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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 649 records · Page 36
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

Effect of braze processing on the microstructure and mechanical properties of SCS-6/beta21S titanium matrix composites

An investigation is conducted of the effects of braze processing on the microstructure and tensile properties of SiC fiber-reinforced Ti-15Mo-2.7Nb-3Al-0.25Si-matrix composite (TMC) laminates; the brazing alloy was the commercial Ti-15Cu-15Ni, in both its conventional and metglass forms. Tensile tests conducted at room temperature, 1200 F, and 1500 F showed that the braze processes (1) had little effect on tensile properties, and (2) appeared to degrade neither the reinforcing fibers not the fiber/matrix interfacial bondline.

Hoffman, Eric K.↗
NASA NTRS1999

Friction Stir Welding for Aluminum Metal Matrix Composites (MMC's) (Center Director's Discretionary Fund, Project No. 98-09)

This technical memorandum describes an investigation of using friction stir welding (FSW) process for joining a variety of aluminum metal matrix composites (MMC's) reinforced with discontinuous silicon-carbide (SiC) particulate and functional gradient materials. Preliminary results show that FSW is feasible to weld aluminum MMC to MMC or to aluminum-lithium 2195 if the SiC reinforcement is <25 percent by volume fraction. However, a softening in the heat-affected zone was observed and is known to be one of the major limiting factors for joint strength. The pin tool's material is made from a low-cost steel tool H-13 material, and the pin tool's wear was excessive such that the pin tool length has to be manually adjusted for every 5 ft of weldment. Initially, boron-carbide coating was developed for pin tools, but it did not show a significant improvement in wear resistance. Basically, FSW is applicable mainly for butt joining of flat plates. Therefore, FSW of cylindrical articles such as a flange to a duct with practical diameters ranging from 2-5 in. must be fully demonstrated and compared with other proven MMC joining techniques for cylindrical articles.

Lee, J. A.↗
NASA NTRS1992

Experimental characterization of nonlinear, rate-dependent behavior in advanced polymer matrix composites

In order to support materials selection for the next-generation supersonic civilian-passenger transport aircraft, a study has been undertaken to evaluate the material stress/strain relationships needed to describe advanced polymer matrix composites under conditions of high load and elevated temperature. As part of this effort, this paper describes the materials testing which was performed to investigate the viscoplastic behavior of graphite/thermoplastic and graphite/bismaleimide composites. Test procedures, results and data-reduction schemes which were developed for generating material constants for tension and compression loading, over a range of useful temperatures, are explained.

Gates, Thomas S.↗
NASA NTRS2000

Ceramic Matrix Composites (CMC) Life Prediction Method Development

Advanced launch systems (e.g., Reusable Launch Vehicle and other Shuttle Class concepts, Rocket-Based Combine Cycle, etc.), and interplanetary vehicles will very likely incorporate fiber reinforced ceramic matrix composites (CMC) in critical propulsion components. The use of CMC is highly desirable to save weight, to improve reuse capability, and to increase performance. CMC candidate applications are mission and cycle dependent and may include turbopump rotors, housings, combustors, nozzle injectors, exit cones or ramps, and throats. For reusable and single mission uses, accurate prediction of life is critical to mission success. The tools to accomplish life prediction are very immature and not oriented toward the behavior of carbon fiber reinforced silicon carbide (C/SiC), the primary system of interest for a variety of space propulsion applications. This paper describes an approach to satisfy the need to develop an integrated life prediction system for CMC that addresses mechanical durability due to cyclic and steady thermomechanical loads, and takes into account the impact of environmental degradation.

Levine, Stanley R.↗
NASA NTRS2001

Fabrication and Testing of Ceramic Matrix Composite Rocket Propulsion Components

NASA has established goals for Second and Third Generation Reusable Launch Vehicles. Emphasis has been placed on significantly improving safety and decreasing the cost of transporting payloads to orbit. Ceramic matrix composites (CMC) components are being developed by NASA to enable significant increases in safety and engineer performance, while reducing costs. The development of the following CMC components are being pursued by NASA: (1) Simplex CMC Blisk; (2) Cooled CMC Nozzle Ramps; (3) Cooled CMC Thrust Chambers; and (4) CMC Gas Generator. These development efforts are application oriented, but have a strong underpinning of fundamental understanding of processing-microstructure-property relationships relative to structural analyses, nondestructive characterization, and material behavior analysis at the coupon and component and system operation levels. As each effort matures, emphasis will be placed on optimizing and demonstrating material/component durability, ideally using a combined Building Block Approach and Build and Bust Approach.

Effinger, M. R.↗
NASA NTRS1997

Probabilistic Evaluation of Bolted Joints in Polymer Matrix Composites

Computational methods are described to probabilistically simulate fracture in bolted composite structures. Progressive fracture is simulated via an innovative approach independent of stress intensity factors and fracture toughness. The effect on structure damage of design variable uncertainties is quantified. The Fast Probability Integrator is used to assess the scatter in the composite structure response before and after damage. Sensitivity of the response to design variables is evaluated. The methods are demonstrated for bolted joint polymer matrix composite panels under end loads. The effects of fabrication process are included in the simulation of damage in the bolted panel. The results show that the most effective way to reduce the end displacement at fracture is to control the load and ply thickness.

Chamis, C. C.↗
NASA NTRS1999

Friction Stir Welding of SiC/Aluminum Metal Matrix Composites

Friction Stir Welding (FSW) is a new solid state process for joining metals by plasticizing and consolidating materials around the bond line using thermal energy producing from frictional forces. A feasibility study for FSW of Metal Matrix Composites (MMC) was investigated using aluminum 6092 alloy reinforced with 17% SiC particulates. FSW process consists of a special rotating pin tool that is positioned to plunge into the MMC surface at the bond line. As the tool rotates and move forward along the bond line, the material at the bond line is heated up and forced to flow around the rotating tip to consolidate on the tip's backside to form a solid state joint. FSW has the potential for producing sound welds with MMC because the processing temperature occurs well below the melting point of the metal matrix; thereby eliminating the reinforcement-to-matrix solidification defects, reducing the undesirable chemical reactions and porosity problems.

Lee, Jonathan A.↗
NASA NTRS1972

Pendulum impact resistance of tungsten fiber/metal matrix composites.

The impact properties of copper, copper-10 nickel, and a superalloy matrix reinforced with tungsten fibers were studied. In most cases the following increased composite impact strength: increased fiber or matrix toughness, decreased fiber-matrix reaction, increased test temperature, hot working and heat treatment. Notch sensitivity was reduced by increasing fiber or matrix toughness. The effect of fiber content depended on the relative toughness of the fibers and matrix. Above 530 K a 60 volume per cent superalloy matrix composite had a greater impact strength than a turbine blade superalloy, whereas below 530 K a hot worked 56 volume per cent composite had a greater impact strength than the superalloy.

Winsa, E. A.↗
NASA NTRS1991

Computational simulation of microfracture in high temperature metal matrix composites

A computational simulation procedure, using three-dimensional finite element method and global strain energy release rates, is described to predict the microfracture process and identify/quantify the hierarchy of respective fracture modes in metal matrix composites. The procedure is used to predict the microfracture in unidirectional composites under longitudinal loads and accounts for the interphase strength in the in situ state. A novel procedure to computationally simulate the fiber pushthrough process is also described. In this simulation, the interface material is replaced by an anisotropic material with greatly reduced shear modulus in order to simulate the fiber pushthrough process using a linear analysis. Such a procedure is easily implemented and is computationally very effective.

Mital, Subodh K.↗
NASA NTRS1990

Influence of interfacial shear strength on the mechanical properties of SiC fiber reinforced reaction-bonded silicon nitride matrix composites

An evaluation is made of the influence of interfacial microstructure and shear strength on the mechanical properties of a 30 vol pct uniaxially-aligned SiC fiber-reinforced reaction-bonded Si3N4-matrix composite whose interface microstructure was varied through control of fabrication conditions and by heat-treatment in an oxidizing environment. The carbon-rich coating of the as-produced SiC fibers was stable in composites fabricated at 1200 C in an N or N + 4-percent H mixture for 40 hrs. This coating was degraded in composites fabricated at 1350 C in N + 4 percent H for 40 and 72 hrs, as well as after heat-treatment in an oxidizing environment at 600 C for 100 hrs even after fabrication at 1200 C in N. This degradation occurred via carbon removal.

Bhatt, Ramakrishna T.↗
NASA NTRS1995

Space environmental effects on polymer matrix composites as a function of sample location on LDEF

This paper presents results on the effect of circumferential location on the variation in solar absorptance (alpha(sub S)) and infrared emittance (epsilon) for five different polymer matrix composites (PMC), and variations in erosion depth due to atomic oxygen (AO) for fourteen different PMC materials. In addition, a chemical content design parameter (gamma) has been found that correlates well with the erosion yield obtained from space flight data and hyperthermal AO tests for hydrocarbon polymeric materials. This parameter defines the ratio of the total number of atoms in a repeat monomer unit to the difference between the total carbon content and the total number of intermolecular oxygen atoms in the same repeat unit.

Tennyson, R. C.↗
NASA NTRS2002

Investigation of Friction Stir Welding and Laser Engineered Net Shaping of Metal Matrix Composite Materials

The improvement in weld quality by the friction stir welding (FSW) process invented by TWI of Cambridge, England, patented in 1991, has prompted investigation of this process for advanced structural materials including Al metal matrix composite (Al-MMC) materials. Such materials can have high specific stiffness and other potential beneficial properties for the extreme environments in space. Developments of discontinuous reinforced Al-MMCs have found potential space applications and the future for such applications is quite promising. The space industry has recognized advantages of the FSW process over conventional welding processes such as the absence of a melt zone, reduced distortion, elimination of the need for shielding gases, and ease of automation. The process has been well proven for aluminum alloys, and work is being carried out for ferrous materials, magnesium alloys and copper alloys. Development work in the FSW welding process for joining of Al-MMCs is relatively recent and some of this and related work can be found in referenced research publications. NASA engineers have undertaken to spear head this research development work for FSW process investigation of Al-MMCs. Some of the reported related work has pointed out the difficulty in fusion welding of particulate reinforced MMCs where liquid Al will react with SiC to precipitate aluminum carbide (Al4C3). Advantages of no such reaction and no need for joint preparation for the FSW process is anticipated in the welding of Al-MMCs. The FSW process has been best described as a combination of extrusion and forging of metals. This is carried out as the pin tool rotates and is slowly plunged into the bond line of the joint as the pin tool's shoulder is in intimate contact with the work piece. The material is friction-stirred into a quality weld.

Ravinder M. Diwan↗
NASA NTRS1992

Nondestructive evaluation of a ceramic matrix composite material

Monolithic ceramic materials have proven their usefulness in many applications, yet, their potential for critical structural applications is limited because of their sensitivity to small imperfections. To overcome this extreme sensitivity to small imperfections, ceramic matrix composite materials have been developed that have the ability to withstand some distributed damage. A borosilicate glass reinforced with several layers of silicon-carbide fiber mat has been studied. Four-point flexure and tension tests were performed not only to determine some of the material properties, but also to initiate a controlled amount of damage within each specimen. Acousto-ultrasonic (AU) measurements were performed periodically during mechanical testing. This paper will compare the AU results to the mechanical test results and data from other nondestructive methods including acoustic emission monitoring and X-ray radiography. It was found that the AU measurements were sensitive to the damage that had developed within the material.

Grosskopf, Paul P.↗
NASA NTRS2000

Fabrication and Testing of Ceramic Matrix Composite Propulsion Components

A viewgraph presentation outlines NASA's goals for the Second and Third Generation Reusable Launch Vehicles, placing emphasis on improving safety and decreasing the cost of transporting payloads to orbit. The use of ceramic matrix composite (CMC) technology is discussed. The development of CMC components, such as the Simplex CMC Blisk, cooled CMC nozzle ramps, cooled CMC thrust chambers, and CMC gas generators, are described, including challenges, test results, and likely future developments.

Effinger, Michael R.↗
NASA NTRS2005

Crack Driving Forces in a Multilayered Coating System for Ceramic Matrix Composite Substrates

The effects of the top coating thickness, modulus and shrinkage strains on the crack driving forces for a baseline multilayer Yttria-Stabilized-Zirconia/Mullite/Si thermal and environment barrier coating (TEBC) system for SiC/SiC ceramic matrix composite substrates are determined for gas turbine applications. The crack driving forces increase with increasing modulus, and a low modulus thermal barrier coating material (below 10 GPa) will have no cracking issues under the thermal gradient condition analyzed. Since top coating sintering increases the crack driving forces with time, highly sintering resistant coatings are desirable to maintain a low tensile modulus and maintain a low crack driving force with time. Finite element results demonstrated that an advanced TEBC system, such as ZrO2/HfO2, which possesses improved sintering resistance and high temperature stability, exhibited excellent durability. A multi-vertical cracked structure with fine columnar spacing is an ideal strain tolerant coating capable of reducing the crack driving forces to an acceptable level even with a high modulus of 50 GPa.

Ghosn, Louis J.↗
NASA NTRS2015

Characterization of Hybrid CNT Polymer Matrix Composites

Carbon nanotubes (CNTs) have been studied extensively since their discovery and demonstrated at the nanoscale superior mechanical, electrical and thermal properties in comparison to micro and macro scale properties of conventional engineering materials. This combination of properties suggests their potential to enhance multi-functionality of composites in regions of primary structures on aerospace vehicles where lightweight materials with improved thermal and electrical conductivity are desirable. In this study, hybrid multifunctional polymer matrix composites were fabricated by interleaving layers of CNT sheets into Hexcel® IM7/8552 prepreg, a well-characterized toughened epoxy carbon fiber reinforced polymer (CFRP) composite. The resin content of these interleaved CNT sheets, as well as ply stacking location were varied to determine the effects on the electrical, thermal, and mechanical performance of the composites. The direct-current electrical conductivity of the hybrid CNT composites was characterized by in-line and Montgomery four-probe methods. For [0](sub 20) laminates containing a single layer of CNT sheet between each ply of IM7/8552, in-plane electrical conductivity of the hybrid laminate increased significantly, while in-plane thermal conductivity increased only slightly in comparison to the control IM7/8552 laminates. Photo-microscopy and short beam shear (SBS) strength tests were used to characterize the consolidation quality of the fabricated laminates. Hybrid panels fabricated without any pretreatment of the CNT sheets resulted in a SBS strength reduction of 70 percent. Aligning the tubes and pre-infusing the CNT sheets with resin significantly improved the SBS strength of the hybrid composite To determine the cause of this performance reduction, Mode I and Mode II fracture toughness of the CNT sheet to CFRP interface was characterized by double cantilever beam (DCB) and end notch flexure (ENF) testing, respectively. Results are compared to the control IM7/8552 laminate.

Grimsley, Brian W.↗
NASA NTRS1989

Finite element applications to explore the effects of partial bonding on metal matrix composite properties

The mechanics of materials approach (definition of E, G, Nu, and Alpha) and the finite element method are used to explore the effects of partial bonding and fiber fracture on the behavior of high temperature metal matrix composites. Composite ply properties are calculated for various degrees of disbonding to evaluate the sensitivity of these properties to the presence of fiber/matrix disbonding and fiber fracture. The mechanics of materials approach allows for the determination of the basic ply material properties needed for design/analysis of composites. The finite element method provides the necessary structural response (forces and displacements) for the mechanics of materials equations. Results show that disbonding of fractured fibers affect only E sub (111) and alpha sub (111) significantly.

Caruso, J. J.↗