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Epoxy-matrix composites with improved fracture toughnesses, tensile strengths, and impact resistances are fabricated by using perforated film to break part of bond between laminae. Separation diffuses local stress concentrations near cracks, inhibiting their ability to propagate. Tests on modified panels showed fifty percent increase in fracture strengths.
In brittle matrix composites, crack propagation occurs along random trajectories reflecting the heterogeneous nature of the strength field. Considering the crack trajectory as a diffusive process, the 'crack diffusion coefficient' is introduced. From fatigue crack propagation experiments on a set of identical SEN polyester composite specimens, the variance of the crack tip position along the loading axis is found to be a linear function of the effective 'time'. The latter is taken as the effective crack length. The coefficient of proportionality between variance of the crack trajectory and the effective crack length defines the crack diffusion coefficient D which is found in the present study to be 0.165 mm. This parameter reflects the ability of the composite to deviate the crack from the energetically most efficient path and thus links fracture toughness to the microstructure.
Metal-matrix composites have been prepared by pressure-infiltration casting of copper-base alloy melts into microporous carbon preforms. The carbon preforms contained varying proportions of amorphous carbon and graphite. Load dependence of the wear and friction behavior of the composite pins has been examined under ambient conditions against cast-iron plates, using a pin-on-plate reciprocating wear tester. The wear resistance of the composite is significantly improved, as compared with the base alloy. Contrary to the normally expected behavior, the addition of graphite to the amorphous carbon does not reduce the friction coefficient, especially at high loads. The wear and friction behavior of the composites is very sensitive to the size and distribution of the microstructural constituents.
Structural Ceramic Matrix Composites (CMC) have the potential for application in the hot sections of a variety of advanced propulsion and power systems. It is therefore necessary to have a general understanding of the key properties of CMC and Reinforcing Fibers. This need is complicated by the wide variety of application conditions and structural requirements for which CMC's will be used, and the proprietary concerns of the design engineers. CMC's, to be successful, must display properties which are competitive with the currently used high temperature structural materials: (i.e., Iron and Nickel based superalloys, tough monolithic ceramics, and carbon/carbon composites.) Structural CMC offers several areas of competition: (1) performance, (i.e., strength and strength retention, creep resistance, and thermal conductivity), (2) reliability (i.e., environmental durability, and damage tolerance) and (3) processing (i.e., capability for varying sizes and shapes, and cost effective fabrication). The presentation further discusses, and illustrates with fiber and CMC data the key fiber properties and processes which strongly affect each CMC area of competition. The presentation further discusses the current knowledge of the important factors which control the key fiber properties. A design guidelines for the optimum fiber characteristics is developed, and the currently available fibers are compared against those guidelines.
The objective of the Advanced High Temperature Engine Materials Technology Program (HITEMP) at the NASA Lewis Research Center is to generate technology for advanced materials and structural analysis that will increase fuel economy, improve reliability, extend life, and reduce operating costs for 21st century civil propulsion systems. The primary focus is on fan and compressor materials (polymer-matrix composites - PMC's), compressor and turbine materials (superalloys, and metal-matrix and intermetallic-matrix composites - MMC's and IMC's), and turbine materials (ceramic-matrix composites - CMC's). These advanced materials are being developed in-house by Lewis researchers and on grants and contracts.
First matrix cracking stress is a critical parameter for application of Sic fiber reinforced composites in highly stressed, environmentally demanding applications such as turbine blades. High matrix fracture toughness is a key property that contributes to high composite fracture stress. Silicon nitride offers reduced matrix elastic modulus, lower coefficient of thermal expansion, and potentially high fracture toughness compared to Sic matrices. All of these factors can be used to advantage to increase matrix fracture stress. As a first model system we are pursuing toughened silicon nitride matrix composites reinforced with SCS-9 fibers. Fabrication is by tape casting the matrix plies and tape lay-up with fiber plies followed by hot pressing at 1800 C. Progress toward this end will be reported.
SiC-fiber-reinforced SiC-matrix composites are considered future materials for high temperature (less than 1200 C), air-breathing applications. For these materials to be successful, they must be able to maintain desirable mechanical properties at high temperatures while existing in highly corrosive environments. The critical constituent of a ceramic matrix composite is a thin interphase layer between the fiber and matrix which enables matrix cracks to deflect around the fibers, that is, to perform even when damaged. Unfortunately, the only interphase materials (to date) that offer the desired properties are carbon and boron nitride. Both of these materials react with oxidizing environments to form gaseous or liquid oxidation products that can lead to fiber-strength degradation or strong bonding between the fiber and the matrix at temperatures above approx. 600 C.
The characterization of selected graphite fiber reinforced epoxy (934 and 5208) and polysulfone (P1700) matrix resin composite materials which received 5 years and 10 months of exposure to the LEO environment on the Long Duration Exposure Facility is reported. Resin loss and a decrease in mechanical performance as well as dramatic visual effects were observed. However, chemical characterization including infrared, thermal, and selected solution property measurements showed that the molecular structure of the polymeric matrix had not changed significantly in response to this exposure. The potential effect of a silicon-containing molecular contamination of these specimens is addressed.
The characterization of selected graphite fiber reinforced epoxy (934 and 5208) and polysulfone (P1700) matrix resin composites materials which received over five years and nine months of exposure to the low earth orbit (LEO) environment in experiment AO134 on the Long Duration Exposure Facility is reported. The changes in mechanical properties of ultimate tensile strength and tensile modulus for exposed flight specimens are compared to the three sets of control specimens. Marked changes in surface appearance are discussed, and resin loss is reported. The chemical characterization including infrared, thermal, and selected solution property measurements showed that the molecular structure of the polymetric matrix had not changed significantly in response to this exposure.
This past year has been one of great accomplishment for the propulsion element of NASA's High Speed Research (HSR) Program. The HSR Program is a NASA/industry partnership to develop the high-risk/high-payoff airframe and propulsion technologies applicable to a second-generation supersonic commercial transport, or High Speed Civil Transport (HSCT). The propulsion element, which also involves industry partners, is managed by the NASA Lewis Research Center. These technologies will contribute greatly to U.S. industry's ability to make an informed product launch decision for an HSCT vehicle. Specific NASA Lewis accomplishments in 1997 include: 1. Small-scale combustor sector tests conducted in Lewis' Engine Research Building contributed to the evolution of approaches to developing a combustor with ultralow NOx emissions. 2. Components were tested in Lewis' CE-9 facility (in Lewis' Engine Research Building) to assess the performance of candidate ceramic matrix composite (CMC) materials in this realistic combustion environment. Test results were promising, and acceptable levels of structural durability were demonstrated for the ceramic matrix composite material tested. Ceramic matrix composites continue to show great promise for use in HSCT combustor liners. 3. Engine emissions tests in Lewis' Propulsion Systems Laboratory provided insight into other classes of emissions (e.g., particulates and aerosols) which will be important to control in HSCT propulsion system designs. 4. Small-scale nozzle tests conducted in Lewis' Aero-Acoustic Propulsion Laboratory are contributing to the design of a low-noise, high-performance mixer/ejector nozzle configuration for HSCT engines. Over 18,000 hours of durability testing were completed in Lewis' materials laboratories to evaluate superalloy and g-titanium aluminide performance for HSCT nozzle applications. A two-dimensional supersonic inlet concept was tested in Lewis' 10- by 10-Foot Supersonic Wind Tunnel. The extensive database and the knowledge gained contributed to the selection of a two-dimensional inlet as the preferred inlet concept for the HSR Program.
Traditional metals like steel and copper alloys have been used for many years to fabricate injector and chamber components of thruster assemblies. While the materials perform well, reducing engine weights would help existing and future vehicles gain performance and payload capability. It may now be possible to reduce current thruster weights up to 50% by applying composite materials. In this task, these materials are being applied to an existing thrust cell design to demonstrate new fabrication processes and potential weight savings. Two ceramic matrix composite (CMC) designs, three polymer matrix composite (PMC) designs, and two metal matrix composite (MMC) designs are being fabricated as small chamber demonstration units. In addition, a new alloy of copper, chrome, and niobium (Cu-8Cr-4Nb) is being investigated for thrust chamber liners since it offers higher strength and increased cycle life over traditional alloys. This new alloy is being used for the liner in each MMC and PMC demonstration unit. During June-August of 2000, hot-fire testing of each unit is planned to validate designs in an oxygen/hydrogen environment at chamber pressures around 850 psi. Although the weight savings using CMC materials is expected to be high, they have proven to be much harder to incorporate into chamber designs based on current fabrication efforts. However, the PMC & MMC concepts using the Cu-8Cr-4Nb liner are nearly complete and ready for testing. Additional efforts intend to use the PMC & MMC materials to fabricate a full size thrust chamber (60K lb(sub f) thrust class). The fabrication of this full size unit is expected to be complete by October 2000, followed by hot-fire testing in November-December 2000.
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.
An apparatus for producing a hybrid boron reinforced polymer matrix composite from precursor tape and a linear array of boron fibers. The boron fibers are applied onto the precursor tapes and the precursor tape processed within a processing component having an impregnation bar assembly. After passing through variable-dimension forming nip-rollers, the precursor tape with the boron fibers becomes a hybrid boron reinforced polymer matrix composite. A driving mechanism is used to pulled the precursor tape through the method and a take-up spool is used to collect the formed hybrid boron reinforced polymer matrix composite.
Ultrasonic velocity and time-of-flight (TOF) imaging that uses back surface reflections to gage volumetric material quality is highly suited for quantitative characterization of microstructural gradients including those due to pore fraction, density, fiber fraction, and chemical composition variations. However, a weakness of conventional pulse echo ultrasonic velocity and TOF imaging is that the image shows the effects of thickness as well as microstructural variations, unless the part is uniformly thick. This limits this imaging method's usefulness in practical applications. Prior studies have described a pulse echo TOF based ultrasonic imaging method that requires using a single transducer in combination with a reflector plate placed behind samples which, eliminates the effect of thickness variation in the image. In those studies, this method was successful at isolating ultrasonic variations due to material in plate like samples of silicon nitride, metal matrix composite, and polymer matrix composite. In this study, the method is engineered for inspection of more complex shaped structures- those having (hollow) tubular or curved geometry. The experimental inspection technique and results are described as applied to a polymer matrix composite "proof of concept" tube that contains machined patches of various depths and an as manufactured monolithic silicon nitride ceramic tube that might be used in "real world" applications.
The invention is an apparatus and method for producing a hybrid boron reinforced polymer matrix composition from powder pre-impregnated fiber tow bundles and a linear array of boron fibers. The boron fibers are applied onto the powder pre-impregnated fiber tow bundles and then are processed within a processing component having an impregnation bar assembly. After passing through variable-dimension forming nip-rollers, the powder pre-impregnated fiber tow bundles with the boron fibers become a hybrid boron reinforced polymer matrix composite tape. A driving mechanism pulls the powder pre-impregnated fiber tow bundles with boron fibers through the processing line of the apparatus and a take-up spool collects the formed hybrid boron-fiber reinforced polymer matrix composite tape.
A family of aerogel-matrix composite materials having thermal-stability and mechanical- integrity properties better than those of neat aerogels has been developed. Aerogels are known to be excellent thermal- and acoustic-insulation materials because of their molecular-scale porosity, but heretofore, the use of aerogels has been inhibited by two factors: (1) Their brittleness makes processing and handling difficult. (2) They shrink during production and shrink more when heated to high temperatures during use. The shrinkage and the consequent cracking make it difficult to use them to encapsulate objects in thermal-insulation materials. The underlying concept of aerogel-matrix composites is not new; the novelty of the present family of materials lies in formulations and processes that result in superior properties, which include (1) much less shrinkage during a supercritical-drying process employed in producing a typical aerogel, (2) much less shrinkage during exposure to high temperatures, and (3) as a result of the reduction in shrinkage, much less or even no cracking.
Ultrasonic velocity/time-of-flight imaging that uses back surface reflections to gauge volumetric material quality is highly suited for quantitative characterization of microstructural gradients including those due to pore fraction, density, fiber fraction, and chemical composition variations. However, a weakness of conventional pulse-echo ultrasonic velocity/time-of-flight imaging is that the image shows the effects of thickness as well as microstructural variations unless the part is uniformly thick. This limits this imaging method's usefulness in practical applications. Prior studies have described a pulse-echo time-of-flight-based ultrasonic imaging method that requires using a single transducer in combination with a reflector plate placed behind samples that eliminates the effect of thickness variation in the image. In those studies, this method was successful at isolating ultrasonic variations due to material microstructure in plate-like samples of silicon nitride, metal matrix composite, and polymer matrix composite. In this study, the method is engineered for inspection of more complex-shaped structures-those having (hollow) tubular/curved geometry. The experimental inspection technique and results are described as applied to (1) monolithic mullite ceramic and polymer matrix composite 'proof-of-concept' tubular structures that contain machined patches of various depths and (2) as-manufactured monolithic silicon nitride ceramic and silicon carbide/silicon carbide composite tubular structures that might be used in 'real world' applications.
The fabrication and thermo-mechanical properties of SiC monofilament- and SiC fiber tow-reinforced reaction-bonded silicon nitride matrix composites (SiC/RBSN) and fully dense SiC monofilament-reinforced silicon nitride matrix composites (SiC/Si3N4) have been reviewed. The SiC/RBSN composites display high strength and toughness, and low thermal conductivity in the as-fabricated condition, but are susceptible to internal oxidation and mechanical property degradation in the intermediate temperature range from 400 to 1100 C. The internal oxidation problem can be avoided by applying functionally graded oxidation resistant coatings on external surfaces of the composite. On the other hand, the fully dense SiC/SiC3N4 composites fabricated by using SiC monofilaments and pressure assisted sintering methods display moderate strength and limited strain capability beyond matrix cracking stress. Advantages, disadvantages, and potential applications of SiC fiber-reinforced silicon nitride matrix composites fabricated using various fiber types and processing methods are discussed.