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All sources NASA NTRS DOE OSTI

NASA NTRS1988

Fibre-matrix bond strength studies of glass, ceramic, and metal matrix composites

An indentation test technique for compressively loading the ends of individual fibers to produce debonding has been applied to metal, glass, and glass-ceramic matrix composites; bond strength values at debond initiation are calculated using a finite-element model. Results are correlated with composite longitudinal and interlaminar shear behavior for carbon and Nicalon fiber-reinforced glasses and glass-ceramics including the effects of matrix modifications, processing conditions, and high-temperature oxidation embrittlement. The data indicate that significant bonding to improve off-axis and shear properties can be tolerated before the longitudinal behavior becomes brittle. Residual stress and other mechanical bonding effects are important, but improved analyses and multiaxial interfacial failure criteria are needed to adequately interpret bond strength data in terms of composite performance.

Grande, D. H.↗

NASA NTRS1992

Options for a lunar base surface architecture

The Planet Surface Systems Office at the NASA Johnson Space Center has participated in an analysis of the Space Exploration Initiative architectures described in the Synthesis Group report. This effort involves a Systems Engineering and Integration effort to define point designs for evolving lunar and Mars bases that support substantial science, exploration, and resource production objectives. The analysis addresses systems-level designs; element requirements and conceptual designs; assessments of precursor and technology needs; and overall programmatics and schedules. This paper focuses on the results of the study of the Space Resource Utilization Architecture. This architecture develops the capability to extract useful materials from the indigenous resources of the Moon and Mars. On the Moon, a substantial infrastructure is emplaced which can support a crew of up to twelve. Two major process lines are developed: one produces oxygen, ceramics, and metals; the other produces hydrogen, helium, and other volatiles. The Moon is also used for a simulation of a Mars mission. Significant science capabilities are established in conjunction with resource development. Exploration includes remote global surveys and piloted sorties of local and regional areas. Science accommodations include planetary science, astronomy, and biomedical research. Greenhouses are established to provide a substantial amount of food needs.

Roberts, Barney B.↗

NASA NTRS1994

Controlled thermal expansion printed wiring boards based on liquid crystal polymer dielectrics

Dielectric materials based on innovative Liquid Crystal Polymers (LCP's) have been used to fabricate surface mount printed wiring boards (PWB's) with a coefficient of thermal expansion matched to leadless ceramic chip carriers. Proprietary and patented polymer processing technology has resulted in self reinforcing material with balanced in-plane mechanical properties. In addition, LCP's possess excellent electrical properties, including a low dielectric constant (less than 2.9) and very low moisture absorption (less than 0.02%). LCP-based multilayer boards processed with conventional drilling and plating processes show improved performance over other materials because they eliminate the surface flatness problems of glass or aramid reinforcements. Laser drilling of blind vias in the LCP dielectric provides a very high density for use in direct chip attach and area array packages. The material is ideally suited for MCM-L and PCMCIA applications fabricated with very thin dielectric layers of the liquid crystal polymer.

Knoll, Thomas E.↗

NASA NTRS1994

Synthesis and characterization of advanced materials for Navy applications

The synthesis of ceramics and ceramic coatings through the sol-gel process has extensive application with the United States Navy and a broad range of potential commercial applications as well. This paper surveys seven specific applications for which the Navy is investigating these advanced materials. For each area, the synthetic process is described and the characteristics of the materials are discussed.

Covino, J.↗

NASA NTRS2004

Current Status of Hybrid Bearing Damage Detection

Advances in material development and processing have led to the introduction of ceramic hybrid bearings for many applications. The introduction of silicon nitride hybrid bearings into the high pressure oxidizer turbopump, on the space shuttle main engine, led NASA to solve a highly persistent and troublesome bearing problem. Hybrid bearings consist of ceramic balls and steel races. The majority of hybrid bearings utilize Si3N4 balls. The aerospace industry is currently studying the use of hybrid bearings and naturally the failure modes of these bearings become an issue in light of the limited data available. In today s turbine engines and helicopter transmissions, the health of the bearings is detected by the properties of the debris found in the lubrication line when damage begins to occur. Current oil debris sensor technology relies on the magnetic properties of the debris to detect damage. Since the ceramic rolling elements of hybrid bearings have no metallic properties, a new sensing system must be developed to indicate the system health if ceramic components are to be safely implemented in aerospace applications. The ceramic oil debris sensor must be capable of detecting ceramic and metallic component damage with sufficient reliability and forewarning to prevent a catastrophic failure. The objective of this research is to provide a background summary on what is currently known about hybrid bearing failure modes and to report preliminary results on the detection of silicon nitride debris, in oil, using a commercial particle counter.

Dempsey, Paula J.↗

NASA NTRS2017

Advanced Ceramic Matrix Composites: Science and Technology of Materials, Design, Applications, Performance and Integration

Overview of NASA Transformational Tools and Technologies Project's 2700F CMC/EBC Technology Challenge J. Hurst, NASA (National Aeronautics and Space Administration, Glenn Research Center, Cleveland, OH USA Key Words: ceramic matrix composites (CMCs), SiC/SiC composites, environmental barrier coatings (EBCs), CMC modeling, simulated engine testing As advanced gas turbine engine designs continue to move toward both higher operating temperatures and increased pressures, materials capable of functioning under these extreme conditions are being sought by both government and industry. As part of its mission, the NASA's Transformational Tools and Technologies Project, under the auspices of NASA's Aeronautics Research Mission Directorate, has been pursuing a five year Technology Challenge problem. This challenge problem has sought to develop high temperature materials for turbine engines that enable a 6% reduction in fuel burn for commercial aircraft, compared to current SOA materials. Specifically this is accomplished by the development and demonstration of a ceramic matrix composite (CMC) and environmental barrier coating (EBC) system capable of sustained performance at temperature of 2700F. The NASA Glenn Research Center has continued its two decade long interest in CMC/EBCs technology by pursuing this 2700F performance goal. This ambitious effort included an array of vendors, universities and engine companies. Included in this challenge was fiber development, fiber architecture considerations, ceramic matrix composition, environmental barrier compositions and processing routes as well as test development. Evaluation of the CMC/EBC materials included a variety of testing, from coupon testing for strength and creep resistance, to testing aimed at determining material behavior under more engine-like conditions. The development and validation of thermomechanical models and computational tools for design, analysis, and life prediction, have been an important part of this effort as well. Simulated engine testing of vane subcomponents by P&W was the final step following years of development. In addition to achieving the temperature goals and enhanced durability performance of the Tech Challenge, an additional goal achieved by this work was reaching a Technology Readiness Level of 5 for the 3-D CMC/EBC system. As this five year Technical Challenge comes to a conclusion, future development interests in environmental barrier coatings and environmental modeling are discussed.

SiC/SiC composites↗

NASA NTRSDate not supplied

Design and Assembly Process Implementation for Embedding Passive and Active Components Introduction to IPC-7092

"This presentation describes the design and assembly challenges for implementing passive and active components, in either formed or inserted methodology, into a printed board. The completed structure including internal electronic components is ready for surface mount and/or through-hole component attachment. The multilayered structure becomes a complete product ready for further processing in an assembly process and be made from organic, inorganic (ceramic) or both types of material."

embedded circuitry↗

NASA NTRS2022

Vitrolube NPI-1220 Solid Lubricant Performance After Ultraviolet and Salt Fog Test Exposures

Vitrolube NPI-1220 is a ceramic-bonded solid lubricant produced by National Process Industries, Inc. (NPI) that uses molybdenum disulfide (MoS2) and graphite as lubricating pigments. It is applied to many space flight components, including nickel-alloy and stainless-steel components. Various applications, such as the powered nut and bolt assemblies in the international space station (ISS) (Illi, 1999), the Space Launch System (SLS) sliding bellows, and the SLS ball strut tie-rod assembly (BSTRA) use Vitrolube. No engineering data exists regarding possible Vitrolube degradation after extended exposure to coastal environments encountered by flight hardware on test stands or launch pads. Such environments include ultraviolet (UV) ray, high humidity, and salt exposures. In this study, nickel-alloy disks coated with Vitrolube by NPI, are exposed to controlled UV ray and ‘salt fog’ environments in facilities at Marshall Space Flight Center (MSFC). The exposed disks are run in tribological pin-on-disk tests to quantify any difference in coating lubricity and/or wear compared to coated disks that were not exposed to those environments.

Tribology↗

NASA NTRS2024

Bringing the Heat: Thermal Protection Systems for Low Earth Orbit Transportation and Lunar Exploration

Thermal protection systems (TPS) protect spacecraft from the heating associated with hypersonic flight through a planet’s atmosphere. The materials are subjected to extreme heating and the overall system must be engineered to reliably protect the spacecraft structure during atmospheric entry. The talk will introduce TPS and describe three NASA-led efforts to develop TPS materials and manufacturing processes. The first effort studied thermally stable ceramic aerogels for use in thermal barriers and high temperature seals. A design framework for such materials is proposed, linking the thermal stability performance data with existing material property measurements. The second project, Additive Manufacturing of Thermal Protection Systems (AMTPS), developed an automated, additive approach for ablative heat shield manufacturing. Novel material systems and manufacturing methods were developed to reduce the time required to manufacture ablative TPS heat shields. The third effort tackles a critical challenge of material obsolescence for silica fiber based reusable TPS. The properties and performance of heritage silica fiber are quantified and compared to modern alternatives to support qualification for flight. The talk will also describe other work in TPS conducted by the Thermal Design Branch at NASA JSC and opportunities for students and faculty to get involved with NASA.

Nathaniel Olson↗

DOE OSTI2015

Method for fabrication of ceramic dielectric films on copper foils

The present invention provides a method for fabricating a ceramic film on a copper foil. The method comprises applying a layer of a sol-gel composition onto a copper foil. The sol-gel composition comprises a precursor of a ceramic material suspended in 2-methoxyethanol. The layer of sol-gel is then dried at a temperature up to about 250.degree. C. The dried layer is then pyrolyzed at a temperature in the range of about 300 to about 450.degree. C. to form a ceramic film from the ceramic precursor. The ceramic film is then crystallized at a temperature in the range of about 600 to about 750.degree. C. The drying, pyrolyzing and crystallizing are performed under a flowing stream of an inert gas. In some embodiments an additional layer of the sol-gel composition is applied onto the ceramic film and the drying, pyrolyzing and crystallizing steps are repeated for the additional layer to build up a thicker ceramic layer on the copper foil. The process can be repeated one or more times if desired.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Additive manufacturing of continuous carbon fiber-reinforced SiC ceramic composite with multiple fiber bundles by an extrusion-based technique

Due to the high cost, complex preparation process and difficulty in structural design, the traditional methods for carbon fiber-reinforced SiC ceramic composite preparation have great limitations. This paper presents a technique for the additive manufacturing multiple continuous carbon fiber bundle-reinforced SiC ceramic composite with core-shell structure using an extrusion-based technique. A conventional nozzle system was modified to print simultaneously a water-based SiC paste with continuous carbon fibers. Different levels of binder contents were investigated to optimize the stickiness, viscosity, thixotropy and viscoelasticity of the paste. After sintering, SiC whiskers were generated on the surface of fiber, which is conjectured to be due to the reaction between SiO and carbon fiber at high temperature. The continuous carbon fiber-reinforced SiC ceramic composite exhibited non-brittle fracture. In conclusion, the flexural strength of the additively manufactured Cf/SiC composites improved from 162 MPa with no fiber bundles to a maximum of 219 MPa with three fiber bundles.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Exploration of Particle Size Engineering and Microencapsulation Technologies for Multifunctional Applications

There is a critical need for high performance materials for functional and space-based applications, including tires for exploratory rovers and external structures for landing vehicles. Novel ternary borides, such as iron aluminum boride (Fe2AlB2) and molybdenum aluminum boride (MoAlB), have emerged as potential materials for such application owing to their hardness, mechanical behavior and oxidation resistance. In this poster presentation, we will present different methods of fabricating these particles and engineering them for additive manufacturing and other related manufacturing practices. As an integral component of this study, we will demonstrate technologies to (a) synthesize these particles and (b) microencapsulate these particles with bioplastics like polylactic acid (PLA). The resulting particles will be evaluated for their processability as coatings on hydroxyapatite and Inconel particles using microstructural and flowability studies. It is expected that these particles can be used for 3D printing.

ceramics↗

NASA NTRS2000

Novel Vibration Damping of Ceramic Matrix Composite Turbine Blades Developed for RLV Applications

The Reusable Launch Vehicle (RLV) represents the next generation of space transportation for the U.S. space program. The goal for this vehicle is to lower launch costs by an order of magnitude from $10,000/lb to $1,000/lb. Such a large cost reduction will require a highly efficient operation, which naturally will require highly efficient engines. The RS-2200 Linear Aerospike Engine is being considered as the main powerplant for the RLV. Strong, lightweight, temperature-resistant ceramic matrix composite (CMC) materials such as C/SiC are critical to the development of the RS-2200. Preliminary engine designs subject turbopump components to extremely high frequency dynamic excitation, and ceramic matrix composite materials are typically lightly damped, making them vulnerable to high-cycle fatigue. The combination of low damping and high-frequency excitation creates the need for enhanced damping. Thus, the goal of this project has been to develop well-damped C/SiC turbine components for use in the RLV. Foster-Miller and Boeing Rocketdyne have been using an innovative, low-cost process to develop light, strong, highly damped turbopump components for the RS-2200 under NASA s Small Business Innovation Research (SBIR) program. The NASA Glenn Research Center at Lewis Field is managing this work. The process combines three-dimensionally braided fiber reinforcement with a pre-ceramic polymer. The three-dimensional reinforcement significantly improves the structure over conventional two-dimensional laminates, including high through-the-thickness strength and stiffness. Phase I of the project successfully applied the Foster-Miller pre-ceramic polymer infiltration and pyrolysis (PIP) process to the manufacture of dynamic specimens representative of engine components. An important aspect of the program has been the development of the manufacturing process. Results show that the three-dimensionally braided carbon-fiber reinforcement provides good processability and good mechanical stiffness and strength in comparison to materials produced with competing processes as shown in the graphs.

Min, James B.↗

DOE OSTI2015

First principles-based multiparadigm, multiscale strategy for simulating complex materials processes with applications to amorphous SiC films

Progress has recently been made in developing reactive force fields to describe chemical reactions in systems too large for quantum mechanical (QM) methods. In particular, ReaxFF, a force field with parameters that are obtained solely from fitting QM reaction data, has been used to predict structures and properties of many materials. Important applications require, however, determination of the final structures produced by such complex processes as chemical vapor deposition, atomic layer deposition, and formation of ceramic films by pyrolysis of polymers. This requires the force field to properly describe the formation of other products of the process, in addition to yielding the final structure of the material. We describe a strategy for accomplishing this and present an example of its use for forming amorphous SiC films that have a wide variety of applications. Extensive reactive molecular dynamics (MD) simulations have been carried out to simulate the pyrolysis of hydridopolycarbosilane. The reaction products all agree with the experimental data. After removing the reaction products, the system is cooled down to room temperature at which it produces amorphous SiC film, for which the computed radial distribution function, x-ray diffraction pattern, and the equation of state describing the three main SiC polytypes agree with the data and with the QM calculations. Extensive MD simulations have also been carried out to compute other structural properties, as well the effective diffusivities of light gases in the amorphous SiC film.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2015

Precursor Derived Nanostructured Si-C-X Materials for Nuclear Applications. Final Report, October 2010 - September 2014

Polymer derived ceramic route is an attractive approach to make structural materials with unique nanostructures that have very desirable high temperature properties. Processing techniques to make a variety of needed shapes and forms (e.g. coatings, matrices for fiber reinforced composites, porous ceramics) have been developed. With appropriate high temperature processing, the precursors can be converted to nano-crystalline materials. In this collaborative project, we investigated the processing, stability and properties of nanostructured Si-C materials, derived from polymeric precursors, and their performance under conditions appropriate for nuclear energy applications. All the milestones of the project were accomplished. Some of the results are being currently analyzed and additional papers being prepared in which support from NEUP will be acknowledged. So far, eight peer-reviewed papers have been published and one invention disclosure made. In this report, we summarize the major findings of this project.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Apatite Based Ceramic Waste Forms for Immobilization of Radioactive Iodine, An Overview - 16155

Apatite based ceramic waste forms are the most promising candidates for immobilization of radioactive iodine (I-129). While lead-vanadium based apatites have been studied for a long time, significant progress has been made in recent years in the domain of calcium-phosphate based apatites for iodine immobilization. This article is an attempt to present an overview of the progress that has been made in terms of developing novel synthesis and processing routes to contain iodine in apatite based ceramic waste forms. The challenges associated with current state-of-the art waste form synthesis techniques along with novel routes to synthesize these waste forms at low temperatures have also been discussed. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1995

A High-Average-Power Free Electron Laser for Microfabrication and Surface Applications

CEBAF has developed a comprehensive conceptual design of an industrial user facility based on a kilowatt ultraviolet (UV) (160-1000 mm) and infrared (IR) (2-25 micron) free electron laser (FEL) driven by a recirculating, energy recovering 200 MeV superconducting radio frequency (SRF) accelerator. FEL users, CEBAF's partners in the Lase Processing Consortium, including AT&T, DuPont, IBM, Northrop Grumman, 3M, and Xerox, are developing applications such as metal, ceramic, and electronic material micro-fabrication and polymer and metal surface processing, with the overall effort leading to later scale-up to industrial systems at 50-100 kW. Representative applications are described. The proposed high-average-power FEL overcomes limitations of conventional laser sources in available power, cost-effectiveness, tunability, and pulse structure.

Dylla, H. F.↗

NASA NTRS2001

Formation of Y(x)Nd(1-x) Ba2Cu3O(7-delta) (0 = or < x < or = 0.7) Superconductors from an Undercooled Melt Via Aero-Acoustic Levitation

Melt processing of RE123 superconductors has gained importance in recent years. While the first high temperature superconductors (HTSCs) were made using traditional ceramic press and sinter technology, recent fabrication efforts have employed alternate processing techniques including laser ablation and ion beam assisted deposition for thin film fabrication of tapes and wires and melt growth for bulk materials. To optimize these techniques and identify other potential processing strategies, phase relation studies on HTSCs have been conducted on a wide variety of superconducting compounds using numerous processing strategies. This data has enhanced the understanding of these complex systems and allowed more accurate modeling of phase interactions. All of this research has proved useful in identifying processing capabilities for HTSCs but has failed to achieve a breakthrough for wide spread application of these materials. This study examines the role of full to partial substitution of Nd in the Y123 structure under rapid solidification conditions. Aero-acoustic levitation (AAL) was used to levitate and undercool RE123 in pure oxygen binary alloys with RE = Nd an Y along a range of compositions corresponding to Y(x)Nd(1-x) Ba2Cu3O(7-delta) (0 = or < x < or = 0.7) which were melted by a CO2 laser. Higher Y content spheres could not be melted in the AAL and were excluded from this report. Solidification structures were examined using scanning electron microscopy, electron dispersive spectroscopy, and powder x-ray diffraction to characterize microstructures and identify phases.

Gustafson, D. E.↗