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NASA NTRS2004

Signal Processing Variables for Optimization of Flaw Detection in Composites Using Ultrasonic Guided Wave Scanning

This study analyzes the effect of signal processing variables on the ability of the ultrasonic guided wave scan method at NASA Glenn Research Center to distinguish various flaw conditions in ceramic matrix composites samples. In the ultrasonic guided wave scan method, several time- and frequency-domain parameters are calculated from the ultrasonic guided wave signal at each scan location to form images. The parameters include power spectral density, centroid mean time, total energy (zeroth moment), centroid frequency, and ultrasonic decay rate. A number of signal processing variables are available to the user when calculating these parameters. These signal processing variables include 1) the time portion of the time-domain waveform processed, 2) integration type for the properties requiring integrations, 3) bounded versus unbounded integrations, 4) power spectral density window type, 5) and the number of time segments chosen if using the short-time fourier transform to calculate ultrasonic decay rate. Flaw conditions examined included delamination, cracking, and density variation.

Roth, Don J.↗

NASA NTRS1994

Composites research at NASA Lewis Research Center

Composites research at NASA Lewis is focused on their applications in aircraft propulsion, space propulsion, and space power, with the first being predominant. Research on polymer-, metal-, and ceramic-matrix composites is being carried out from an integrated materials and structures viewpoint. This paper outlines some of the topics being pursued from the standpoint of key technical issues, current status, and future directions.

Levine, Stanley R.↗

NASA NTRS1996

Mullite fiber reinforced reaction bonded Si3N4 composites

Fracture toughnesses of brittle ceramic materials have been improved by introducing reinforcements and carefully tailored interface layers. Silicon carbide and Si3N4 have been emphasized as matrices of structural composites intended for high temperature service because they combine excellent mechanical, chemical, thermal and physical properties. Both matrices have been successfully toughened with SiC fibers, whiskers and particles for ceramic matrix composite (CMC) parts made by sintering, hot pressing or reaction forming processes. These SiC reinforced CMCs have exhibited significantly improved toughnesses at low and intermediate temperature levels, as well as retention of properties at high temperatures for selected exposures; however, they are vulnerable to attack from elevated temperature dry and wet oxidizing atmospheres after the matrix has cracked. Property degradation results from oxidation of interface layers and/or reinforcements. The problem is particularly acute for small diameter (-20 tim) polymer derived SiC fibers used for weavable toes. This research explored opportunities for reinforcing Si3N4 matrices with fibers having improved environmental stability; the findings should also be applicable to SiC matrix CMCs.

Saleh, T.↗

NASA NTRS1989

Elastic crack bridging in ceramic and intermetallic matrix composites

A micromechanics analytical model based on the consistent shear lag theory is developed for predicting the failure modes in a fiber reinforced unidirectional ceramic and intermetallic matrix composite. The model accounts for the relatively large matrix stiffness. The fiber and matrix stresses are established as functions of the applied stress, crack geometry, and most importantly, the microstructural properties of the constituents. From the predicted stress, the mode of failure is established based on the point stress criterion.

Dharani, L. R.↗

NASA NTRS1988

Nondestructive evaluation of advanced ceramics

A review is presented of Lewis Research Center efforts to develop nondestructive evaluation techniques for characterizing advanced ceramic materials. Various approaches involved the use of analytical ultrasonics to characterize monolythic ceramic microstructures, acousto-ultrasonics for characterizing ceramic matrix composites, damage monitoring in impact specimens by microfocus X-ray radiography and scanning ultrasonics, and high resolution computed X-ray tomography to identify structural features in fiber reinforced ceramics.

Klima, Stanley J.↗

NASA NTRS1989

A hybrid procedure for dynamic characterization of ceramics at elevated temperature

A hybrid experimental-numerical procedure to characterize the dynamic fracture response of ceramics and ceramic composites at temperatures in excess of 1400 C is described. This hybrid methodology was developed to characterize dynamic fracture responses and to study the effect of temperature on dynamic fracture responses of ceramics and ceramic matrix composites. The hybrid methodology was used to determine the dynamic stress intensity factors (SIF) associated with a running crack in a three-point bend specimen at elevated temperature. This procedure was utilized to determine the dynamic SIF versus crack velocity relations of alumina, TiB2-particulate/SiC-matrix composite, and SiC-whisker/Al2O3-matrix composite. Minor differences in the dynamic SIF versus crack velocity relations at room and elevated temperature were seen, and significant differences under impact and static loadings were observed in the dynamic SIF versus crack velocity relations.

Yang, K. H.↗

NASA NTRS1995

Acousto-ultrasonic decay in metal matrix composite panels

Acousto-ultrasonic (A-U) decay rates (UD) were measured in metal matrix composite (MMC) panels. The MMC panels had fiber architectures and cross-sectional thicknesses corresponding to those designed for aerospace turbine engine structures. The wavelength-to-thickness ratio produced by the combination of experimental frequency setting conditions and specimen geometry was found to be a key parameter for identifying optimum conditions for UD measurements. The ratio was shown to be a useful rule of thumb when applied to ceramic matrix composites (CMC)s and monolithic thermo-plastics.

Kautz, Harold E.↗

NASA NTRS2004

Thermal Conductivity of Advanced Ceramic Thermal Barrier Coatings Determined by a Steady-state Laser Heat-flux Approach

The development of low conductivity and high temperature capable thermal barrier coatings requires advanced testing techniques that can accurately and effectively evaluate coating thermal conductivity under future high-performance and low-emission engine heat-flux conditions. In this paper, a unique steady-state CO2 laser (wavelength 10.6 microns) heat-flux approach is described for determining the thermal conductivity and conductivity deduced cyclic durability of ceramic thermal and environmental barrier coating systems at very high temperatures (up to 1700 C) under large thermal gradients. The thermal conductivity behavior of advanced thermal and environmental barrier coatings for metallic and Si-based ceramic matrix composite (CMC) component applications has also been investigated using the laser conductivity approach. The relationships between the lattice and radiation conductivities as a function of heat flux and thermal gradient at high temperatures have been examined for the ceramic coating systems. The steady-state laser heat-flux conductivity approach has been demonstrated as a viable means for the development and life prediction of advanced thermal barrier coatings for future turbine engine applications.

Zhu, Dong-Ming↗

NASA NTRS1989

Dynamic stress intensity factors of brittle materials

A new hybrid experimental-numerical procedure was used to characterize dynamic fracture response of structural ceramics at elevated temperature. The dynamic stress intensity factor (SIF) versus crack velocity relations of glass and reaction bonded silicon nitride (RBSN), are reviewed. The dynamic SIF versus crack velocity relations of alumina, TiB2-particulate/SiC-matrix composite and SiCw/Alumina-matrix composite are also presented. Available data indicated that dynamic arrest SIF was not observed in glass and monolithic ceramics, and suggested that further studies be conducted to resolve the existence or lack of existence of a dynamic arrest SIF in ceramic matrix composites.

Kobayashi, Albert S.↗

NASA NTRS2004

Boron Nitride Nanotubes Synthesized by Pressurized Reactive Milling Process

Nanotubes, because of their very high strength, are attractive as reinforcement materials for ceramic matrix composites (CMCs). Recently there has been considerable interest in developing and applying carbon nanotubes for both electronic and structural applications. Although carbon nanotubes can be used to reinforce composites, they oxidize at high temperatures and, therefore, may not be suitable for ceramic composites. Boron nitride, because it has a higher oxidation resistance than carbon, could be a potential reinforcement material for ceramic composites. Although boron nitride nanotubes (BNnT) are known to be structurally similar to carbon nanotubes, they have not undergone the same extensive scrutiny that carbon nanotubes have experienced in recent years. This has been due to the difficulty in synthesizing this material rather than lack of interest in the material. We expect that BNnTs will maintain the high strength of carbon nanotubes while offering superior performance for the high-temperature and/or corrosive applications of interest to NASA. At the NASA Glenn Research of preparing BN-nTs were investigated and compared. These include the arc jet process, the reactive milling process, and chemical vapor deposition. The most successful was a pressurized reactive milling process that synthesizes BN-nTs of reasonable quantities.

Hurst, Janet B.↗

NASA NTRS1993

Engine materials characterization and damage monitoring by using x ray technologies

X ray attenuation measurement systems that are capable of characterizing density variations in monolithic ceramics and damage due to processing and/or mechanical testing in ceramic and intermetallic matrix composites are developed and applied. Noninvasive monitoring of damage accumulation and failure sequences in ceramic matrix composites is used during room-temperature tensile testing. This work resulted in the development of a point-scan digital radiography system and an in situ x ray material testing system. The former is used to characterize silicon carbide and silicon nitride specimens, and the latter is used to image the failure behavior of silicon-carbide-fiber-reinforced, reaction-bonded silicon nitride matrix composites. State-of-the-art x ray computed tomography is investigated to determine its capabilities and limitations in characterizing density variations of subscale engine components (e.g., a silicon carbide rotor, a silicon nitride blade, and a silicon-carbide-fiber-reinforced beta titanium matrix rod, rotor, and ring). Microfocus radiography, conventional radiography, scanning acoustic microscopy, and metallography are used to substantiate the x ray computed tomography findings. Point-scan digital radiography is a viable technique for characterizing density variations in monolithic ceramic specimens. But it is very limited and time consuming in characterizing ceramic matrix composites. Precise x ray attenuation measurements, reflecting minute density variations, are achieved by photon counting and by using microcollimators at the source and the detector. X ray computed tomography is found to be a unique x ray attenuation measurement technique capable of providing cross-sectional spatial density information in monolithic ceramics and metal matrix composites. X ray computed tomography is proven to accelerate generic composite component development. Radiographic evaluation before, during, and after loading shows the effect of preexisting volume flaws on the fracture behavior of composites. Results from one-, three-, five-, and eight-ply ceramic composite specimens show that x ray film radiography can monitor damage accumulation during tensile loading. Matrix cracking, fiber-matrix debonding, fiber bridging, and fiber pullout are imaged throughout the tensile loading of the specimens. In situ film radiography is found to be a practical technique for estimating interfacial shear strength between the silicon carbide fibers and the reaction-bonded silicon nitride matrix. It is concluded that pretest, in situ, and post-test x ray imaging can provide greater understanding of ceramic matrix composite mechanical behavior.

Baaklini, George Y.↗

NASA NTRS2012

Active Oxidation of a UHTC-Based CMC

The active oxidation of ceramic matrix composites (CMC) is a severe problem that must be avoided for multi-use hypersonic vehicles. Much work has been performed studying the active oxidation of silicon-based CMCs such as C/SiC and SiC-coated carbon/carbon (C/C). Ultra high temperature ceramics (UTHC) have been proposed as a possible material solution for high-temperature applications on hypersonic vehicles. However, little work has been performed studying the active oxidation of UHTCs. The intent of this paper is to present test data indicating an active oxidation process for a UHTC-based CMC similar to the active oxidation observed with Si-based CMCs. A UHTC-based CMC was tested in the HyMETS arc-jet facility (or plasma wind tunnel, PWT) at NASA Langley Research Center, Hampton, VA. The coupon was tested at a nominal surface temperature of 3000 F (1650 C), with a stagnation pressure of 0.026 atm. A sudden and large increase in surface temperature was noticed with negligible increase in the heat flux, indicative of the onset of active oxidation. It is shown that the surface conditions, both temperature and pressure, fall within the region for a passive to active transition (PAT) of the oxidation.

Glass, David E.↗

NASA NTRS2012

Simulation of Complex Cracking in Plain Weave C/SiC Composite under Biaxial Loading

Finite element analysis is performed on a mesh, based on computed geometry of a plain weave C/SiC composite with assumed internal stacking, to reveal the pattern of internal damage due to biaxial normal cyclic loading. The simulation encompasses intertow matrix cracking, matrix cracking inside the tows, and separation at the tow-intertow matrix and tow-tow interfaces. All these dissipative behaviors are represented by traction-separation cohesive laws. Not aimed at quantitatively predicting the overall stress-strain relation, the simulation, however, does not take the actual process of fiber debonding into account. The fiber tows are represented by a simple rule-of-mixture model where the reinforcing phase is a hypothetical one-dimensional material. Numerical results indicate that for the plain weave C/SiC composite, 1) matrix-crack initiation sites are primarily determined by large intertow matrix voids and interlayer tow-tow contacts, 2) the pattern of internal damage strongly depends on the loading path and initial stress, 3) compressive loading inflicts virtually no damage evolution. KEY WORDS: ceramic matrix composite, plain weave, cohesive model, brittle failure, smeared crack model, progressive damage, meso-mechanical analysis, finite element.

Cheng, Ron-Bin↗

NASA NTRS2020

Characterization of SiC/SiC Composites Subjected to Sequential Tensile Creep and Dwell Fatigue in Air under Thermal Gradient Conditions

Uncoated SiC/SiC composites, with 2D and 3D fiber architectures, were investigated under steady state thermal gradient conditions with sequential tensile creep and dwell fatigue. Melt infiltration (MI), chemical vapor infiltration (CVI), polymer impregnation and pyrolysis (PIP), and hybrid (CVI and PIP) techniques were used to fabricate ceramic matrix composites (CMCs) with a 2D balanced fiber architecture. CMCs with 3D fiber weaves were also fabricated using MI and hybrid methods. Steady state through the thickness thermal gradients were generated for the tensile specimens using laser heating on the front (hot side) and forced air cooling on the back (cold side). Hot side and cold side temperatures of 2400 and 2200 Â°F, respectively, were used for testing CMCs fabricated with the MI process, whereas hot side and cold side temperatures of 2700 and 2400 Â°F, respectively, were used for CMCs fabricated with CVI, PIP, and hybrid processes. Each CMC specimen was initially tested under tensile creep at 69 MPa (10 ksi) for 80 hours, which was then followed by tensile dwell fatigue testing at a maximum stress of 69 MPa (10 ksi) for another 80 hours for a total of 160 hours. This type of sequential tensile creep followed by tensile dwell fatigue testing was performed to ascertain the integrity of uncoated CMCs under steady state thermal gradient conditions. Tensile creep and dwell fatigue test results, generated under steady state thermal gradient conditions on different types of SiC/SiC composites, are compared with corresponding creep behaviors observed under isothermal conditions to determine the influence of both monotonic creep (static fatigue) and dwell fatigue on accumulated strains and deformation behaviors of the CMCs.

Kalluri, Sreeramesh↗

NASA NTRS2004

Subscale Testing of a Ceramic Composite Cooled Panel Led to Its Design and Fabrication for Scramjet Engine Testing

In a partnership between the NASA Glenn Research Center and Pratt & Whitney, a ceramic heat exchanger panel intended for use along the hot-flow-path walls of future reusable launch vehicles was designed, fabricated, and tested. These regeneratively cooled ceramic matrix composite (CMC) panels offer lighter weight, higher operating temperatures, and reduced coolant requirements in comparison to their more traditional metallic counterparts. A maintainable approach to the design was adopted which allowed the panel components to be assembled with high-temperature fasteners rather than by permanent bonding methods. With this approach, the CMC hot face sheet, the coolant containment system, and backside structure were all fabricated separately and could be replaced individually as the need occurred during use. This maintainable design leads to both ease of fabrication and reduced cost.

Jaskowiak, Martha H.↗

NASA NTRS2004

Thermo-Mechanical Properties of Super Sylramic SiC Fibers

Ceramic matrix composites (CMC) reinforced by Sic fibers, such as SiC/SiC, are targeted for application in hot-section components of advanced engines for aerospace propulsion and for electrical power generation. Two Super Sylramic Sic fiber types recently developed at NASA using the Sylramic fiber from COI Ceramics are candidates fof providing these components with improved thermal capability and improved performance. This paper reports on the state-of-the-art ability of these new fiber types to meet the key fiber requirements of these applications: high strength, high creep-rupture resistance, high environmental resistance, and high thermal conductivity. For example, creep-rupture tests performed at from 1350 to 1500 C under various environments to simulate CMC fabrication and service conditions show creep resistance in air improved -20 and -7 times in comparison to current Sylramic and Sylramic-iBN fiber types, respectively. This in turn resulted in an increase in fiber rupture life by up to two orders of magnitude. TEM and AES microscopic observations are presented to indicate that these improvements can be correlated with the replacement of weak grain boundary phases with stronger phases that hinder grain boundary sliding more effectively. SiC/SiC composite results are also provided to show the advantages of the Super Sylramic fiber types both for CMC fabrication and high temperature application.

Yun, H. M.↗

NASA NTRS2015

CMC Research at NASA Glenn in 2015: Recent Progress and Plans

An overview of recent research in Ceramic Matrix Composite materials at NASA Glenn Research Center. For presentation at the July 16, 2015 GRC Dialogue Day with Ohio Academia, as part of the establishment of the Ohio Federal Research Network.

Ceramics and Composites↗

NASA NTRS1986

Carbon-rich ceramic composites from ethynyl aromatic precrusors

A number of polyfunctional aromatic acetylenes thermally polymerize at low temperatures (180 C) and pyrolyze with greater than 90 char yield. In nonoxidizing environments, they are thermally stable to 1450 C. These monomers were chosen as the basis of a model system to study the fabrication and mechanical properties of continuous filament ceramic matrix composite. Composites were fabricated from aryl poly(acetylenes), SiC particulate filler and graphite, Avco SiC, Nicalon and Nextel fibers. Microstructure, physical and mechanical properties are reported.

Hurwitz, F. I.↗