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At least 721 records · Page 40
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Foreign Object Damage in a Yb2Si2O7 Environmental Barrier Coating

Foreign object damage (FOD) is one of the key damage/failure modes in environmental barrier coatings (EBCs) developed for gas turbine engines. A limiting factor of EBC development is the growth of a SiO2 thermally grown oxide (TGO) layer which exacerbates spallation. While there has been extensive research on FOD in metals, ceramics, and ceramic matrix composites (CMCs), there is a limited understanding of the effects of FOD in EBC systems. Previous work studied the effects of TGO growth on FOD in NASA’s Generation II Ytterbium Disilicate EBC. Recently, it has been shown that the addition of oxide modifiers to the Ytterbium Disilicate EBC resulted in significant reduction in TGO growth. The present work will compare FOD in a modified Ytterbium Disilicate EBC to that of the baseline Ytterbium Disilicate EBC. FOD testing was conducted on both as-processed and steam cycled samples at room temperature using a 1.59mm steel ball projectile with particle velocities ranging from 50–300 m/s at a normal incidence angle. The impact damage was characterized by optical profilometry and scanning electron microscopy (SEM) of the cross-sections.

Leland Hoffman↗
NASA NTRS2024

A Phenomenological Durability Model for Environmental Barrier Coating Systems Subjected to Steam Oxidation

Environmental barrier coatings (EBC) are used to protect the silicon carbide fiber reinforced silicon carbide matrix (SiC/SiC) ceramic matrix composites (CMC) from rapid surface recession due to volatization by water vapor in a steam oxidation environment. A phenomenological modeling approach is outlined to estimate the durability of a given EBC system when exposed to steam oxidation. The report provides a step-by-step procedure to estimate the life of a given EBC system subjected to thermal loads only. Once calibrated, the methodology can predict the critical thickness of an oxide layer that will cause failure initiation/spallation as well as the remaining strength or stress that the EBC system can take for a given oxide layer thickness

Subodh K Mital↗
NASA NTRSDate not supplied

High-Temperature Slurry Environmental Barrier Coating With Graded HfO 2 -HfSiO 4 Topcoat

Environmental barrier coatings (EBCs) have enabled the use of silicon carbide (SiC)-based ceramic matrix composites (CMCs) in gas turbine engines by protecting the underlying CMC from corrosive combustion species. Current-generation EBCs consist of a rare earth silicate topcoat and a silicon bond coat. The relatively low melting point of the silicon bond coat (1414°C) limits the upper use temperature of these coatings. To protect SiC-based CMCs at temperatures beyond that achievable by the current state-of-the-art, an oxide-based bond coat capable of withstanding temperatures of up to 1482°C has been developed at NASA Glenn Research Center. Hafnia (HfO2) is a promising EBC topcoat material due to its stability in high-temperature steam; however, its coefficient of thermal expansion (CTE) is highly anisotropic and much larger than that of SiC. In this study, a graded HfO2-HfSiO4 topcoat was deposited via a slurry process on the NASA-developed oxide-based bond coat. The oxidation resistance of this EBC system was evaluated at 1482°C in a steam cycling environment. The durability and stability of this slurry-deposited HfO2-HfSiO4 topcoat was compared to that of HfO2 deposited by plasma spray physical vapor deposition (PS-PVD).

EBC↗
NASA NTRSDate not supplied

Foreign Object Damage in Ytterbium Disilicate Based Environmental Barrier Coatings Modified for Oxidation Resistance

Environmental barrier coatings (EBCs) have been developed as an enabling technology for silicon carbide based ceramic matrix composites (CMCs) in gas turbine engines. Two of the key failure mechanisms identified in EBC systems are foreign object damage (FOD) and the oxidative growth of a SiO 2 thermally grown oxide (TGO) layer that can lead to premature coating spallation. Previously the effects of FOD on NASA’s ytterbium disilicate based EBC were studied and recently it was shown that the addition of oxide modifiers resulted in improved oxidation resistance in the EBC. This work will compare FOD of the baseline ytterbium disilicate EBC to that of the modified EBC. FOD was performed at room temperature using a 1.59 mm hardened steel ball with projectile velocities of 50-300 m/s. Additionally, the effects of oxidation via cyclic steam exposure prior to impact were investigated.

foreign object damage (FOD)↗
NASA NTRS2024

Effects of CMAS Application on the Isothermal and Gradient Thermal Cycling Behavior of a Yb 2 Si 2 O 7 EBC

Environmental barrier coatings (EBCs) are critical to the continued advancement of gas turbine hot section materials technology. EBCs are required to protect Si-based ceramics such as silicon carbide fiber-reinforced silicon carbide (SiC/SiC) ceramic matrix composites (CMCs) from oxidation and corrosion in the combustion environment. One of the current challenges concerning EBC lifetime is the thermochemical reactions between calcium-magnesium-aluminosilicate (CMAS) deposits and the EBC that leads to changes in both composition and stress state. These changes can severely reduce the integrity of the EBC leading to crack formation, delamination, and spallation. Current techniques for evaluating CMAS in the laboratory rely on the pre-application of CMAS. Two commonly used application methods to deposit CMAS on EBC materials are tape-casting and air spray. In both methods, the CMAS is applied to the EBC surface at ambient temperature, and then subject to a heat treatment process for binder burnout. The purpose of this study is to compare the tape-cast and air spray methods on the CMAS corrosion of an ytterbium disilicate (Yb 2 Si 2 O 7 ) EBC subject to isothermal, and gradient thermal cycling. The results highlight if any differences exist in the CMAS infiltration kinetics between the two application methods.

Environmental barrier coatings (EBCs)↗
NASA NTRSDate not supplied

Foreign Object Damage in Yb 2 Si 2 O 7 Environmental Barrier Coatings

Environmental Barrier Coatings (EBCs) have been developed as an enabling technology for silicon carbide based ceramic matrix composites in gas turbine engines. Two of the key failure mechanisms identified in EBC systems are foreign object damage (FOD) and the oxidative growth of a SiO 2 thermally grown oxide (TGO) layer that can lead to premature coating spallation. Previously the effects of FOD on NASA’s second generation Ytterbium Disilicate EBC were studied and recently it was shown that the addition of oxide modifiers resulted in improved oxidation resistance in the EBC. This work will compare FOD of the baseline Ytterbium Disilicate EBC to the that of the modified EBC. FOD was performed at room temperature using a 1.59 mm hardened steel ball with projectile velocities of 50-300 m/s. Additionally, the effects of oxidation via cyclic steam exposure prior to impact were investigated.

environmental barrier coatings (EBCs)↗
NASA NTRS2024

Hybrid Thermally Efficient Core (HyTEC) HyTEC Phase 1 – Advanced Aerodynamics Final Report

The objective of the Hybrid Thermally Efficient Core (HyTEC) – Advanced High Pressure Turbine (HPT) Aerodynamics project is to develop technology for a compact core that contributes to significant fuel burn reductions of 5-10% over current generation technologies. To accomplish this, the HPT is incorporating a range of aerodynamic features and technologies to improve component efficiency and provide favorable systems level trades. In particular, this project explored low solidity airfoils, advanced tip treatments, platform contouring, and advanced ceramic matrix composite (CMC) Stage 2 Nozzle (S2N) airfoils to eliminate the need for post throat cooling in a compact core environment. The maturation of these technology areas is expected to provide a significant improvement in component efficiencies, and consequently reductions in fuel burn, over the current state of the art (SoA). To mature these technologies to Technology Readiness Level (TRL) 4, a test campaign was performed that consisted of four tests at three facilities. TRL 3 testing was performed in the CW22 linear cascade at NASA Glenn for blade and nozzle technologies, TRL 4 nozzle testing was performed at GE Aerospace (GEA) Test Cell A8, and TRL 4 blade testing was performed at the Notre Dame Turbomachinery Laboratory (NDTL) using the Transonic Research Turbine (TRT) rig. Low solidity was successfully demonstrated to a TRL 4 level. Low solidity nozzles showed benefits in line with pre-project expectations, while low solidity blades were shown to have an aerodynamic penalty. Crucially, this program only considered the aerodynamic losses, and systems trades such as reductions in cooling flows are expected to continue to make low solidity blades a net positive. By successfully quantifying the aerodynamic performance in this project, these trades can be conducted to determine where in the engine architecture low solidity blades will contribute positively to system operation. Platform contouring was demonstrated to a TRL 4 level, with performance in line with the lower end of the pre-project expected range. Advanced tip treatments performance levels were indeterminate, showing the expected improvements to flow physics but with a performance level confounded by several rig issues including whirl mode induced variation in tip clearance. The elimination of post-throat cooling on the S2N was successfully demonstrated to provide a performance benefit, however that benefit was approximately half the level that was expected in pre-project predictions. Overall, the technology maturation plan for HyTEC Phase 1 was successful, bringing the suite of technologies to TRL 4.

High pressure turbine↗
NASA NTRSDate not supplied

Advanced Environmental Barrier Coating Testing and Development for Gas Turbine Engines

Environmental barrier coatings (EBCs) are an enabling technology for the use of SiC-based ceramic matrix composites (CMCs) in next generation gas turbine engines. SiC-based CMCs are lightweight and have higher temperature stability than traditional nickel based superalloys. However, SiC is susceptible to rapid oxidation and recession due to high temperature reactions with water vapor and other combustion species. Thus, EBCs were developed to protect these components and extend operating lifetime. In the extreme engine environment, EBCs must be able to withstand a variety of damage mechanisms and the synergies of degradation between them. This presentation will provide an overview of NASA Glenn Research Center, current aeronautics research, and an introduction to EBC failure modes and environmental durability test methods.

Jamesa L Stokes↗
NASA NTRSDate not supplied

Environmental Barrier Coating Surface Temperature Mapping Using a Compatible Er-Doped Sc 2 SiO 5 Temperature-Sensing Layer

Accurate surface temperature-mapping capabilities in the 1300 to 1500 °C range are needed for SiC/SiC ceramic matrix composites protected by environmental barrier coatings (EBCs) under testing in turbine engine environment facilities. The strong background thermal radiation at these higher temperatures is a challenging issue. Er-doped Y 2 SiO 5 was previously shown to be capable of achieving luminescence lifetime-based temperature mapping up to 1560 °C as a standalone material. However, compatibility issues between an Er-doped Y 2 SiO 5 surface temperature sensing layer and an underlying Sc 2 Si 2 O 7 -based EBC topcoat limited temperature mapping of the EBC surface to a maximum of 1380 °C. Therefore, an Er-doped Sc 2 SiO 5 temperature sensing layer has been subsequently developed with better compatibility with the Sc2Si2O7-based EBC topcoat. Localized spot temperature measurements as well as luminescence lifetime imaging-based temperature mapping were demonstrated up to 1535 °C from a 15 µm thick Er-doped Sc 2 SiO 5 layer at the surface of a Sc2Si2O7-based EBC topcoat, a significant improvement over the Er-doped Y2SiO5 layer 1380 °C temperature sensing limit. No degradation of the Er-doped Sc 2 SiO 5 temperature sensing surface layer was observed.

temperature measurement↗
NASA NTRSDate not supplied

SiO2 Activity Measurements in the Gd2O3-SiO2 System Via Knudsen Effusion Mass Spectrometry (KEMS)

Environmental barrier coatings (EBCs) are required for the use of silicon carbide (SiC)-based ceramic matrix composites (CMCs) in gas turbine engines, as they protect the SiO 2 thermally grown oxide (TGO) formed at the CMC/coating interface from volatilization in a combustion environment. Current-generation EBCs consist of a silicon bond coat and a rare earth (RE) silicate topcoat. The RE silicate topcoat is exposed to high-velocity steam during engine operation, and SiO 2 within the coating can preferentially volatilize to form Si(OH) 4 gas species, albeit at a lesser degree than SiO 2 alone. Therefore, it is of interest to investigate the stability of these materials in steam as a function of their RE. In this study, SiO 2 activity, which can be related to the partial pressure of Si(OH) 4 , was measured across the Gd 2 O 3 -SiO 2 phase diagram, which includes Gd 2 SiO 5 , Gd 9.33 (SiO 4 ) 6 O 2 , and Gd 2 Si 2 O 7 as line compounds, via Knudsen Effusion Mass Spectrometry (KEMS). Values obtained for the Gd 2 O 3 -SiO 2 system were compared to those of other RE2O3-SiO2 systems and contextualized in terms of EBC viability.

EBCs↗
NASA NTRSDate not supplied

Dynamic Analysis of Reynolds Number Effects on Trailing Edge Transonic Vortex Shedding and Its Impact on Turbine Blade Aerodynamic Performance

Time-resolved, high-speed self-aligned focusing schlieren images were acquired in the NASA Glenn Research Center Transonic Turbine Blade Cascade facility to help understand the aerodynamic behavior of high-pressure, thick trailing edge turbine blades. The trailing edge thickness of 9% of axial chord tested represents simulated ceramic matrix composite fabrication constraints, which was verified previously to possess a high-loss flow regime at high inlet turbulence conditions over a narrow range of Reynolds numbers and at a fixed design exit Mach number of 0.74. Our high-speed images, which were acquired at 10 distinct Reynolds numbers, show a significant increase in energy from flow oscillations due to transonic vortex shedding at Reynolds numbers corresponding to the high loss conditions. For those conditions, strong acoustic waves turn into shock waves. Spectral Proper Orthogonal Decomposition of the high-speed images shows acoustic waves from trailing edge vortex shedding at all conditions, with increased spectral energy at the high-loss conditions and slightly increasing frequency (about 6%) as a function of Reynolds number. Analysis of potential feedback timing is performed using velocity fields from a previous LES simulation, considering different feedback mechanisms. Most noteworthy is the acoustic/shock-boundary layer interaction mechanism on the suction surface at the blade geometric throat, which likely plays an important role in realistic curved blade passages.

Trailing Edge↗
NASA NTRSDate not supplied

Dynamic Analysis of Reynolds Number Effects on Trailing Edge Transonic Vortex Shedding and Its Impact on Turbine Blade Aerodynamic Performance

In this work, we will discuss observations from images acquired from a time-resolved, high-speed self-aligned focusing Schlieren campaign that was performed at the CW-22 facility at NASA Glenn Research Center to understand the dynamic behavior of thick trailing-edge high-pressure turbine blades simulating a ceramic matrix composite (CMC) construction at high inlet turbulence conditions. For the CMC-9 blade, which has a trailing edge thickness of 9% of the axial chord, we identified a regime where an excessive total pressure loss (loss anomaly) is observed only for a narrow range of Reynolds numbers at a fixed exit Mach number of 0.74. The loss anomaly is qualitatively explained by our images, which were taken at 10 distinct blade Reynolds numbers spanning a factor of 6. The images show a significant increase in energy related to the oscillations due to transonic vortex shedding at the Reynolds numbers related to the high loss conditions. This increased energy leads to the formation of strong acoustic waves that turn into shock waves at the highest loss conditions. From our observations stemming from Spectral POD analysis of the high-speed images, we see the acoustic waves produced by the trailing edge vortex shedding exist in all conditions tested; but the shedding frequency has a very slight trend upwards as the Reynolds number is increased, varying about 6% in the range tested. Considering this variation of shedding frequency as a function of Reynolds number, which is well-established for other bluff-body flows, we stipulate there may be a potential feedback mechanism involving an acoustic information transfer path across neighboring blades that may explain why only a narrow range of Reynolds numbers displays strong, shock-forming vortex shedding. We consider a few feedback paths and examine the timing based on the mean flow field from a high-resolution LES simulation. It appears that all feedback mechanisms are viable, presenting an integer number of delay cycles with respect to disturbances generated at the trailing edge. Most noteworthy, however, is the acoustic/shock-boundary layer interaction mechanism at the blade geometric throat. Based on our analysis, this mechanism likely plays an important role in realistic, curved turbine blade passages.

Aerodynamics↗
NASA NTRS1991

Structural characterization of high temperature composites

Glass, ceramic, and carbon matrix composite materials have emerged in recent years with potential properties and temperature resistance which make them attractive for high temperature applications such as gas turbine engines. At the outset of this study, only flexural tests were available to evaluate brittle matrix composites at temperatures in the 600 to 1000 C range. The results are described of an ongoing effort to develop appropriate tensile, compression, and shear test methods for high temperature use. A tensile test for unidirectional composites was developed and used to evaluate the properties and behavior of ceramic fiber reinforced glass and glass-ceramic matrix composites in air at temperatures up to 1000 C. The results indicate generally efficient fiber reinforcement and tolerance to matrix cracking similar to polymer matrix composites. Limiting properties in these materials may be an inherently very low transverse strain to failure, and high temperature embrittlement due to fiber/matrix interface oxidation.

Mandell, J. F.↗
NASA NTRS1992

X ray attenuation measurements for high-temperature materials characterization and in-situ monitoring of damage accumulation

The scope of this dissertation is to develop and apply x ray attenuation measurement systems that are capable of: (1) characterizing density variations in high-temperature materials, e.g., monolithic ceramics, ceramic and intermetallic matrix composites, and (2) noninvasively monitoring damage accumulation and failure sequences in ceramic matrix composites under room temperature tensile testing. This dissertation results in the development of: (1) a point scan digital radiography system, and (2) an in-situ x ray material testing system. Radiographic evaluation before, during, and after loading shows the effect of preexisting volume flaws on the fracture behavior of composites. Results 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. Further in-situ 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 for greater understanding of ceramic matrix composite mechanical behavior.

Baaklini, George Y.↗
NASA NTRS1988

Interfaces in polymer, ceramic, and metal matrix composites; Proceedings of the Second International Conference on Composite Interfaces (ICCI-II), Cleveland, OH, June 13-17, 1988

The present conference on interfacial factors in advanced composite materials discusses such topics in their development status and properties as silane coupling, the electrochemical and plasma-surface treatment of carbon fibers, fiber surface-analytical techniques, polymer molecular scale characterization by atom-probe field-ion microscopy, the study of carbon fiber-epoxy resin interface interactions by means of labeling techniques, and the surface tailoring of SiC by ion implantation. Also discussed are developments in laser light-scattered photoelasticity, microstructural evolutions under heat treatment and radiation damage, TEM for composites, the interfaces of carbon fiber-reinforced Al composites, the influence of the interface on macroscopic composite properties, and the status of the theoretical understanding of composite interfaces.

Ishida, Hatsuo↗
NASA NTRS1997

The Effect of Gravity on the Combustion Synthesis of Porous Ceramics and Metal Matrix Composites

Combustion synthesis (self propagating, high temperature synthesis-SHS) is a novel technique that is capable of producing many advanced materials. The ignition temperature (Tig) of such combustion synthesis reactions is often coincident with that of the lowest melting point reactant. The resultant liquid metal wets and spreads around the other solid reactant particles of higher melting points, thereby improving the reactant contact and kinetics, followed by formation of the required compounds. This ignition initiates a combustion propagating wave whose narrow reaction front rapidly travels through the reactants. Since this process is highly exothermic, the heat released by combustion often melts the reactant particles ahead of the combustion front and ignites the adjacent reactant layer, resulting in a self-sustaining reaction. Whenever a fluid phase (liquid or gas) is generated by the reaction system, gravity-driven phenomena can occur. Such phenomena include convective flows of fluid by conventional or unstable convection and settling of the higher density phases. A combustion process is often associated with various kinds of fluid flow. For instance, if the SHS reaction is carried out under inert or reactive gas atmospheres, or a volatile, e.g., B2O3, is deliberately introduced as a reactant, convective flows of the gas will occur due to a temperature gradient existing in the atmosphere when a combustion wave is initiated. The increased gas flow will produce a porous (or expanded) SHS product. Owing to the highly exothermic nature of many SHS reactions, liquid phase(s) can also form before, at, or after the combustion front. The huge temperature gradient at the combustion front can induce convective flows (conventional or unstable) of the liquid phase. Each of these types of convective fluid flow can change the combustion behavior of the synthesizing reaction, and, therefore, the resultant product microstructure. In addition, when two or more phases of different density are produced at or ahead of the propagating combustion front settling of the higher density phase will occur resulting in a non-uniform product microstructure and properties.

Moore, J. J.↗
NASA NTRS2016

InSitu SEM Investigation of Microstructural Damage Evolution and Strain Relaxation in a Melt Infiltrated SiC/SiC Composite

With CMC components poised to complete flight certification in turbine engines on commercial aircraft within the near future, there are many efforts within the aerospace community to model the mechanical and environmental degradation of CMCs. Direct observations of damage evolution are needed to support these modeling efforts and provide quantitative measures of damage parameters used in the various models. This study was performed to characterize the damage evolution during tensile loading of a melt infiltrated (MI) silicon carbide reinforced silicon carbide (SiC/SiC) composite. A SiC/SiC tensile coupon was loaded to a maximum global stress of 30 ksi in a tensile fixture within an SEM while observations were made at 5 ksi increments. Both traditional image analysis and DIC (digital image correlation) were used to quantify damage evolution. With the DIC analysis, microscale damage was observed at the fiber-matrix interfaces at stresses as low as 5 ksi. First matrix cracking took place between 20 and 25 ksi, accompanied by an observable relaxation in strain near matrix cracks. Matrix crack opening measurements at the maximum load ranged from 200 nm to 1.5 m. Crack opening along the fiber-matrix interface was also characterized as a function of load and angular position relative to the loading axis. This characterization was funded by NASA GRC and was performed to support NASA GRC modeling of SiC/SiC environmental degradation

testing↗
NASA NTRS2014

Processing and Characterization of Basalt Fiber Reinforced Ceramic Composites for High Temperature Applications Using Polymer Precursors

The development of high temperature structural composite materials has been very limited due to the high cost of the materials and the processing needed. Ceramics can take much higher temperatures, but they are difficult to produce and form in bulk volumes. Polymer Derived Ceramics (PDCs) begin as a polymer matrix, allowing a shape to be formed and cured and then to be pyrolized in order to obtain a ceramic with the associated thermal and mechanical properties. The two PDCs used in this development are polysiloxane and polycarbosilane. Polysiloxanes contain a silicon oxycarbide backbone when pyrolized up to 1000C. Polycarbosilane, an organosilicon polymer, contain a silicon-carbon backbone; around 1200C, beta-SiC begins to crystallize. The use of basalt in structural and high temperature applications has been under development for over 50 years, yet there has been little published research on the incorporation of basalt fibers as a reinforcement in composites. Basalt is a naturally occurring material found in volcanic rock. Continuous basalt fiber reinforced PDCs have been fabricated and tested for the applicability of this composite system as a high temperature structural composite material. Thermal and mechanical testing includes oxyacetylene torch testing and three point bend testing.

Ceramic Matrix Composites↗