glenn research center at lewis field 1 standardization efforts for mechanical testing and design of...
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1Glenn Research Center at Lewis Field
STANDARDIZATION EFFORTS FOR MECHANICAL TESTING AND DESIGN OF ADVANCED
CERAMICS AND COMPONENTS
NES Working Group Meeting
September 2004NASA GRC
Jon Salem NASA GRC
2Glenn Research Center at Lewis Field
OUTLINE
Standards Being Developed Under NTSP: - Machining Practices for Ceramics - Determination of Slow Crack Growth Parameters
Motivations: - Failure of a leading edge - Failure of a sapphire solar concentrator - Test specimens for a combustion facility window
Status & Related Standardization Efforts in ASTM C28, ISO TC206, and NASA GRC
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FAILURE OF A LEADING EDGE
Sharp Leading Edges are Needed :
- maneuverability - aerodynamics - Re-entry vehicles - airframes Issues : - higher edge temperatures
- more oxidation, etc.
Candidate Materials are UHTC’s
(Ultra-High Temperature Ceramics)
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FAILURE OF A LEADING EDGE
Testing of UHTC Edge Segments Resulted in Failures:
Failed test component showing thermocouple hole.
Bad design or a more basic issue?
2 mm
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FAILURE OF A LEADING EDGE
Fractographic investigations indicate that the thermocouple hole was poorly machined:
Crack network on inside walls of the thermocouple hole. Could standards have prevented the failure?
10 mm
6Glenn Research Center at Lewis Field
FAILURE OF A LEADING EDGE
Holes were made via electro-discharge machining.
EDM results in localized surface damage.
No EDM guidelines for ceramics.
Machining techniques in current standards are test specimen specific (e.g. flexure beams).
Literature indicates that other techniques with follow-up treatment could eliminate machining damage.
Need for machining guidelines.
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TEST SPECIMENS FOR A COMBUSTION FACILITY WINDOW
Space Station Fluids and Combustion Facility
Combustion Integrated Rack:
Mission - Supports a wide
range of microgravity
combustion investigations.
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BACKGROUNDCombustion Chamber and Subsystems
Fuel/OxidizerManagement
Assembly (FOMA)• Gas Distribution
• Exhaust Vent
OpticsBench
CombustionChamber
Rack ClosureDoor**
SAMSRTS**
Active RackIsolation
Subsystem(ARIS)*
Environmental Control (ECS)• Air Thermal Control**
• Fire Detection* & Suppression**• Water Thermal Control**
• Gas Interfaces (GN2, VES, VRS)**
Input/OutputProcessor(IOP)**Experiment Specific
Chamber Insert
OpticsBench Slides**
Window Section
4”
9Glenn Research Center at Lewis Field
TEST SPECIMENS FOR A COMBUSTION FACILITY WINDOW
Window is required to transmit 1 to 5 micron IR.
Candidate material is sapphire.
Two sets of test specimens were made according to commonly used scratch-dig specification.
Testing indicated minimal scatter in one test set and substantial scatter in the other set.
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TEST SPECIMENS FOR A COMBUSTION FACILITY WINDOW
Strength and crack growth test results:
Too much scatter to determine crack growth parameters.R-plane set A-plane set
Stress Rate, , MPa/s Stress Rate, , MPa/s
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TEST SPECIMENS FOR A COMBUSTION FACILITY WINDOW
X-ray topography indicate subsurface damage and a “short finish” in one test sets:
Could standards have reduced the scatter?
4 mm
0.20 mm
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TEST SPECIMENS FOR A COMBUSTION FACILITY WINDOW
Scratch-dig specifications do not require removal of damage created during previous polishing stage.
Sufficient removal reduces damage from the early polishing stages:
Guidelines requiring stages of removal should help! Also, a standard for SCG parameters is needed.
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STATUS
SCG Parameters Standard:- Balloted in spring (ASTM)
- Re-ballot in November
Machining Guide:- draft completed
- Needs to be put in the new format
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NASA-RELATED STANDARDS for ADVANCED CERAMICS
ASTM Standards NASA Helped Develop:
C1212 - 98 Practice for Fabricating Ceramic Reference Specimens Containing Seeded Voids
C1239 – 95 Practice for Reporting Uniaxial Strength Data and Estimating Weibull Distribution Parameters
C1368 - 01 Test Method for Determination of Slow Crack Growth Parameters by Constant Stress-Rate Testing
C1421- 01 Test Methods for the Determination of Fracture Toughness of Advanced Ceramics
C1499 - 01 Test Method for Monotonic Equibiaxial Flexural Strength Testing Of Advanced Ceramics
Above Standards used for SSME bearings, FEANICS windows, FCF windows.
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Potential Future Work
Standards of Interest to NASA & ASTM: Determination of the inert strength.
Determination of elevated temperature fracture toughness (proposed).
Determination of elevated temperature monotonic equibiaxial strength.
Equibiaxial strength of very thin plates (fuel cells and substrates).
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SUMMARY
Many NASA missions use advanced ceramic materials (ISS, SSME, RSC).
Standards for advanced ceramics have been and are being developed by NASA, ASTM, and ISO.
A need exists for the development of new standards for advanced ceramics and ceramic composites.