CMCs) subjected to creep. The viscoplasticity formulation is based on Hill's orthotropic plastic potential, an associative flow rule, and the Norton-Bailey creep power law with Arrhenius temperature dependence. A fracture mechanics-informed isotropic matrix damage model is used to account for CMC brittle matrix damage initiation and propagation, in which two scalar damage variables capture the effects of matrix porosity as well as matrix property degradation due to matrix crack initiation and propagation. The Curtin progressive fiber damage model is utilized to simulate progressive fiber failure. The creep-damage formulation is subsequently implemented as a constitutive model in the generalized method of cells (GMC) micromechanics formulation to simulate time-dependent deformation and material damage under creep loading conditions. The developed framework is used to simulate creep of single fiber SiC/SiC microcomposites. Simulation results are in excellent agreement with experimental and numerical data available in the literature.

36 MATERIALS SCIENCE↗
NASA NTRS1994

Implementation of thermal residual stresses in the analysis of fiber bridged matrix crack growth in titanium matrix composites

In this research, thermal residual stresses were incorporated in an analysis of fiber-bridged matrix cracks in unidirectional and cross-ply titanium matrix composites (TMC) containing center holes or center notches. Two TMC were investigated, namely, SCS-6/Timelal-21S laminates. Experimentally, matrix crack initiation and growth were monitored during tension-tension fatigue tests conducted at room temperature and at an elevated temperature of 200 C. Analytically, thermal residual stresses were included in a fiber bridging (FB) model. The local R-ratio and stress-intensity factor in the matrix due to thermal and mechanical loadings were calculated and used to evaluate the matrix crack growth behavior in the two materials studied. The frictional shear stress term, tau, assumed in this model was used as a curve-fitting parameter to matrix crack growth data. The scatter band in the values of tau used to fit the matrix crack growth data was significantly reduced when thermal residual stresses were included in the fiber bridging analysis. For a given material system, lay-up and temperature, a single value of tau was sufficient to analyze the crack growth data. It was revealed in this study that thermal residual stresses are an important factor overlooked in the original FB models.

Bakuckas, John G., Jr.↗
NASA NTRS1997

A Coupled/Uncoupled Computational Scheme for Deformation and Fatigue Damage Analysis of Unidirectional Metal-Matrix Composites

A fatigue damage computational algorithm utilizing a multiaxial, isothermal, continuum-based fatigue damage model for unidirectional metal-matrix composites has been implemented into the commercial finite element code MARC using MARC user subroutines. Damage is introduced into the finite element solution through the concept of effective stress that fully couples the fatigue damage calculations with the finite element deformation solution. Two applications using the fatigue damage algorithm are presented. First, an axisymmetric stress analysis of a circumferentially reinforced ring, wherein both the matrix cladding and the composite core were assumed to behave elastic-perfectly plastic. Second, a micromechanics analysis of a fiber/matrix unit cell using both the finite element method and the generalized method of cells (GMC). Results are presented in the form of S-N curves and damage distribution plots.

Wilt, Thomas E.↗
NASA NTRS1986

Modeling the curing process of thermosetting resin matrix composites

A model is presented for simulating the curing process of a thermosetting resin matrix composite. The model relates the cure temperature, the cure pressure, and the properties of the prepreg to the thermal, chemical, and rheological processes occurring in the composite during cure. The results calculated with the computer code developed on the basis of the model were compared with the experimental data obtained from autoclave-curved composite laminates. Good agreement between the two sets of results was obtained.

Loos, A. C.↗
NASA NTRS1990

Interfacial reactions in high temperature metallic and intermetallic matrix composites - A status review

Interdiffusion and interdiffusion-related phenomena in metal and intermetallic matrix composites can be of crucial interest for the prolonged application of these systems at high temperature. The level of complication that these effects can have can vary significantly from system to system. Reviewed herein are recent efforts to address interdiffusion and reaction kinetics for both a simple system, the single phase W/Nb system, and more complex systems such as tungsten fiber reinforced superalloys (TFRS) and beryllide reinforced aluminides. Additionally, recent work on inhibiting interdiffusion in MMCs via ion-implanted diffusion barriers will be presented.

Tien, J. K.↗
NASA NTRS1995

An Investigation of Theories of Failure for Ceramic Matrix Composites

In order to further advance the understanding of the mechanical behavior of ceramic matrix composites (CMCs), acoustic emission (AE) techniques were imple mented to monitor and identify damage mechanisms in CMCs under tensile loading. In addition to real-time AE monitoring techniques, a data acquisition system was developed and implemented in order to capture AE waveforms resulting from stress-induced damage. Waveforms were inspected for multiple events, separated in distinct events, and then analyzed to determine waveform characteristics in the time and frequency domains. Waveform characteristics included peak amplitude, event duration, MARSE, energy, and dominant and centroidal frequency. In addition to conventional methods for determining a damage discrimination criteria, a study of the distribution and correlation the waveform characteristics was performed to aid in the determination of a damage discrimination criteria. The damage discrimination criteria was tested for "uniqueness", i.e., the effectiveness of the criteria to identify and monitor damage independent of the stress-strain relationship. Insitu radiography was used to substantiate the damage accumulation.

Hemann, John H.↗
NASA NTRS1998

Anomalous Buckling Characteristics of Laminated Metal-Matrix Composite Plates with Central Square Holes

Compressive buckling analysis was performed on metal-matrix composite (MMC) plates with central square holes. The MMC plates have varying aspect ratios and hole sizes and are supported under different boundary conditions. The finite-element structural analysis method was used to study the effects of plate boundary conditions, plate aspect ratio, hole size, and the composite stacking sequence on the compressive buckling strengths of the perforated MMC plates. Studies show that by increasing the hole sizes, compressive buckling strengths of the perforated MMC plates could be considerably increased under certain boundary conditions and aspect ratios ("anomalous" buckling behavior); and that the plate buckling mode could be symmetrical or antisymmetrical, depending on the plate boundary conditions, aspect ratio, and the hole size. For same-sized plates with same-sized holes, the compressive buckling strengths of the perforated MMC plates with [90/0/0/90]2 lamination could be as much as 10 percent higher or lower than those of the [45/- 45/- 45/45]2 laminations, depending on the plate boundary conditions, plate aspect ratios, and the hole size. Clamping the plate edges induces far stronger "anomalous" buckling behavior (enhancing compressive buckling strengths at increasing hole sizes) of the perforated MMC plates than simply supporting the plate edges.

Ko, William L.↗
NASA NTRS2000

Ceramic Matrix Composite Turbine Disk for Rocket Engines

NASA has recently completed testing of a ceramic matrix composite (CMC), integrally bladed disk (blisk) for rocket engine turbopumps. The turbopump's main function is to bring propellants from the tank to the combustion chamber at optimal pressures, temperatures, and flow rates. Advantages realized by using CMC blisks are increases in safety by increasing temperature margins and decreasing costs by increasing turbopump performance. A multidisciplinary team, involving materials, design, structural analysis, nondestructive inspection government, academia, and industry experts, was formed to accomplish the 4.5 year effort. This article will review some of the background and accomplishments of the CMC Blisk Program relative to the benefits of this technology.

Effinger, Mike↗