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NASA NTRS2004

Advanced Ceramic Matrix Composites with Multifunctional and Hybrid Structures

Ceramic matrix composites are leading candidate materials for a number of applications in aeronautics, space, energy, and nuclear industries. Potential composite applications differ in their requirements for thickness. For example, many space applications such as "nozzle ramps" or "heat exchangers" require very thin (< 1 mm) structures whereas turbine blades would require very thick parts (> or = 1 cm). Little is known about the effect of thickness on stress-strain behavior or the elevated temperature tensile properties controlled by oxidation diffusion. In this study, composites consisting of woven Hi-Nicalon (trademark) fibers a carbon interphase and CVI SiC matrix were fabricated with different numbers of plies and thicknesses. The effect of thickness on matrix crack formation, matrix crack growth and diffusion kinetics will be discussed. In another approach, hybrid fiber-lay up concepts have been utilized to "alloy" desirable properties of different fiber types for mechanical properties, thermal stress management, and oxidation resistance. Such an approach has potential for the C(sub I)-SiC and SiC(sub f)-SiC composite systems. CVI SiC matrix composites with different stacking sequences of woven C fiber (T300) layers and woven SiC fiber (Hi-Nicalon (trademark)) layers were fabricated. The results will be compared to standard C fiber reinforced CVI SiC matrix and Hi-Nicalon reinforced CVI SiC matrix composites. In addition, shear properties of these composites at different temperatures will also be presented. Other design and implementation issues will be discussed along with advantages and benefits of using these materials for various components in high temperature applications.

Singh, Mrityunjay↗

NASA NTRS2002

The Influence of Interfacial Roughness on Fiber Sliding in Oxide Composites with La-Monazite Interphases

Room temperature debonding and sliding of La-Monazite coated fibers is assessed using a composite with a polycrystalline alumina matrix and fibers of several different single crystal (mullite, sapphire) and directionally solidified eutectic (Al2O3/Y3Al5O12 and Al2O3/Y-ZrO2) compositions. These fibers provide a range of residual stresses and interfacial roughnesses. Sliding occurred over a debond crack at the fiber-coating interface when the sliding displacement and surface roughness were relatively small. At large sliding displacements with relatively rough interfaces, the monazite coatings were deformed extensively by fracture, dislocations and occasional twinning, whereas the fibers were undamaged. Dense, fine-grained (10 nm) microstructures suggestive of dynamic recrystallization were also observed in the coatings. Frictional heating during sliding is assessed. The possibility of low temperature recrystallization is discussed in the light of the known resistance of monazite to radiation damage. The ability of La-Monazite to undergo plastic deformation relatively easily at low temperatures may be enabling for its use as a composite interface.

Davis, J. B.↗

NASA NTRS1982

HOST instrumentation R and D program overview

The turbine hot-section technology (HOST) Instrumentation R&D program focuses on two main classes of instrumentation: (1) those that characterizes the environment around the turbine engine components, which include gas flows measurement, gas temperatures, and heat fluxes; (2) to characterize the effect of the environment on the turbine engine components, which include strain measurements and an optical system to structural responses such as cracking, buckling, spalling, carbon buildup. The HOST Instrumentation R&D program concentrates on the critical measurements that can not be made by commercially available instruments or with instruments that are already in development. The measurements of strain and gas flow are emphasized, these measurements are extremely critical to the success of the HOST program and the HOST requirements differ from the current state of the art by a considerable margin.

Wenger, N. C.↗

NASA NTRS1988

A constitutive model with damage for high temperature superalloys

A unified constitutive model is searched for that is applicable for high temperature superalloys used in modern gas turbines. Two unified inelastic state variable constitutive models were evaluated for use with the damage parameter proposed by Kachanov. The first is a model (Bodner, Partom) in which hardening is modeled through the use of a single state variable that is similar to drag stress. The other (Ramaswamy) employs both a drag stress and back stress. The extension was successful for predicting the tensile, creep, fatigue, torsional and nonproportional response of Rene' 80 at several temperatures. In both formulations, a cumulative damage parameter is introduced to model the changes in material properties due to the formation of microcracks and microvoids that ultimately produce a macroscopic crack. A back stress/drag stress/damage model was evaluated for Rene' 95 at 1200 F and is shown to predict the tensile, creep, and cyclic loading responses reasonably well.

Sherwood, J. A.↗

NASA NTRS1957

Influence of Crucible Materials on High-temperature Properties of Vacuum-melted Nickel-chromium-cobalt Alloy

A study of the effect of induction-vacuum-melting procedure on the high-temperature properties of a titanium-and-aluminum-hardened nickel-base alloy revealed that a major variable was the type of ceramic used as a crucible. Reactions between the melt and magnesia or zirconia crucibles apparently increased high-temperature properties by introducing small amounts of boron or zirconium into the melts. Heats melted in alumina crucibles had relatively low rupture life and ductility at 1,600 F and cracked during hot-working as a result of deriving no boron or zirconium from the crucible.

MATERIALS, PROPERTIES - STRESS-RUPTURE↗

NASA NTRS2001

Approaches to Design and Evaluation of Sandwich Composites

This report describes research during the period June 15, 1997 to October 31, 2000. This grant yielded a low cast manufacturing of composite sandwich structures technology and characterization interfacial and subinterfacial cracks in foam core sandwich panels. The manufacturing technology is called the vacuum assisted resin transfer (VARTM). The VARTM is suitable for processing composite materials both at ambient and elevated temperatures and of unlimited component size. This technology has been successfully transferred to a small business fiber preform manufacturing company 3TEX located in Cary, North Carolina. The grant also supported one Ph.D, one M.S and a number of under graduate students, and nine publications and Presentations.

Shivakumar, Kunigal↗

NASA NTRS2017

Tutorial on Atomic Oxygen Effects and Contamination

Atomic oxygen is the most predominant specie in low Earth orbit (LEO) and is contained in the upper atmosphere of many other planetary bodies. Formed by photo-dissociation of molecular oxygen, it is highly reactive and energetic enough to break chemical bonds on the surface of many materials and react with them to form either stable or volatile oxides. The extent of the damage for spacecraft depends a lot on how much atomic oxygen arrives at the surface, the energy of the atoms, and the reactivity of the material that is exposed to it. Oxide formation can result in shrinkage, cracking, or erosion which can also result in changes in optical, thermal, or mechanical properties of the materials exposed. The extent of the reaction can be affected by mechanical loading, temperature, and other environmental components such as ultraviolet radiation or charged particles. Atomic oxygen generally causes a surface reaction, but it can scatter under coatings and into crevices causing oxidation much farther into a spacecraft surface or structure than would be expected. Contamination can also affect system performance. Contamination is generally caused by arrival of volatile species that condense on spacecraft surfaces. The volatiles are typically a result of outgassing of materials that are on the spacecraft. Once the volatiles are condensed on a surface, they can then be fixed on the surface by ultraviolet radiation andor atomic oxygen reaction to form stable surface contaminants that can change optical and thermal properties of materials in power systems, thermal systems, and sensors. This tutorial discusses atomic oxygen erosion and contaminate formation, and the effect they have on typical spacecraft materials. Scattering of atomic oxygen, some effects of combined environments and examples of effects of atomic oxygen and contamination on spacecraft systems and components will also be presented.

Earth orbital environments↗

NASA NTRS2018

Atomic Oxygen Environments, Effects, and Mitigation

Oxygen atoms↗

NASA NTRS2013

Ceramic Adhesive and Methods for On-Orbit Repair of Re-Entry Vehicles

This adhesive is capable of repairing damaged leading edge components of reentry vehicles while in space, and is novel with regard to its ability to be applied in the vacuum of space, and in a microgravity environment. Once applied, the adhesive provides thermal and oxidation protection to the substrate (in this case, reinforced carbon/carbon composites, RCCs) during re-entry of a space vehicle. Although there may be many formulations for repair adhesives, at the time of this reporting, this is the first known adhesive capable of an on-orbit repair. The adhesive is an engineered ceramic material composed of a pre-ceramic polymer and refractory powders in the form of a paste or putty that can be applied to a scratched, cracked, or fractured composite surface, covering and protecting the damaged area. The adhesive is then "cured" with a heat cycle, thereby cross-linking the polymer into a hardened material and bonding it to the substrate. During the heat of reentry, the material is converted to a ceramic coating that provides thermal and oxidative stability to the repaired area, thus allowing the vehicle to pass safely from space into the upper atmosphere. Ceramic powders such as SiC, ZrB2 and Y2O3 are combined with allylhydridopolycarbosilane (AHPCS) resin, and are mixed to form a paste adhesive. The material is then applied to the damaged area by brush, spatula, trowel, or other means to fill cracks, gaps, and holes, or used to bond patches onto the damaged area. The material is then cured, in a vacuum, preferably at 250F (approximately equal to 121C) for two hours. The re-entry heating of the vehicle at temperatures in excess of 3,000F (approximately equal to 1,650C) then converts this material into a ceramic coating. This invention has demonstrated advantages in resistance to high temperatures, as was demonstrated in more than 100 arc-jet tests in representative environments at NASA. Extensive testing verified oxidation protection for the repaired substrate (RCC), and confirmed that the microstructure of the resulting repair leads to durability and resistance to melting or flow. Its processability and working life in a vacuum was demonstrated by NASA astronauts in glovebox processing studies, as well as on-orbit in the open space shuttle bay. All of these advantages increase the working life of NASA vehicles, as well as improve safety for any crew on a manned vehicle. The adhesive, trademarked NOAX(TM). or Non-Oxide Adhesive Experimental, flew on all space shuttle missions from Return To Flight (STS-114) until the final flight (STS- 135) as a crack repair material for the leading edges and nose cap of the vehicle. NOAX(TM) was patented under U.S. Patents 7,628,878 and 7,888,277.

Riedell, James A.↗

NASA NTRS1966

X-ray analysis of fatigue damage in copper

A Warren-Averbach x-ray line profile analysis was applied to, broadened x-ray diffraction peaks from copper deformed in fatigue. The copper specimens were fatigued by four point bending at various strain amplitudes, and measurements were made at various fractions of the total fatigue life. The analysis results in an estimation of 1) an average coherently diffracting domain size in a direction normal to the diffracting planes; and 2) a strain distribution function. The strain distribution function is in terms of the root mean square strain, <ϵ^(2)> where ϵ is averaged over a given distance at all points in the diffracting crystals. This rms strain is expressed as a function of averaging distance for a direction normal to the diffracting planes. The rms strains were found to be a function of the fatigue strain amplitude level, increasing with amplitude and reaching a maximum limiting value during the first 2% of the fatigue life. The strains were normally larger in the 4lO0 direction compared to the <111> direction and the absolute values were quite small. These results may be explained by assuming the dislocations are present in the form of dipoles because the lattice strain around a dipole is much less than around single dislocations. Conclusions arrived at in this analysis are in agreement with current theories of fatigue damage in metals. The result that maximum hardening is achieved during the initial few percent of the fatigue life is confirmed by many other investigators using entirely different analytical techniques. It is felt that the structure of the material is changing during this initial hardening stage to an eventual steady state characteristic of the testing conditions. A unique substructure is developed which thereafter persists, and the remainder of the fatigue test is taken up by crack propagation through this substructure until ultimate failure occurs by fracture. The formation of this steady state structure is dependent on the maximum fatigue strain amplitude and on the frequency and temperature of cycling for a particular material.

COPPER↗

NASA NTRS1978

Residual stresses in angleplied laminates and their effects on laminate behavior

Evidence of the presence of lamination residual stresses in angleplied laminates were transply cracks and warpage of unsymmetric laminates which occur prior to application of any mechanical load. Lamination residual strains were measured using the embedded strain gage technique. These strains result from the temperature differences between cure and room temperature and vary linearly within this temperature range. Lamination residual stresses were usually present in angleplied fiber composites laminates; they were also present in unidirectional hybrids and superhybrids. For specific applications, the magnitudes of lamination residual stresses were determined and evaluated relative to the anticipated applied stresses. Particular attention was given to cyclic thermal loadings in applications where the thermal cycling takes place over a wide temperature range.

Chamis, C. C.↗

NASA NTRS1981

Thermal expansion accommodation in a jet engine frame

Design advancements to enhance stress accommodation in gas turbine engine frames are described. Consideration is given to mechanical stiffness to maintain an adequate spring rate, and to thermal stresses in both ambient and transient modes. Noting that thermal stresses occur due to differing temperatures at different parts of the frame, the matching of the thermal expansion rates of different structural materials is emphasized. Adequate stiffness is necessary to avoid dynamic reactions leading to case cracking as a result of normal imbalances of moving parts. Stress and deflection analysis of a total frame concept using a three-dimensional finite element stress analysis computer program, with modelling of all frame components, is presented, and illustrations are provided.

Schneider, M. H.↗

NASA NTRS1984

Computer simulation of fracture using long range pair potentials

The behavior of a crack in iron is studied using computer simulation. A Morse interatomic potential is used which is of a longer ranged nature than the potentials used in previous studies. With this potential, blunting of the crack tip by spontaneous dislocation nucleation occurs under most conditions. The presence of hydrogen appears to inhibit this blunting and thus to encourage brittle fracture. In the absence of hydrogen, a temperature dependent brittle-ductile transition is observed for some loads. This behavior is quite different from that observed when shorter ranged potentials are used, and it appears to be in somewhat better agreement with experimental results. This agreement with experiment is not conclusive, however, indicating the need for further work to determine more accurate potentials.

Mullins, M.↗

NASA NTRS1993

The effects of long-duration space exposure on the mechanical properties of some carbon-reinforced resin matrix composites

Long Duration Exposure Facility (LDEF) Experiment A0175 involved the non-instrumented exposure of seven carbon-fiber reinforced resin-matrix advanced composite panels contained in two trays - A7 and A1. These two trays were located, respectively, on the leading and trailing faces of LDEF, obliquely oriented to the RAM (Row 9) and WAKE (Row 3) directions. The identity and location of the seven panels, which consisted of six flat laminates of the following material systems are shown: carbon/epoxy (T300/934), carbon/bismaleimide (T300/F178), and carbon/polyimide (C6000/LARC-160 and C6000/PMR-15), plus one bonded honeycomb sandwich panel (T300/934 face sheets and Nomex core) patterned after the Space Shuttle payload bay door construction. These material systems were selected to represent a range of then-available matrix resins which, by virtue of their differing polymer chemistry, could conceivably exhibit differing susceptibility to the low-earth orbit (LEO) environment. The principal exposure conditions of the LDEF environment at these tray locations are shown. Noteworthy to some of the observations discussed is the four-orders-of magnitude difference in the atomic oxygen (AO) fluence, which made a shallow incidence angle (approximately 22 deg) to Tray A7, while Tray A1 on the trailing face was essentially shielded from AO exposure. This evaluation focused on determining the individual and relative suitability of a variety of resin-matrix composite systems for long-term space structural applications. This was accomplished primarily by measuring and comparing a range of engineering mechanical properties on over 300 test coupons sectioned from the flight panels and from identical control panels, and tested at ambient and elevated temperatures. This testing was supported by limited physical characterization, involving visual examination of flight panel surface features, measurements of weight loss and warpage, and examination for changes in internal integrity (micro cracking, delamination) by ultrasonic c-scan and polished cross-sections.

Vyhnal, Richard F.↗

NASA NTRS1992

Low-temperature formation of magnetic iron oxides

Elemental analysis and magnetic measurements of the surface of Mars have indicated the presence of an iron oxide with a considerable magnetic moment. Identification of the oxide phase(s) is an important subject as this may be used to identify the process of weathering on the martian surface as well as the composition of the Mars regolith itself. Consequently, interest was in evidence of new formation of strongly magnetic phases (e.g., magnetite, maghemite, feroxyhyte) in terrestrially derived Mars sample analogs. Within the group of Mars sample analogs derived from low-temperature weathering of basalts in Arctic regions, evidence of magnetic oxides formed at the outermost weathering rind was never observed. However, in one instance where the weathering products accumulating in a crack of a basaltic stone were investigated, evidence of magnetite was found. The experimental details are presented.

Koch, Chr. Bender↗

NASA NTRS1994

Thermal Shock Behavior of Silicon Nitride Flexure Beam Specimens with Indentation Cracks

The experimental results of thermal shock testing of silicon nitride flexure beam specimens containing indentation cracks are presented. The thermal stress induced by water quenching is much greater in the transverse direction than in the longitudinal direction, resulting in an insensitivity of residual bend strength to temperature differences up to 580 C. This result indicates that a flexure beam configuration is not an appropriate geometry for thermal shock testing when thermal shock behavior is to be evaluated from residual bend strength data.

Choi, Sung R.↗

NASA NTRS1997

Determination of Residual Stress in Composite Materials Using Ultrasonic Waves

The performance of high temperature composites can be significantly affected by the presence of residual stresses. These stresses arise during cooling processes from fabrication to room temperature due to mismatch of thermal expansion coefficients between matrix and fiber materials. This effect is especially pronounced in metal matrix and intermetallic composites. It can lead to plastic deformations, matrix cracking and fiber/matrix interface debonding. In this work the feasibility of ultrasonic techniques for residual stress assessment in composites is addressed. A novel technique for absolute stress determination in orthotropic materials from angular dependencies of ultrasonic velocities is described. The technique is applicable for determination of both applied and residual stresses and does not require calibration measurements on a reference sample. The important advantage of this method is that stress is determined simultaneously with stress-dependent elastic constants and is thus decoupled from the material texture. It is demonstrated that when the principal plane stress directions coincide with acoustical axes, the angular velocity data in the plane perpendicular to the stress plane may be used to determine both stress components. When the stress is off the acoustical axes, the shear and the difference of the normal stress components may be determined from the angular dependence of group velocities in the plane of stresses. Synthetic sets of experimental data corresponding to materials with different anisotropy and stress levels are used to check the applicability of the technique. The method is also verified experimentally. A high precision ultrasonic wave transmission technique is developed to measure angular dependence of ultrasonic velocities. Examples of stress determination from experimental velocity data are given. A method is presented for determination of velocities of ultrasonic waves propagating through the composite material with residual stresses. It is based on the generalized self-consistent multiple scattering model. Calculation results for longitudinal and shear ultrasonic wave velocities propagating perpendicular to the fibers direction in SCS-6/Ti composite with and without residual stresses are presented. They show that velocity changes due to presence of stresses are of order 1%.

Rokhlin, S. I.↗

NASA NTRS2000

Ultrasonic Assessment of Impact-Induced Damage and Microcracking in Polymer Matrix Composites

The main objective of this NASA FAR project is to conduct ultrasonic assessment of impact-induced damage and microcracking in polymer matrix composites at various temperatures. It is believed that the proposed study of impact damage assessment on polymer matrix composites will benefit several NASA's missions and current interests, such as ballistic impact testing of composite fan containment and high strain rate deformation modeling of polymer matrix composites. Currently, impact-induced delamination and fracture in 6061-T6 aluminum/cast acrylic sandwich plates adhered by epoxy were generated in an instrumented drop-weight impact machine. Although only a small dent was produced on the aluminum side when a hemispherical penetrator tup was dropped onto it from a couple of inches, a large ring of delamination at the interface was observed. The delamination damage was often accompanied by severe shattering in the acrylic substratum. Damage patterns in the acrylic layer include radial and ring cracks and, together with delamination at the interface, may cause peeling-off of acrylic material from the sandwich plate. Theory of stress-wave propagation can be used to explain these damage patterns. The impact tests were conducted at various temperatures. The results also show clearly that temperature effect is very important in impact damage. For pure cast acrylic nil-ductile transition (NDT) occurs between 185-195 F Excessive impact energy was dissipated into fracture energy when tested at temperature below this range or through plastic deformation when tested at temperature above the NDT temperature. Results from this study will be used as baseline data for studying fiber-metal laminates, such as GLARE and ARALL for advanced aeronautical and astronautical applications.

Liaw, Benjamin↗