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At least 1,207 records · Page 67

Thermal Cyclic Behavior of Thermal and Environmental Barrier Coatings Investigated Under High-Heat-Flux Conditions

Environmental barrier coatings (EBC's) have been developed to protect silicon-carbide- (SiC) based ceramic components in gas turbine engines from high-temperature environmental attack. With continuously increasing demands for significantly higher engine operating temperature, future EBC systems must be designed for both thermal and environmental protection of the engine components in combustion gases. In particular, the thermal barrier functions of EBC's become a necessity for reducing the engine-component thermal loads and chemical reaction rates, thus maintaining the required mechanical properties and durability of these components. Advances in the development of thermal and environmental barrier coatings (TBC's and EBC's, respectively) will directly impact the successful use of ceramic components in advanced engines. To develop high-performance coating systems, researchers must establish advanced test approaches. In this study, a laser high-heat-flux technique was employed to investigate the thermal cyclic behavior of TBC's and EBC's on SiC-reinforced SiC ceramic matrix composite substrates (SiC/SiC) under high thermal gradient and thermal cycling conditions. Because the laser heat flux test approach can monitor the coating's real-time thermal conductivity variations at high temperature, the coating thermal insulation performance, sintering, and delamination can all be obtained during thermal cycling tests. Plasma-sprayed yttria-stabilized zirconia (ZrO2-8 wt% Y2O3) thermal barrier and barium strontium aluminosilicate-based environmental barrier coatings (BSAS/BSAS+mullite/Si) on SiC/SiC ceramic matrix composites were investigated in this study. These coatings were laser tested in air under thermal gradients (the surface and interface temperatures were approximately 1482 and 1300 C, respectively). Some coating specimens were also subject to alternating furnace cycling (in a 90-percent water vapor environment at 1300 C) and laser thermal gradient cycling tests (in air), to investigate the water vapor effect. All cyclic tests were conducted using a 60-min hot-time temperature.

Zhu, Dongming↗

Processing and Characterization of Peti Composites Fabricated by High Temperature Vartm (Section)

The use of composites as primary structures on aerospace vehicles has increased dramatically over the past decade, but so have the production costs associated with their fabrication. For certain composites, high temperature vacuum assisted resin transfer molding (HT-VARTM) can offer reduced fabrication costs compared to conventional autoclave techniques. The process has been successfully used with phenylethynyl terminated imide (PETI) resins developed by NASA Langley Research Center (LaRC). In the current study, three PETI resins have been used to make test specimens using HT-VARTM. Based on previous work at NASA LaRC, larger panels with a quasi-isotropic lay-up were fabricated. The resultant composite specimens exhibited void contents of ~ 3% by volume depending on the type of carbon fabric preform used. Mechanical properties of the panels were determined at both room and elevated temperatures. Fabric permeability characterizations and limited process modeling efforts were carried out to determine infusion times and composite panel size limitations. In addition, new PETI based resins were synthesized specifically for HT-VARTM.

Ghose, Sayata↗

The Mechanical Properties of Candidate Superalloys for a Hybrid Turbine Disk

The mechanical properties of several cast blade superalloys and one powder metallurgy disk superalloy were assessed for potential use in a dual alloy hybrid disk concept of joined dissimilar bore and web materials. Grain size was varied for each superalloy class. Tensile, creep, fatigue, and notch fatigue tests were performed at 704 to 815 degC. Typical microstructures and failure modes were determined. Preferred materials were then selected for future study as the bore and rim alloys in this hybrid disk concept. Powder metallurgy superalloy LSHR at 15 micron grain size and single crystal superalloy LDS-1101+Hf were selected for further study, and future work is recommended to develop the hybrid disk concept.

Gabb, Timothy P.↗

Extended Life PZT Stack Test Fixture

Piezoelectric stacks are being sought to be used as actuators for precision positioning and deployment of mechanisms in future planetary missions. Beside the requirement for very high operation reliability, these actuators are required for operation at space environments that are considered harsh compared to normal terrestrial conditions.These environmental conditions include low and high temperatures and vacuum or high pressure. Additionally, the stacks are subjected to high stress and in some applications need to operate with a very long lifetime durability.Many of these requirements are beyond the current industry design margins for nominal terrestrial applications. In order to investigate some of the properties that will indicate the durability of such actuators and their limitations we have developed a new type of test fixture that can be easily integrated in various test chambers for simulating environmental conditions, can provide access for multiple measurements while being exposed to adjustable stress levels. We designed and built two test fixtures and these fixtures were made to be adjustable for testing stacks with different dimensions and can be easily used in small or large numbers. The properties that were measured using these fixtures include impedance, capacitance, dielectric loss factor, leakage current, displacement, breakdown voltage, and lifetime performance. The fixtures characteristics and the test capabilities are presented in this paper.

test fixtures↗

Lunar surface engineering properties experiment definition. Volume 2: Mechanics of rolling sphere-soil slope interaction

The soil deformation mode under the action of a rolling sphere (boulder) was determined, and a theory based on actual soil failure mechanism was developed which provides a remote reconnaissance technique for study of soil conditions using boulder track observations. The failure mechanism was investigated by using models and by testing an instrumented spherical wheel. The wheel was specifically designed to measure contact pressure, but it also provided information on the failure mechanism. Further tests included rolling some 200 spheres down sand slopes. Films were taken of the rolling spheres, and the tracks were measured. Implications of the results and reevaluation of the lunar boulder tracks are discussed.

Hovland, H. J.↗

Thermal-vacuum facility with in-situ mechanical loading

The paper describes a thermal-vacuum space simulator used to assess property changes of fiber-reinforced polymer composite systems. The facility can achieve a vacuum of approximately .0000001 torr with temperatures ranging from -200 to +300 F. Some preliminary experimental results are presented for materials subjected to thermal loading up to 200 F. The tests conducted include the evaluation of matrix modulus and strength, coefficients of thermal expansion, and fracture toughness. Though the experimental program is at an early stage, the data appear to indicate that these parameters are influenced by hard vacuum.

Tennyson, R. C.↗

Mechanisms of fatigue damage in boron/aluminum composites

Tensile fatigue tests were conducted on several laminates of boron/aluminum (6061-0). In laminates with 0 deg fibers on the outside, an analysis that identifies "shakedown" conditions predicted the stress amplitude below which no fatigue damage accumulated. A fatigue damage accumulation model which relates matrix fatigue cracking and the overall laminate properties is described. A model for the saturation damage stage development is presented, that identical laminates, tested in directions 90 deg apart (such that one layup has 90 deg outer plies and the other 0 deg), have different fatigue behaviors due to the stacking sequence. The 90 deg plies on the surface develop cracks earlier than predicted by shakedown. An attempt was made to explain this stacking sequence effect. Variable load history effects on the fatigue damage response were investigated. Tests reveal that for a given stress ratio the specimen seeks the saturation damage state for the largest stress range to which it is subjected. It was also found that little damage is generated by shifting a given stress range down, whereas significant damage may be created by shifting it upward. The laminate stresses were always tensile.

Johnson, W. S.↗

Fiber Effects on Minicomposite Mechanical Properties for Several Silicon Carbide Fiber: Chemically Vapor-Infiltrated Silicon Carbide Matrix Systems

Several different types of SiC fiber tows were coated with BN and composited using chemically vapor-infiltrated SiC to form single-tow minicomposites. The types of SiC fiber included Nicalon(sup TM), Hi-Nicalon(sup TM), and the new Sylramic(sup TM) polycrystalline SiC fiber. The interfacial shear stresses were determined from unload-reload tensile hysteresis-loop tests. The ultimate stress and strain properties also were determined for the minicomposites. The ultimate strengths of the newer Hi-Nicalon and Sylramic fibers were superior to that of Nicalon minicomposites with similar fiber volume fractions. The Sylramic minicomposites had the lowest strain to failure and highest interfacial shear strength, respectively, because of the high modulus of the fiber and the rough surface of this fiber type. The apparent interfacial shear strength increased as the stress increased for the Sylramic minicomposites, which also was attributed to the surface roughness of this fiber.

Morscher, Gregory N.↗

Bioinspired multilayered cellular composites with enhanced energy absorption and shape recovery

Inspired by the multiscale configuration of the microstructure of cork, the paper describes the design, 3D printing, and evaluation of a new type of multilayered cellular composite (MCC) structure composed of hard brittle and soft flexible phases. The mechanical behavior of 3D printed MCC structures have been investigated both experimentally and numerically. The experiments show that the MCC structure absorbs four times the amount of energy of a conventional cellular configuration under compressive strains up to 70%. Finite element simulations and 2D digital image correlation (DIC) also show that the multilayered architecture provides a more uniform strain distribution and higher stress transfer efficiency, with a resulting progressive failure mode rather than a catastrophic one. Cyclic loading tests demonstrate that the MCC structure also possesses exceptional shape recoverability under compressive deformations up to 40%. These remarkable performance characteristics result from synergies between the properties of the two constituent materials and the chosen multilayered cellular microstructure. The soft phase, in particular, plays a pivotal role in absorbing elastic energy during loading and then releasing the stored energy while unloading. The volume fraction of the soft phase is also essential to control energy absorption and the transition of failure modes. The deformation mechanisms demonstrated here are robust and applicable to other architected cellular materials across multiple length scales and suggest new ways to design lightweight and high-resilience structural materials.

bioinspired composites↗

Detailed Microstructural Characterization of the Disk Alloy ME3

The advanced powder metallurgy disk alloy ME3 was designed using statistical screening and optimization of composition and processing variables in the NASA/General Electric/Pratt & Whitney HSR/EPM disk program to have extended durability for large disks at maximum temperatures of 600 to 700 C. Scaled-up disks of this alloy were then produced at the conclusion of that program to demonstrate these properties in realistic disk shapes. The objective of the present study was to assess the microstructural characteristics of these ME3 disks at two consistent locations, in order to enable estimation of the variations in microstructure across each disk and across several disks of this advanced alloy. Scaled-up disks processed in the HSR/EPM Compressor/Turbine Disk program had been sectioned, machined into specimens, and tested in tensile, creep, fatigue, and fatigue crack growth tests by NASA Glenn Research Center, in cooperation with General Electric Engine Company and Pratt & Whitney Aircraft Engines. For this study, microstructures of grip sections from tensile specimens in the bore and rim were evaluated from these disks. The major and minor phases were identified and quantified using transmission electron microscopy (TEM). Particular attention was directed to the .' precipitates, which along with grain size can predominantly control the mechanical properties of superalloy disks.

Gabb, Timothy P.↗

Lunar Dust and Lunar Simulant Activation, Monitoring, Solution and Cellular Toxicity Properties

During the Apollo missions, many undesirable situations were encountered that must be mitigated prior to returning humans to the moon. Lunar dust (that part of the lunar regolith less than 20 m in diameter) was found to produce several problems with astronaut s suits and helmets, mechanical seals and equipment, and could have conceivably produced harmful physiological effects for the astronauts. For instance, the abrasive nature of the dust was found to cause malfunctions of various joints and seals of the spacecraft and suits. Additionally, though efforts were made to exclude lunar dust from the cabin of the lunar module, a significant amount of material nonetheless found its way inside. With the loss of gravity correlated with ascent of the lunar module from the lunar surface to rendezvous with the command module, much of the major portions of the contaminating soil and dust began to float, irritating the astronaut s eyes and being inhaled into their lungs. Our goal has been to understand some of the properties of lunar dust that could lead to possible hazards for humans. Due to the lack of an atmosphere, there is nothing to protect the lunar soil from ultraviolet radiation, solar wind, and meteorite impacts. These processes could all serve to activate the soil, or produce reactive surface species. In order to understand the possible toxic effects of the reactive dust, it is necessary to reactivate the dust, as samples returned during the Apollo missions were exposed to the atmosphere of the Earth. We have used grinding and UV exposure to mimic some of the processes occurring on the Moon. The level of activation has been monitored using two methods: fluorescence spectroscopy and electron paramagnetic resonance spectroscopy (EPR). These techniques allow the monitoring of hydroxyl radical production in solution. We have found that grinding of lunar dust produces 2-3 times the concentration of hydroxyl radicals as lunar simulant and 10 times that of quartz. Exposure of the lunar dust to UV radiation under vacuum was also found to lead to hydroxyl radical production. After grinding, we have also monitored loss of reactivity of the dusts by exposing them to conditions of known humidity and temperature. From these tests, it was found that the reactivity half-life of lunar simulant is approximately 3 hours, while that of quartz is approximately 2 hours. Placing lunar dust in solution could lead to effects on mechanical and physiological systems, as well as other biological systems. For instance, while it is known that lunar dust is highly abrasive and caused a variety of problems with suits and equipment during Apollo, it is unknown as to how these properties might be affected in the presence of water or other liquids. It is possible that the dust may release minerals (e.g., metallic nanophase Fe) into solution that could speed corrosion or rust. Also, as lunar dust produces hydroxyl radicals (and possibly other reactive oxygen species) in solution, these radicals could also lead to the breakdown of suit or habitat materials. In the body (i.e., in lung solution), the effects could be two-fold. First, if the lunar dust dissolves, it may release an excess of elements (such as zero-valence metallic Fe) that are necessary for bodily functions but only in certain concentration ranges. For lunar dust, the presence of nanophase iron being released into the body is a concern. Secondly, the hydroxyl radicals or other reactive oxygen species produced by the dust in solution could conceivably interact with cells, leading to various problems. We have studied the dissolution of both ground and unground lunar simulant in buffer solutions of different pH. The concentration of a number of species was determined using mass spectrometry. These studies showed that lowering the pH of the solution causes a dramatic increase in the amount of each element released into solution and that grinding also produces higher concentrations. Finally, we have perfmed initial tests aimed at understanding the effects of lunar simulant on cellular systems. Alveolar epithelial cells were cultured and exposed to different concentrations of dust suspended in cell culture media. After predetermined amounts of time, the media was removed and the concentrations of important inflammatory cytokines (IL6, IL8, and TNF-alpha ) were measured. The results of these tests are being used to develop the correct protocols for tests to be performed using lunar dust samples.

Jeevarajan, A.S.↗

Composite Overwrap Pressure Vessels: Mechanics and Stress Rupture Lifing Philosophy

The NASA Engineering and Safety Center (NESC) has been conducting an independent technical assessment to address safety concerns related to the known stress rupture failure mode of filament wound pressure vessels in use on Shuttle and the International Space Station. The Shuttle's Kevlar-49 fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar-49 filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However due to the presence of load sharing liners and the complex manufacturing procedures, the state of actual fiber stress in flight hardware and test articles is not clearly known. Indeed non-conservative life predictions have been made where stress rupture data and lifing procedures have ignored the contribution of the liner in favor of applied pressure as the controlling load parameter. With the aid of analytical and finite element results, this paper examines the fundamental mechanical response of composite overwrapped pressure vessels including the influence of elastic-plastic liners and degraded/creeping overwrap properties. Graphical methods are presented describing the non-linear relationship of applied pressure to Kevlar-49 fiber stress/strain during manufacturing, operations and burst loadings. These are applied to experimental measurements made on a variety of vessel systems to demonstrate the correct calibration of fiber stress as a function of pressure. Applying this analysis to the actual qualification burst data for Shuttle flight hardware revealed that the nominal fiber stress at burst was in some cases 23% lower than what had previously been used to predict stress rupture life. These results motivate a detailed discussion of the appropriate stress rupture lifing philosophy for COPVs including the correct transference of stress rupture life data between dissimilar vessels and test articles.

Thesken, John C.↗

Study of high performance alloy electroforming

More panels electroformed with intentional variations of pulse plating parameters are being made. Pulse plating frequency was noted to have a significant effect regarding mechanical properties. The use of a high pulse frequency (assuming fixed duty cycles) results in an increase in ductility and a decrease in ultimate and yield strengths. Electroforming to intermediate frequencies is being done to obtain the best possible combination of ductility and strength. Results of some tests from high frequency specimens are tabulated.

Malone, G. A.↗

The NASA GSFC MEMS Colloidal Thruster

A number of upcoming missions require different thrust levels on the same spacecraft. A highly scaleable and efficient propulsion system would allow substantial mass savings. One type of thruster that can throttle from high to low thrust while maintaining a high specific impulse is a Micro-Electro-Mechanical System (MEMS) colloidal thruster. The NASA GSFC MEMS colloidal thruster has solved the problem of electrical breakdown to permit the integration of the electrode on top of the emitter by a novel MEMS fabrication technique. Devices have been successfully fabricated and the insulation properties have been tested to show they can support the required electric field. A computational finite element model was created and used to verify the voltage required to successfully operate the thruster. An experimental setup has been prepared to test the devices with both optical and Time-Of-Flight diagnostics.

Cardiff, Eric H.↗

Thermal-Stress Control of Microshutter Arrays in Cryogenic Applications for the James Webb Space Telescope

We report on methods to minimize thermally-induced deformation in a MEMS-based reconfigurable aperture. The device is an enabling component of the Near-Infrared Spectrometer, a principle instrument on NASA's James Webb Space Telescope. The Microshutter Array consists of 384 x 175 individually addressable shutters which can be magnetically rotated 90 deg into the plane of the array and electrostatically latched open. Each shutter is a 100 x 200 micron rectangular membrane suspended by a small neck region and torsion flexure. The primary materials in the shutter are a 5000A Si3N4 layer for mechanical rigidity, 2000A Al for opacity and electrostatic latching, and 2800A CoFe for magnetic actuation. This multi-layer stack presents a challenge due to the operating temperatures required for the device: both room temperature (300K) and cryogenic temperature (35K). Thermal expansion of the materials causes the shutters to bow out of plane excessively, which can prevent actuation of the shutters, cause damage to portions of the array, and allow light leakage around closed shutters. Here we present our investigation of several methods to prevent microshutter bowing including deposition of additional materials on the shutters to create a symmetrical layer stack and replacing the current stack with low-coefficient of thermal expansion materials. Using shutter-size suspended cantilever beams as a rapid-development test bed, we have reduced out-of-plane bowing between 300K and 35K to 10% or better. We are currently applying these results to microshutter arrays to develop shutters that remain flat from room temperature to cryogenic temperature while retaining the required mechanical, optical, and magnetic properties.

Kelly, Daniel P.↗

GRCop-84 Developed for Rocket Engines

GRCop-84 (Cu-8 at.% Cr-4 at.% Nb) was developed at the NASA Glenn Research Center for use in regeneratively cooled rocket engines. This alloy possesses an excellent combination of conductivity, thermal expansion, strength, creep resistance, ductility, and low-cycle fatigue (LCF) life. In comparison to the currently used alloy, NARloy-Z (Cu-3 wt % Ag-0.5 wt % Zr), GRCop-84's significantly better properties give it the potential for significant gains in engine performance and reliability. For GRCop-84 to be safely used in a rocket engine, it is critical to develop a detailed data base of the important thermophysical and mechanical properties. Work has focused on five major properties: thermal conductivity, thermal expansion, tensile strength, creep resistance, and LCF life. The analysis went beyond simply measuring the data and reporting averages. A detailed statistical analysis was conducted that allowed regression of the data over the entire temperature range tested and establishment of design minimums. The design values were expressed as simple mathematical formulas that are highly amenable to use in computer codes such as in finite element analysis and related computer modeling work.

Ellis, David L.↗

Joining and Assembly of Silicon Carbide-based Advanced Ceramics and Composites for High Temperature Applications

Silicon carbide based advanced ceramics and fiber reinforced composites are under active consideration for use in wide variety of high temperature applications within the aeronautics, space transportation, energy, and nuclear industries. The engineering designs of ceramic and composite component 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. In addition these components have to be joined or assembled with metallic sub-components. 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 o high temperature joints in ceramic matrix composites will be presented. Silicon carbide based advanced ceramics (CVD and hot pressed), and C/SiC and SiC/SiC composites, in different shapes and sizes, have been joined using an affordable, robust ceramic joining technology (ARCJoinT). Microstructure and high temperature mechanical properties of joints in silicon carbide ceramics and CVI and melt infiltrated SiC matrix composites will,be reported. Various joint design philosophies and design issues in joining of ceramics and composites well be discussed.

Singh, M.↗

Dynamic Mechanical Properties and Fracture Surface Morphologies of Core-Shell Rubber (CSR) Toughened Epoxy at Liquid Nitrogen (Ln2) Temperatures

The dynamic mechanical properties and fracture surface morphologies were evaluated for a commercial epoxy resin toughened with two types of core-shell rubber (CSR) toughening agents (Kane Ace(Registered TradeMark) MX130 and MX960). The impact resistance (R) was evaluated by the resulting breaking energy measured in Charpy impact tests conducted on an instrumented drop tower. The resulting fracture surface morphologies were examined using Scanning Electron Microscopy (SEM). Fractographic observations of the CSR toughened epoxy tested at ambient temperature, showed a fracture as characterized by slender dendrite textures with large voids. The increasing number of dendrites and decreasing size of scale-like texture with more CSR particles corresponded with increased R. As the temperature decreased to Liquid Nitrogen (LN 2), the fracture surfaces showed a fracture characterized by a rough, torn texture containing many river markings and deep furrows.

Wang, J.↗