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At least 1,189 records · Page 66

Update on CMH-17 Volume 5 Ceramic Matrix Composites

A wide range of issues must be addressed during the process of certifying CMC (ceramic matrix composite) components for use in commercial aircraft. The Composite Materials Handbook-17, Volume 5, Revision A on ceramic matrix composites has just been revised to help support FAA certification of CMCs for elevated temperature applications. The handbook supports the development and use of CMCs through publishing and maintaining proven, reliable engineering information and standards that have been thoroughly reviewed. Volume 5 contains detailed sections describing CMC materialsprocessing design, analysisguidelines, testing procedures, and data analysis and acceptance. A review of the content of this latest revision will be presented along with a description of how CMH-17, Volume 5 could be used by the FAA (Federal Aviation Administration) and others in the future.

characterization↗

CMH-17 Volume 5 Ceramic Matrix Composites

A wide range of issues must be addressed during the process of certifying CMC (ceramic matrix composite) components for use in commercial aircraft. The Composite Materials Handbook-17, Volume 5, Revision A on ceramic matrix composites has just been revised to help support FAA certification of CMCs for elevated temperature applications. The handbook supports the development and use of CMCs through publishing and maintaining proven, reliable engineering information and standards that have been thoroughly reviewed. Volume 5 contains detailed sections describing CMC materials processing, design analysis guidelines, testing procedures, and data analysis and acceptance. A review of the content of this latest revision will be presented along with a description of how CMH-17, Volume 5 could be used by the FAA (Federal Aviation Administration) and others in the future.

characterization↗

TEM Analysis of Diffusion-Bonded Silicon Carbide Ceramics Joined Using Metallic Interlayers

SiC fiber-bonded ceramics (SA-Tyrannohex: SA-THX) diffusion-bonded with TiCu metallic interlayers were investigated. Thin samples of the ceramics were prepared with a focused ion beam (FIB) and the interfacial microstructure of the prepared samples was studied by transmission electron microscopy (TEM) and scanning TEM (STEM). In addition to conventional microstructure observation, for detailed analysis of reaction compounds in diffusion-bonded area, we performed STEM-EDS measurements and selected area electron diffraction (SAD) experiments. The TEM and STEM experiments revealed the diffusion-bonded area was composed of only one reaction layer, which was characterized by TiC precipitates in Cu-Si compound matrix. This reaction layer was in good contact with the SA-THX substrates, and it is concluded that the joint structure led to the excellent bonding strength.

Ceramics↗

Effect of Mechanical and Thermal Loading Histories on Residual Properties of SiCf/SiC Ceramic Matrix Composites

Silicon Carbide based Ceramic Matrix Composites (CMCs) are attractive materials for use in high-temperature structural applications in the aerospace and nuclear industries. Under high stresses and temperatures, creep degradation is the dominant damage mechanism in CMCs. Consequently, chemical vapor infiltration (CVI) SiCf/SiC ceramic matrix composites (CMC) incorporating SylramicTM-iBN SiC fibers coated with boron nitride (BN) interphase and CVI-SiC matrix were tested to examine creep behavior in air at a range of elevated temperatures of (2200 - 2700 F). Samples that survived creep tests were evaluated via RT fast fracture tensile tests to determine residual properties, with the use of acoustic emission (AE) to assess stress dependent damage initiation and progression. Microscopy of regions within the gage section of the tested specimens was performed. Observed material degradation mechanisms are discussed.

creep↗

Application of Ab Initio Methods in the Development of Advanced Technical Ceramics

A significant need exists to develop materials not only capable of providing desired electronic and mechanical properties but also survival at extreme temperatures during service and device fabrication, such as co-firing. Computational methods offers an efficient and systematic manner to design new materials and guide their development. As an example computational -based material approaches can be used to determine the suitability of a given materials as a practical thermoelectric for energy harvesting. In this presentation examples are given of applications to relevant technical ceramics such as thermoelectrics, dielectrics, and magnetic systems. The calculation were based on density functional theory and carried out with norm conserving and projector augmented wave (PAW) methods using commercial codes Materials Studio ( Biovia, Inc) with the Cambridge Serial Total Energy Package (CASTEP) and MedeA (Materials Design Inc.) utilizing the Vienna Ab-initio Simulation Package (VASP) as the respective computational engines. This study makes predictions of relevant technical properties of ceramic materials.

thermoelectric↗

High Temperature Solid Particle Erosion in a Melt-Infiltrated SiC/SiC Ceramic Matrix Composite

Ceramic matrix composites (CMCs) are an enabling propulsion material system that offer weight benefits over current Ni-based superalloys, and have higher temperature capabilities that can reduce cooling requirements. Incorporating CMCs into the hot section of gas-turbine engines therefore leads to an increase in engine efficiency. While significant advancements have been made, challenges still remain for current and next-generation gas-turbines; particularly when operating in dust-laden or erosive environments. Solid particles entrained in the gas flow can impact engine hardware resulting in localized damage and material removal due to repeated, cumulative impacts. In this study, the erosion behavior of a melt-infiltrated (MI) silicon carbide fiber-reinforced silicon carbide (SiC/SiC) CMC is investigated at high temperature (1,200 °C) in a simulated combustion environment using 150 µm alumina particles as erodent. Particle impact velocities ranged from 100 to 200 m/s and the angle of impingement varied from 30° to 90°. Erosion testing was also performed on α-SiC to elucidate similarities and differences in the erosion response of the composite compared to that of a monolithic ceramic. Scanning electron microscopy (SEM) was used to study the post-erosion damage morphology and the governing mechanisms of material removal.

Ceramic matrix composites (CMCs), solid particle e↗

Composite Materials Handbook 17 (CMH-17) Volume 5—Ceramic Matrix Composites

The intent of the Composite Materials Handbook‐17 (CMH‐17) Vol 5A—Ceramic Matrix Composites is that it will provide the information and guidance necessary to design, fabricate, and implement ceramic matrix composite components for commercial aircraft engines. The CMH-17 sponsor is the FAA (Federal Aviation Administration). This presentation describes the updating of the handbook, and covers the objectives and activities of the Working Groups that are preparing new content and revising existing text. The 5 Working Groups are: 1) Data Review, 2) Testing, 3) Materials & Processes, 4) Design and Analysis, and 5) Engine Applications. Goal: release Vol 5B in 2023.

Environmental barrier coating (EBC), Ceramic Matri↗

Composite Materials Handbook 17 (CMH-17) Volume 5—Ceramic Matrix Composites

The Composite Materials Handbook‐17 (CMH‐17) Volume 5 for Ceramic Matrix Composites (formerly MIL-HANDBOOK-17) provides the information and guidance necessary to design, fabricate, and implement ceramic matrix composite (CMC) components in aviation applications. This presentation provides an overview of the handbook content, and covers the objectives and activities of the Working Groups that are preparing new content and revising existing text for the next revision. The five Working Groups are: 1) Data Review, 2) Testing, 3) Materials & Processes, 4) Design & Analysis, and 5) Engine Applications. The goal is to release Revision B in 2023. While the handbook is focused on the application of SiC/SiC and Ox/Ox CMCs and EBCs (environmental barrier coatings), the methodologies (testing, data analysis, characterization, etc.) are also applicable to other CMC systems, and the intent is to start incorporating information for Carbon/Carbon (C/C) composites.

Environmental barrier coating (EBC)↗

Wear-Resistance Investigations on Ceramic Coatings for Lunar Dust Mitigation

Lunar dust has posed a major challenge to exploration efforts due to abrasion and impact. This work focuses on fundamental studies on ceramic coatings as candidates for enhanced resistance to impact and wear. As a first step, standard and modified approaches to the method of abrasion testing were explored for options to incorporate lunar regolith as wear media, the effects of which were presented for AL6061-T6 control samples. Following this, wear results for air plasma-sprayed (APS) alumina coatings were investigated due to their superior strength and surface hardness. In addition, APS 8 wt % yttria-stabilized zirconia (8YSZ) coatings were studied for their strength and martensitic transformation toughness. Measurements were made by assessing the mass loss, with a standard scale at various intervals. In addition, surface roughness was measured with a profilometer and features identified with a high-resolution microscope. The findings demonstrated that wear media has a distinct effect on the abrasion. The alumina coatings demonstrated improved wear over 8YSZ. However, the tailorability of 8YSZ makes it an attractive option to continue to modify as a wear-resistant coating to protect against lunar dust abrasion. The results of these measurements provide insight into the wear behavior of future directions in candidate ceramic coatings for the harsh lunar environment.

ceramic coatings↗

Wear-Resistance Investigations on Ceramic Coatings for Lunar Dust Mitigation

Lunar dust has posed a major challenge to exploration efforts due to abrasion and impact. This work focuses on fundamental studies on ceramic coatings as candidates for enhanced resistance to impact and wear. As a first step, standard and modified approaches to the method of abrasion testing were explored for options to incorporate lunar regolith as wear media, the effects of which were presented for AL6061-T6 control samples. Following this, wear results for air plasma-sprayed (APS) alumina coatings were investigated due to their superior strength and surface hardness. In addition, APS 8 wt % yttria-stabilized zirconia (8YSZ) coatings were studied for their strength and martensitic transformation toughness. Measurements were made by assessing the mass loss, with a standard scale at various intervals. In addition, surface roughness was measured with a profilometer and features identified with a high-resolution microscope. The findings demonstrated that wear media has a distinct effect on the abrasion. The alumina coatings demonstrated improved wear over 8YSZ. However, the tailorability of 8YSZ makes it an attractive option to continue to modify as a wear-resistant coating to protect against lunar dust abrasion. The results of these measurements provide insight into the wear behavior of future directions in candidate ceramic coatings for the harsh lunar environment.

ceramic coatings↗

The Production of Advanced Glass Ceramic HLW Forms using Cold Crucible Induction Melter

Cold Crucible Induction Melters (CCIMs) will favorably change how High-Level radioactive Waste (from nuclear fuel recovery) is treated in the 21st century. Unlike the existing Joule-Heated Melters (JHMs) currently in operation for the glass-based immobilization of High-Level Waste (HLW), CCIMs offer unique material features that will increase melt temperatures, increase throughput, increase mixing, increase loading in the waste form, lower melter foot prints, eliminate melter corrosion and lower costs. These features not only enhance the technology for producing HLW forms, but also provide advantageous attributes to the waste form by allowing more durable alternatives to glass. This paper discusses advantageous features of the CCIM, with emphasis on features that overcome the historical issues with the JHMs presently utilized, as well as the benefits of glass ceramic waste forms over borosilicate glass waste forms. These advantages are then validated based on recent INL testing to demonstrate a first-of-a-kind formulation of a non-radioactive ceramic-based waste form utilizing a CCIM.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Developing 300°C Ceramic Circuit Boards

This paper covers the development of a geothermal ceramic circuit board technology using 3D traces in a machinable ceramic. Test results showing the circuit board to be operational to at least 550°C. Discussion on producing this type of board is outlined along with areas needing improvement.

15 GEOTHERMAL ENERGY↗

Discrete Modeling of Early-Life Thermal Fracture in Ceramic Nuclear Fuel

Fracturing of ceramic fuel pellets heavily influences performance of light water reactor (LWR) fuel. Early in the life of fuel, starting with the initial power ramp, large thermal gradients cause high tensile hoop and axial stresses in the outer region of the fuel pellets, resulting in the formation of radial and axial cracks. Circumferential cracks form due to thermal gradients that occur when the power is ramped down. These thermal cracks cause the fuel to expand radially, closing the pellet/cladding gap and enhancing the thermal conductance across that gap, while decreasing the effective conductivity of the fuel in directions normal to the cracking. At lower length scales, formation of microcracks is an important contributor to the decrease in bulk thermal conductivity that occurs over the life of the fuel as the burnup increases. Because of the important effects that fracture has on fuel performance, a realistic, physically based fracture modeling capability is essential to predict fuel behavior in a wide variety of normal and abnormal conditions. Modeling fracture within the context of the finite element method, which is based on continuous interpolations of solution variables, has always been challenging because fracture is an inherently discontinuous phenomenon. Work is underway at Idaho National Laboratory to apply two modeling techniques model fracture as a discrete displacement discontinuity to nuclear fuel: The extended finite element method (XFEM), and discrete element method (DEM). XFEM is based on the standard finite element method, but with enhancements to represent discontinuous behavior. DEM represents a solid as a network of particles connected by bonds, which can arbitrarily fail if a fracture criterion is reached. This paper presents initial results applying the aforementioned techniques to model fuel fracturing. This work has initially focused on early life behavior of ceramic LWR fuel. A coupled thermal-mechanical XFEM method that includes discontinuities in both temperature and displacement fields at crack locations has been developed and is being applied to thermal fracture of LWR fuel. A DEM model of coupled heat conduction and solid mechanics has been developed and used to simulate random initiation and propagation of thermally driven cracks during initial power cycles. This DEM model predicts the formation of realistic radial cracking patterns during power rise and circumferential cracks as power is ramped down. These initial results are very encouraging, and these techniques are expected to provide improved understanding of fuel behavior in a wide variety of conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Separate-Effects Validation Experiments for Models of Fracture in Ceramic Nuclear Fuel

A number of advances have recently been made in modeling fracture initiation and propagation in ceramic light water reactor (LWR) fuel. These include the use of techniques such as peridynamics, the extended finite element method (XFEM), the discrete element method (DEM), and phase field fracture. Improved predictions of fracture in LWR fuel can benefit fuel performance simulations in a number of ways, with important implications for radial relocation, pellet-cladding mechanical interactions, and fragmentation during accident conditions. Although these modeling approaches appear promising, to-date most of their applications have been to fresh fuel. A major limitation in applying these approaches with confidence to a wider variety of conditions, such as fragmentation of high-burnup fuel, is that there is very limited data that can be directly used to validate the results of these fracture models. While fracture patterns are available from cross-sections of numerous irradiated fuel rods, the fuel rods have typically been subjected to complex irradiation histories. To validate models of fracture propagation, focused experiments that give snapshots of the initiation and propagation of fracture under well characterized prototypical reactor conditions are needed. Under a multi-institutional U.S. Department of Energy Integrated Research Project (IRP), three separate-effects validation experiments are underway to provide information on the propagation of cracks in LWR fuel under controlled conditions. The primary challenge in developing such an experiment is in providing conditions that result in a radial temperature distribution that is prototypical of LWR in-reactor conditions. Two out-of-reactor experiments are being planned that employ very different approaches to achieve such a temperature distribution. The first of these achieves this by employing a combination of inductive and resistive electrical heating to generate volumetric heating. The second experiment involves slowly heating a pellet in a metal rod to a high temperature, and then quenching that rod in a cold bath. The quenching process generates a temperature profile approximating that in an LWR fuel rod for a moment, but has a very different temperature history from the LWR. Finally, an experiment is being planned for the Idaho National Laboratory TREAT reactor that will use nuclear fission as a heat source, and which will employ a metal heat sink to replicate the thermal conditions provided by coolant in an LWR. These experiments all have their advantages and drawbacks, with varying levels of ability to reproduce actual LWR conditions and varying ability to use instruments to monitor quantities of interest over the course of the experiment that can be used to validate fracture models. For that reason, these different experimental approaches are complimentary to each other, and the combined results are expected to significantly improve confidence in the ability of computational models to simulate fracture in ceramic nuclear fuel.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Brazings for Metal-Ceramic Joining in Sodium Thermal Electrochemical Converter (Na-TEC) Devices

Sodium thermal electrochemical converters (Na-TECs) offer a high efficiency advancement for converting thermal energy into electrical energy without moving parts. Since the cell operates using a Na pressure difference between the high temperature evaporator and the lower temperature condenser, a hermetic seal capable of maintaining that pressure difference is essential. This study looked at brazing of the ceramic electrolyte used in these cells, which is a β”-alumina solid-electrolyte referred to as BASE. Since a literature search found no papers pertaining to brazing of BASE, knowledge from ceramic to metal brazing called widegap brazing was used. Specifically, the widegap brazing of α-alumina to nickel-based alloys. Initial brazing trials used a traditional inert atmospheric brazing technique with an Ar-H2 gas mixture. However, the very low pO2 atmosphere resulted in the destruction of the BASE layers due to the diffusion of carbon to the outer surface of the electrolyte during brazing. A new and radically different brazing technique called air brazing was then attempted. This brazing technique proved successful using the brazing alloy Ag-8CuO. Both Ag and Cu are not deleteriously affected by Na corrosion; thus, Ag-8CuO were a good choice for the braze alloy. Leak tests were performed on these cells to establish their hermeticity. This cell structure and brazing technique proved to be successful. Air brazing is an exciting joining operation for these types of cells.

14 SOLAR ENERGY↗

The production of advanced glass ceramic HLW forms using cold crucible induction melter

Cold Crucible Induction Melters (CCIM) will favorably change how High-Level radioactive Waste (from nuclear fuel recovery) is treated in a near future. Unlike the existing Joule-Heated Melters (JHM) currently in operation for the glass-based immobilization of High-Level Waste (HLW), CCIM offers unique material features that will increase melt temperatures, increase throughput, increase mixing, increase loading in the waste form, lower melter foot prints, eliminate melter corrosion and lower costs. These features not only enhance the technology for producing HLW forms, but also provide advantageous attributes to the waste form by allowing more durable alternatives to glass. It is concluded that glass ceramic waste forms that are tailored to immobilize fission products of HLW can be can be made from the HLW processed with the CCIM. The advantageous higher temperatures reached with the CCIM and unachievable with JHM allows the lanthanides, alkali, alkaline earths, and molybdenum to dissolve into a molten glass. Upon controlled cooling they go into targeted crystalline phases to form a glass ceramic waste form with higher waste loadings than achievable with borosilicate glass waste forms. Natural cooling proves to be too fast for the formation of all targeted crystalline phases.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Fabrication and Properties of Advanced Ceramic Technetium Waste Forms - 17311

Technetium-99 (Tc, t{sub 1/2} = 2.13 x 10{sup 5} years) is a challenge from a nuclear waste perspective and is one of the most abundant, long-lived radioisotopes found in used nuclear fuel (UNF). Within the Hanford Tank Waste Treatment and Immobilization Plant, technetium volatilises at typical glass melting temperature, is captured in the off-gas treatment system and recycled back into the feed to eventually increase Tc-loadings of the glass. In this research we are providing a technical solution for continuously depleting the Tc-content of the glass melter feed by precipitating Tc from the off-gas effluents and effectively immobilizing {sup 99}Tc as durable ceramic waste form. We have developed a wet-chemical coprecipitation-based synthesis route to fabricate gram-size Tc-based pyrochlores with the model composition Sm{sub 2}(Tc{sub 0.5-x}Ru{sub x}Ti{sub 0.5}){sub 2}O{sub 7}. These ceramic Tc waste forms exhibit better technetium retention and corrosion resistance in ASTM C1220-10 based testing compared with technetium-containing LAWE4-type borosilicate glass, combined with optimal waste loading. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Ceramic Plugs for Deep Borehole Seals - 17316

In the deep borehole nuclear waste disposal concept, waste packages are emplaced deep in crystalline rock formations under conditions of high pressures, high mineral content water, and elevated temperatures. Well seals and plugs must perform for thousands of years. A novel ceramic plug system under development capitalizes on the thermal energy of thermite mixtures and engineered additives to react and form ceramic-like plugs in place with favorable structural, flow, and geochemical properties. Depending on the ingredients, the reaction can produce aluminosilicates, plagioclase feldspars, or other combinations in crystalline or amorphous forms. Normative mineralogy techniques were applied to predict product mineralogy and evaluate compatibility with host rocks, and showed they are comparable to igneous rock analogs. The results support a tentative geochemical compatibility between these formulations and granitic host rock. Because the reaction produces a significant amount of thermal energy, the thermal/structural/fluid response of the plug and surrounding media was evaluated with the FEHM code. Temperatures near the plug/rock interface are estimated to peak at less than 600 deg. C and cool to near ambient temperature within a day. Rock stresses resulting from the thermal pulse are predicted to be similar to the unconfined compressive strength of granites, and generally lower than triaxial test results. Entrained fluid expansion due to heating was shown to be lower than failure stresses. Little or no failure in the surrounding media would be expected due to the plug formation process. The present efforts are focused on refining the material formulations, evaluating the geochemical and mechanical interactions between the plug and host rock, and testing the plug formation process in scaled granite and basalt masses. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗