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At least 1,063 records · Page 59

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NASA NTRS2004

Foreign Object Damage Resistance of Uncoated and EBC Coated SiC/SiC Composites

SiC/SiC composites fabricated by the melt infiltration method are candidate materials for the turbine components such as combustor liners, nozzle vanes and blades because of their high temperature strength, and thermal conductivity. To avoid surface recession in a combustion environment containing moisture, these materials also require an environmental barrier coating (EBC). Under thermal loading condition alone, the EBC coated SiC/SiC components show microstructural and strength stability after -1 5000 hr exposure to 12OO0C in combustion environment. However, the stability of SiC/SiC composites under impact conditions is not fully understood. In this study, both uncoated and EBC coated SiC/SiC composite specimens were impact tested by steel-ball projectiles at room temperature and at 1300 C in air. After impact, the specimens were analyzed under a scanning electron microscope to assess coating damage, and then tensile and bend tested at room temperature to determine their residual strength. The extent of coating and substrate damage with increasing projectile velocity was imaged and analyzed using nondestructive evaluation (NDE) methods such as micro focus x-ray radiography, tomography, and thermal wave imaging. The mechanical property results of impacted specimens are correlated with the NDE results and the scanning electron microscopy (SEM) observations. Influence of projectile velocity on impact damage of the coating/substrate, and the implication coating damage on durability of the composite will be discussed.

Bhatt, R. T.↗

NASA NTRS2004

Capillary Pressure of a Liquid Between Uniform Spheres Arranged in a Square-Packed Layer

The capillary pressure in the pores defined by equidimensional close-packed spheres is analyzed numerically. In the absence of gravity the menisci shapes are constructed using Surface Evolver code. This permits calculation the free surface mean curvature and hence the capillary pressure. The dependences of capillary pressure on the liquid volume constructed here for a set of contact angles allow one to determine the evolution of basic capillary characteristics under quasi-static infiltration and drainage. The maximum pressure difference between liquid and gas required for a meniscus passing through a pore is calculated and compared with that for hexagonal packing and with approximate solution given by Mason and Morrow [l]. The lower and upper critical liquid volumes that determine the stability limits for the equilibrium capillary liquid in contact with square packed array of spheres are tabulated for a set of contact angles.

Alexader, J. Iwan D.↗

NASA NTRS2004

Advanced Constituents and Processes for Ceramic Composite Engine Components

The successful replacement of metal alloys by ceramic matrix composites (CMC) in hot-section engine components will depend strongly on optimizing the processes and properties of the CMC microstructural constituents so that they can synergistically provide the total CMC system with improved temperature capability and with the key properties required by the components for long-term structural service. This presentation provides the results of recent activities at NASA aimed at developing advanced silicon carbide (Sic) fiber-reinforced hybrid Sic matrix composite systems that can operate under mechanical loading and oxidizing conditions for hundreds of hours at 2400 and 2600 F, temperatures well above current metal capability. These SiC/SiC composite systems are lightweight (-30% metal density) and, in comparison to monolithic ceramics and carbon fiber-reinforced ceramic composites, are able to reliably retain their structural properties for long times under aggressive engine environments. It is shown that the improved temperature capability of the SiC/SiC systems is related first to the NASA development of the Sylramic-iBN Sic fiber, which displays high thermal stability, creep resistance, rupture resistance, and thermal conductivity, and possesses an in-situ grown BN surface layer for added environmental durability. This fiber is simply derived from Sylramic Sic fiber type that is currently produced at ATK COI Ceramics. Further capability is then derived by using chemical vapor infiltration (CVI) to form the initial portion of the hybrid Sic matrix. Because of its high creep resistance and thermal conductivity, the CVI Sic matrix is a required base constituent for all the high temperature SiC/SiC systems. By subsequently thermo- mechanical-treating the CMC preform, which consists of the S ylramic-iBN fibers and CVI Sic matrix, process-related defects in the matrix are removed, further improving matrix and CMC creep resistance and conductivity.

Yun, H. M.↗

NASA NTRS2003

Challenges and Opportunities in Reactive Processing and Applications of Advanced Ceramic Materials

Recently, there has been a great deal of interest in the research, development, and commercialization of innovative synthesis and processing technologies for advanced ceramics and composite materials. Reactive processing approaches have been actively considered due to their robustness, flexibility, and affordability. A wide variety of silicon carbide-based advanced ceramics and composites are currently being fabricated using the processing approaches involving reactive infiltration of liquid and gaseous species into engineered fibrous or microporous carbon performs. The microporous carbon performs have been fabricated using the temperature induced phase separation and pyrolysis of two phase organic (resin-pore former) mixtures and fiber reinforcement of carbon and ceramic particulate bodies. In addition, pyrolyzed native plant cellulose tissues also provide unique carbon templates for manufacturing of non-oxide and oxide ceramics. In spite of great interest in this technology due to their affordability and robustness, there is a lack of scientific basis for process understanding and many technical challenges still remain. The influence of perform properties and other parameters on the resulting microstructure and properties of final material is not well understood. In this presentation, mechanism of silicon-carbon reaction in various systems and the effect of perform microstructure on the mechanical properties of advanced silicon carbide based materials will be discussed. Various examples of applications of reactively processed advanced silicon carbide ceramics and composite materials will be presented.

Singh, Mrityunjay↗

NASA NTRS2003

Robust Joining and Assembly of Ceramic Matrix Composites for High Temperature Applications

Advanced ceramic matrix composites (CMCs) are under active consideration for use in a wide variety of high temperature applications within the aerospace, energy, and nuclear industries. The engineering designs of CMC components require fabrication and manufacturing of large and complex shaped parts of various thicknesses. In many instances, it is more economical to build up complex shapes by joining simple geometrical shapes. Thus, joining and attachment have been recognized as enabling technologies for successful utilization of ceramic components in various demanding applications. In this presentation, various challenges and opportunities in design, fabrication, and testing of high temperature joints in ceramic matrix composites will be presented. A wide variety of ceramic composites, in different shapes and sizes, have been joined using an affordable, robust ceramic joining technology (ARCJoinT). Microstructure and mechanical properties of joints in melt infiltrated and CVI Sic matrix composites will be reported. Various joint design philosophies and design issues in joining of composites will be discussed.

Singh, Mrityunjay↗

NASA NTRS2005

Damage Accumulation in SiC/SiC Composites with 3D Architecture

Matrix cracking in Sic fiber reinforced, melt-infiltrated Sic composites with 3D orthogonal architectures was determined for specimens tested in tension at room temperature. Acoustic emission (AE) was used to monitor the matrix cracking activity and was later confirmed by microscopic examination of specimens that had failed. Exact location of AE demonstrated that initial cracking occurred in the matrix rich regions when a large z-direction fiber bundle was used. For specimens with large z-direction fiber tows, the earliest matrix cracking could occur at half the stress for standard 2D woven composites with similar constituents.

Yun, Hee-Mann↗

NASA NTRS2002

Reactive Processing of Environment Conscious, Biomorphic Ceramics: A Novel and Eco-friendly Route to Advanced Ceramic

Environment-conscious, biomorphic ceramics (Ecoceramics) are a new class of materials that can be produced with renewable resources (wood) and wood wastes (wood sawdust). These materials have tailorable properties with numerous potential applications. Silicon carbide-based ecoceramics have been fabricated by the infiltration of wood-derived carbonaceous preforms with oxide and silicon based materials. The wood-derived carbonaceous preforms have been shown to be quite useful in producing porous or dense materials with different microstructures and compositions. The microstructure and mechanical properties (flexural strength, fracture toughness, elastic modulus, and compressive strength) of a wide variety of Sic-based ecoceramics have been measured. Ecoceramics have tailorable properties and behave like ceramic materials manufactured by conventional approaches. In this presentation the fabrication approach, microstructure, and thermomechanical properties of a wide variety of Sic-based Ecoceramics will be reported.

Singh, M.↗

NASA NTRS2004

Scatter in Carbon/Silicon Carbide (C/SiC) Composites Quantified

Carbon-fiber-reinforced silicon carbide matrix (C/SiC) composites processed by chemical vapor infiltration are candidate materials for aerospace thermal structures. Carbon fibers can retain properties at very high temperatures, but they are known to have poor oxidation resistance in adverse, high-temperature environments. Nevertheless, the combination of CVI-SiC matrix with higher stiffness and oxidation resistance, the interfacial coating, and additional surface-seal coating provides the necessary protection to the carbon fibers, and makes the material viable for high-temperature space applications operating under harsh environments. Furthermore, C/SiC composites, like other ceramic matrix composites (CMCs), exhibit graceful non-catastrophic failure because of various inherent energy dissipating mechanisms. The material exhibits nonlinearity in deformation even at very low stress levels. This is the result of the severe matrix microcracking present in the as processed composite because of large differences between the coefficients of thermal expansion of the fiber and the matrix. Utilization of these advanced composites in next generation space vehicles will require innovative structural configurations, updated materials, and refined analyses. Structural safety issues for these vehicles are in direct competition with performance and cost. One would have to quantify the uncertainties associated with the design using formal probabilistic methods. Specifically four fundamental aspects on which analyses are based-- (1) loading conditions, (2) material behavior, (3) geometrical configurations, and (4) structural connections between the composite components and baseline structure--are stochastic in nature. A direct way to formally account for uncertainties is to develop probabilistic structural analysis methods where all participating variables are described by appropriate probability density functions. The present work, however, focuses on analyzing the stochastic material behavior of these advanced composites using formal probabilistic analysis methods. Often, some of the desirable property characteristics that allow composites to offer advantages over conventional structural materials (like tailoring of composite properties) and the complexity are in fact responsible for their greater statistical variability and the requirements for more characterization tests. Composite properties are anisotropic as well, having different properties in different directions. This means that characterization of a property such as stiffness--which will vary greatly depending on the orientation of the fiber relative to the direction of the testing--must be repeated for several different directions and loading conditions. The fabrication process for composites also introduces statistical variations in properties and geometry. A composite part is produced in a number of steps, each of which introduces statistical variability. The matrix is usually produced from a combination of raw materials; and the fiber, which has its own set of properties, is often coated or surface treated, introducing yet another source of variability.

Murthy, Pappu L. N.↗

NASA NTRS2005

Permeability of Candidate Stirling Heater Head Materials Measured

Researchers at the NASA Glenn Research Center are evaluating high-temperature materials for Stirling heater heads for second- and third-generation Stirling radioisotope power systems that would help to increase the system efficiency to 30 to 35 percent and the system specific power to 8 to 10+ W/kg. Ceramic materials could make it possible for the convertor hot-end temperature to be increased to 1050 to 1200 C, in comparison to the current 650 C with an Inconel 718 heater head. A hermetically sealed Stirling heater head must retain a constant internal pressure of nearly 400-psi helium (He) throughout its useful life (120,000 hr) at the design operating temperature. Therefore, He permeability was measured for eight potential materials and compared with the permeability of the current heater head material, Inconel 718. The eight materials included silicon nitride (Si3N4), silicon dioxide (SiO2), both sintered and chemical vapor deposited (CVD) silicon carbide (SiC), alumina (Al2O3), two types of melt-infiltrated (MI) SiC/SiC composites, and a carbon/SiC composite (C/SiC). Glenn submitted samples of each material to Porous Materials, Inc., Ithaca, New York, for permeability analysis. At room temperature and 30-psi He, four materials--Si3N4, Al2O3, SiO2, and sintered SiC--demonstrated lower permeability than Inconel 718. The CVD SiC and all the composite materials were significantly more permeable to He than the baseline material.

Freedman, Marc R.↗

NASA NTRS2005

Physical and hydraulic properties of baked ceramic aggregates used for plant growth medium

Baked ceramic aggregates (fritted clay, arcillite) have been used for plant research both on the ground and in microgravity. Optimal control of water and air within the root zone in any gravity environment depends on physical and hydraulic properties of the aggregate, which were evaluated for 0.25-1-mm and 1-2-mm particle size distributions. The maximum bulk densities obtained by any packing technique were 0.68 and 0.64 g cm-3 for 0.25-1-mm and 1-2-mm particles, respectively. Wettable porosity obtained by infiltration with water was approximately 65%, substantially lower than total porosity of approximately 74%. Aggregate of both particle sizes exhibited a bimodal pore size distribution consisting of inter-aggregate macropores and intra-aggregate micropores, with the transition from macro- to microporosity beginning at volumetric water content of approximately 36% to 39%. For inter-aggregate water contents that support optimal plant growth there is 45% change in water content that occurs over a relatively small matric suction range of 0-20 cm H2O for 0.25-1-mm and 0 to -10 cm H2O for 1-2-mm aggregate. Hysteresis is substantial between draining and wetting aggregate, which results in as much as a approximately 10% to 20% difference in volumetric water content for a given matric potential. Hydraulic conductivity was approximately an order of magnitude higher for 1-2-mm than for 0.25-1-mm aggregate until significant drainage of the inter-aggregate pore space occurred. The large change in water content for a relatively small change in matric potential suggests that significant differences in water retention may be observed in microgravity as compared to earth.

NASA Center JSC↗

NASA NTRS2006

Thermal Cycling of Thermal Control Paints on Carbon-Carbon and Carbon-Polyimide Composites

Carbon-carbon composites and carbon-polyimide composites are being considered for space radiator applications owing to their light weight and high thermal conductivity. For those radiator applications where sunlight will impinge on the surface, it will be necessary to apply a white thermal control paint to minimize solar absorptance and enhance infrared emittance. Several currently available white thermal control paints were applied to candidate carbon-carbon and carbon-polyimide composites and were subjected to vacuum thermal cycling in the range of -100 C to +277 C. The optical properties of solar absorptance and infrared emittance were evaluated before and after thermal cycling. In addition, adhesion of the paints was evaluated utilizing a tape test. The test matrix included three composites: resin-derived carbon-carbon and vapor infiltrated carbon-carbon, both reinforced with pitch-based P-120 graphite fibers, and a polyimide composite reinforced with T-650 carbon fibers, and three commercially available white thermal control paints: AZ-93, Z-93-C55, and YB-71P.

Jaworske, Donald A.↗

NASA NTRS2005

NASALife-Component Fatigue and Creep Life Prediction Program and Illustrative Examples

NASALife is a life prediction program for propulsion system components made of ceramic matrix composites (CMC) under cyclic thermo-mechanical loading and creep rupture conditions. Although, the primary focus was for CMC components the underlying methodologies are equally applicable to other material systems as well. The program references data for low cycle fatigue (LCF), creep rupture, and static material properties as part of the life prediction process. Multiaxial stresses are accommodated by Von Mises based methods and a Walker model is used to address mean stress effects. Varying loads are reduced by the Rainflow counting method. Lastly, damage due to cyclic loading (Miner s rule) and creep are combined to determine the total damage per mission and the number of missions the component can survive before failure are calculated. Illustration of code usage is provided through example problem of a CMC turbine stator vane made of melt-infiltrated, silicon carbide fiber-reinforced, silicon carbide matrix composite (MI SiC/SiC)

Murthy, Pappu L. N.↗

NASA NTRS2006

Modeling the Elastic Modulus of 2D Woven CVI SiC Composites

The use of fiber, interphase, CVI SiC minicomposites as structural elements for 2D-woven SiC fiber reinforced chemically vapor infiltrated (CVI) SiC matrix composites is demonstrated to be a viable approach to model the elastic modulus of these composite systems when tensile loaded in an orthogonal direction. The 0deg (loading direction) and 90deg (perpendicular to loading direction) oriented minicomposites as well as the open porosity and excess SiC associated with CVI SiC composites were all modeled as parallel elements using simple Rule of Mixtures techniques. Excellent agreement for a variety of 2D woven Hi-Nicalon(TradeMark) fiber-reinforced and Sylramic-iBN reinforced CVI SiC matrix composites that differed in numbers of plies, constituent content, thickness, density, and number of woven tows in either direction (i.e, balanced weaves versus unbalanced weaves) was achieved. It was found that elastic modulus was not only dependent on constituent content, but also the degree to which 90deg minicomposites carried load. This depended on the degree of interaction between 90deg and 0deg minicomposites which was quantified to some extent by composite density. The relationships developed here for elastic modulus only necessitated the knowledge of the fractional contents of fiber, interphase and CVI SiC as well as the tow size and shape. It was concluded that such relationships are fairly robust for orthogonally loaded 2D woven CVI SiC composite system and can be implemented by ceramic matrix composite component modelers and designers for modeling the local stiffness in simple or complex parts fabricated with variable constituent contents.

Morscher, Gregory N.↗

NASA NTRS2006

Carbon Nanotube-enhanced Carbon-phenolic Ablator Material

Phenolic impregnated carbon ablator (PICA) is a thermal protection system (TPS) material developed at NASA Ames Research Center in the mid-90 s for Discovery missions. It was used on the Stardust return capsule heat shield which successfully executed the highest speed Earth entry to date on January 15, 2006. PICA is a porous fibrous carbon insulation infiltrated with phenolic resin, and is an excellent ablator that is effective for heating rates up to 1000 W/sq cm. It is one of several candidate TPS materials for the next generation of crewed spacecraft for Lunar and Mars missions. We will describe an ongoing research effort at NASA to improve mechanical properties of the phenolic matrix with carbon nanotubes. The aim is two-fold: to increase overall TPS strength during reentry and to improve Micrometeoroid/Orbital Debris (MMOD) protection in space. The former requires at least a good dispersion of nanotubes in phenolic, while the latter also requires covalent bonding between them to couple and transfer impact energy effectively from matrix to nanotubes. We will discuss the required chemical functionalization of nanotubes, processing issues and test results.

Nikolaev, P.↗

NASA NTRS1993

COAST:The Controller's Assistant

COAST, the Controller's Assistant, is a semi-automated player of the CBS wargave training simulation. It uses rule-based techniques to maneuver a collection of platoons through a complex infiltration mission in response to a single high-level order from a CBS controller.

Game Controller semi-automated player↗

NASA NTRS2001

Androids: application of EAP as artificial muscles to entertainment industry

The classic movie Metropolis (1926), which is nowadays considered a cinema milestone, has shown the possibility to build robots called androids that are science and fiction run together to realize a dream: the human-like robot. In that movie, Dr. Rotwang transforms a simple and cold calculating robot into the body of a beautiful woman. Robots have often been depicted as metal creatures with cold steel bodies, but there is no reason why metals should be the only kind of material for construction of robots. The authors examined the issues related to applying electroactive polymers materials (EAP) to the entertainment industry. EAP are offering attractive characteristics with the potential to produce more realistic models of living creatures at significantly lower cost. This paper seeks to elucidate how EAP might infiltrate and ultimately revolutionize entertainment, showing some applicative examples.

Animatronics↗

NASA NTRS2007

Strengthening Aluminum Alloys for High Temperature Applications Using Nanoparticles of Al203 and Al3-X Compounds (X= Ti, V, Zr)

In this paper the effect of nanoparticles A12O3 and A13-X compounds (X= Ti, V, Zr) on the improvement of mechanical properties of aluminum alloys for elevated temperature applications is presented. These nanoparticles were selected based on their chemical stability and low diffusions rates in aluminum matrix at high temperatures. The strengthening mechanism for aluminum alloy is based on the mechanical blocking of dislocation movements by these nanoparticles. Samples were prepared from A12O3 nanoparticle preforms, which were produced using ceramic injection molding process and pressure infiltrated by molten aluminum. A12O3 nanoparticles can also be homogeneously mixed with aluminum powder and consolidated into samples through hot pressing and sintering. On the other hand, the Al3-X nanoparticles are produced as precipitates via in situ reactions with molten aluminum alloys using conventional casting techniques. The degree of alloy strengthening using nanoparticles will depend on the materials, particle size, shape, volume fraction, and mean inter-particle spacing.

Lee, Jonathan A.↗

NASA NTRS2007

A Symmetrical, Planar SOFC Design for NASA's High Specific Power Density Requirements

Solid oxide fuel cell (SOFC) systems for aircraft applications require an order of magnitude increase in specific power density (1.0 kW/kg) and long life. While significant research is underway to develop anode supported cells which operate at temperatures in the range of 650-800 C, concerns about Cr-contamination from the metal interconnect may drive the operating temperature down further, to 750 C and lower. Higher temperatures, 900-1000 C, are more favorable for SOFC stacks to achieve specific power densities of 1.0 kW/kg. Since metal interconnects are not practical at these high temperatures and can account for up to 75% of the weight of the stack, NASA is pursuing a design that uses a thin, LaCrO3-based ceramic interconnect that incorporates gas channels into the electrodes. The bi-electrode supported cell (BSC) uses porous YSZ scaffolds, on either side of a 10-20 microns electrolyte. The porous support regions are fabricated with graded porosity using the freeze-tape casting process which can be tailored for fuel and air flow. Removing gas channels from the interconnect simplifies the stack design and allows the ceramic interconnect to be kept thin, on the order of 50 -100 microns. The YSZ electrode scaffolds are infiltrated with active electrode materials following the high temperature sintering step. The NASA-BSC is symmetrical and CTE matched, providing balanced stresses and favorable mechanical properties for vibration and thermal cycling.

Cable, Thomas L.↗