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NASA Technical Memorandum 100212

High Temperature Metal Matrix Composites

for Future Aerospace Systems
(NASA-TII- ?OD2 1 2 ) H I G H TEHPERATCIR E 8ETAL 888-10938
M A T R I X COBPOSITES FOR FUTURE AEROSPACE
SYSTERS (NASA) 18 p a v a i l : N T I S BC
A03/HF A01 CSCL 1 I F Unclas
63/26 0 106 4 84

Joseph R. Stephens
Lavis Research Center
Cleveland, Ohio

Prepared for the

ASM Inte&od Ccmqmsb Session
Cincinnati, Ohio, October 13-15, 1987
 H I G H TEMPERATURE METAL MATRIX COMPOSITES

FOR FUTURE AEROSPACE SYSTEMS

Joseph R. Stephens
National Aeronautics and Space A d m i n i s t r a t i o n
Lewis Research Center
Cleveland, Ohio 44135

SUMMARY

The o b j e c t i v e o f o u r research on metal m a t r i x composites and i n t e r m e t a l -

l i c m a t r i x composites i s t o understand t h e i r behavior under a n t i c i p a t e d f u t u r e
o p e r a t i n g c o n d i t i o n s envisioned f o r aerospace power and p r o p u l s i o n systems o f
rl
the 2 1 s t century. Extremes i n environmental c o n d i t i o n s , h i g h temperature,
long o p e r a t i n g l i v e s , and c y c l i c c o n d i t i o n s d i c t a t e t h a t o u r t e s t e v a l u a t i o n s
I
n o t o n l y i n c l u d e l a b o r a t o r y t e s t i n g , b u t simulated f l i g h t c o n d i t i o n s . This
w paper w i l l discuss t h e v a r i o u s processing techniques we employ t o f a b r i c a t e
composites, the b a s i c research,underway t o understand the behavior o f h i g h tem-
p e r a t u r e composites, and r e l a t e some o f t h i s research t o f u t u r e aerospace
sys tems .
INTRODUCTION

Aerospace p r o p u l s i o n and power systems for the 1990s and i n t o t h e 21st

century w i l l p l a c e ever i n c r e a s i n g demands on l o a d bearing m a t e r i a l s . The
emphasis on p u t t i n g g r e a t e r payloads i n t o space, p r o v i d e e l e c t r i c a l power for
space experiments and to meet t h e demands o f manned and unmanned s p a c e c r a f t ,
and t o f l y a t hypersonic v e l o c i t i e s w i l l r e q u i r e m a t e r i a l s t h a t are l i g h t
weight and t h a t can withstand h i g h temperatures for long periods o f t i m e i n
h o s t i l e environments. To meet these demands NASA Lewis Research Center has
undertaken an aggressive research program on advanced m a t e r i a l s t o p r o v i d e a
technology base f o r f u t u r e aerospace systems. A major p o r t i o n of t h i s program
i s focused on metal m a t r i x composites (MMC) and i n t e r m e t a l l i c m a t r i x compos-
i t e s (IMC). I t i s the purpose o f t h i s paper t o describe t h e b a s i c and a p p l i e d
research t h a t we have underway on MMCIIMC technology t o meet the demands of
major NASA and n a t i o n a l programs such as e l e c t r i c a l power systems f o r t h e
Space S t a t i o n ( f i g . 11, engines for advanced Space S h u t t l e s ( f i g . 2 ) , and
engines f o r the National Aerospace Plane (NASP) as i l l u s t r a t e d i n f i g u r e 3.
Each o f the aforementioned programs b r i n g s w i t h i t a s p e c i a l s e t o f opera-
t i o n a l requirements which tax the c a p a b i l i t i e s o f the composite m a t e r i a l s .
For example, as shown i n f i g u r e 4, space power systems for such a p p l i c a t i o n s
as t h e Space S t a t i o n are planned t o operate f o r 7 t o 10 years w i t h v e r y f e w
heat up and cool down cycles and i n the nonaggressive environment o f space.
However, f o r maxlmum power e f f i c i e n c y o p e r a t i n g temperatures may be i n excess
o f 1450 O C (2640 O F ) throughout the l i f e o f t h e power system and l i f e w i l l be
creep l i m i t e d . Low weight i s a premium t o minimize the number of launches
r e q u i r e d t o p u t the power system i n space. Space p r o p u l s i o n systems w i l l be
r e q u i r e d to f u n c t i o n I n t e r m s o f minutes w i t h probably l e s s than 100 c y c l e s ,
b u t i n an extremely aggressive environment which may be e i t h e r reducing or oxi-
d i z i n g throughout the l i f e o f t h e p r o p u l s i o n system depending upon t h e f u e l
and o p e r a t i n g c o n d i t i o n s . Temperatures may go from cryogenic t o i n excess o f
1200 O C (2190 O F ) i n a m a t t e r o f seconds so t h a t thermal-mechanical f a t i g u e
becomes t h e l i f e l i m i t i n g f a c t o r f o r space p r o p u l s i o n systems. I n c o n t r a s t ,
aero p r o p u l s i o n systems w i l l operate f o r thousands o f hours w i t h a s i m i l a r
number o f cycles i n an o x l d i z i n g - c o r r o s i v e environment. To achieve h i g h e f f i -
ciency, m a t e r i a l temperatures may reach 1650 O C (3000 O F ) and w i l l f l u c t u a t e
d u r i n g t h e course o f a f l i g h t by several hundred degrees. Creep-fatigue
becomes t h e l i f e l i m i t i n g c r i t e r i o n for aeropropulsion systems. Lou weight i s
an important c o n s i d e r a t i o n f o r b o t h aero and space p r o p u l s i o n systems i n o r d e r
to enhance payloads.

Metal m a t r i x composites have t h e p o t e n t i a l t o meet these wide v a r i e t y of

requirements as shown i n f i g u r e 5. By s e l e c t i o n o f the proper h i g h tempera-
t u r e f i b e r and combining t h e f i b e r s w i t h an a p p r o p r i a t e m a t r i x , a h i g h tempera-
t u r e , l i g h t weight MMC or I M C can be produced w i t h t h e advantages l i s t e d i n
the f i g u r e . Two major disadvantages f a c i n g these composite m a t e r i a l s a r e t h e
i n t e r d i f f u s i o n between f i b e r and m a t r i x which leads t o degradation of t h e
f i g u r e s t r e n g t h and the d i f f e r e n c e i n thermal expansion between the f i b e r and
m a t r i x which can l e a d t o degradation o f the composite, e s p e c i a l l y under c y c l i c
c o n d i t i o n s . The f o l l o w i n g s e c t i o n s o f t h i s paper w i l l describe t h e processing
techniques t o produce MMC and I M C and describe some o f the experimental
r e s u l t s we have obtained t o date.

COMPOSITE PROCESSING

High temperature MMC and IMC a r e produced a t NASA Lewis p r i m a r i l y by one

o f two processes. The f i r s t o f these i s t h e powder c l o t h technique shown sche-
m a t i c a l l y i n f i g u r e 6. This i s a simple s t r a i g h t f o r w a r d process t h a t makes
use o f t h e m a t r i x m a t e r i a l i n powder form. The metal or i n t e r m e t a l l i c powder
i s mixed w i t h a b i n d e r ( t e f l o n ) and mixed i n a stoddard s o l u t i o n , d r i e d , and
r o l l e d i n t o a t h i n , powder c l o t h . A l t e r n a t e l a y e r s o f powder c l o t h and evenly
spaced, o r i e n t e d f i b e r s a r e stacked, heated i n vacuum t o d r i v e o f f t h e b i n d e r
and s o l u t i o n , and then h o t pressed. This process has t h e advantages of u s i n g
the m a t r i x i n powder form which i s e a s i l y o b t a i n e d from commercial vendors,
employs c o n s o l i d a t i o n equipment t h a t i s common t o a number o f powder metal-
l u r g y companies, and volume f r a c t i o n o f f i b e r content can be c o n t r o l l e d . The
major disadvantage o f t h i s process i s t h e use o f a b i n d e r and s o l u t i o n which
can leave behind d e t r i m e n t a l i m p u r i t i e s d u r i n g t h e processing i f t h e i r removal
i s n o t complete. Typical composites 5 by 15 by 0.075 cm (2 by 6 by 0.030 i n . )
w i t h a f i b e r volume f r a c t i o n o f 40 percent are produced by the powder c l o t h
technique.

The second processing technique which was developed a t NASA Lewis i s the
a r c spray process shown s c h e m a t i c a l l y i n f i g u r e 7. A continuous f i b e r i s
wound on a drum u s i n g a l a t h e t o assure proper spacing. The wound drum i s
i n s e r t e d i n t o a vacuum chamber and subsequently a r c sprayed w i t h t h e d e s i r e d
m a t r i x m a t e r i a l . The m a t r i x m a t e r i a l for t h i s process i s i n t h e form o f
0.16 cm (0.0625 i n . ) w i r e . The w i r e from two spools o f the m a t r i x m a t e r i a l i s
f e d i n t o an a r c spray gun which s t r i k e s an a r c between the two wires and w i t h
h i g h pressure helium or argon, sprays t h e molten metal o n t o t h e f i b e r wound
drum t o form a monotape. Monotapes a r e stacked w i t h d e s i r e d f i b e r o r i e n t a t i o n
and consolidated by h o t p r e s s i n g or h o t i s o s t a t i c p r e s s i n g (HIPing). This
process has the advantages o f producing a clean, h i g h p u r i t y composite f r e e o f

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 extraneous m a t e r i a l s , i s economical, and s i z e i s l i m i t e d o n l y by t h e s i z e of
the vacuum chamber and t h e drum. Monotapes 0.4 by 1.0 by 0.004 m (16 by 40 by
0.015 i n . ) have been produced by t h i s process. The p r i m a r y disadvantage of
the a r c spray process i s t h e requirement t h a t the m a t r i x m a t e r i a l be i n t h e
form o f w i r e which i n t h e case of i n t e r m e t a l l i c compounds, i s n o t always tech-
n i c a l l y feasible.

A t h i r d process being adapted to producing composites i s the plasma spray

technique shown schematically i n f i g u r e 8. This process has t h e advantages o f
u s i n g t h e m a t r i x m a t e r i a l i n powder form and does n o t r e q u i r e t h e use o f bind-
ers. Because o f t h e use o f small diameter p a r t i c l e s a t h i g h temperatures, oxy-
gen contamination may be a problem e s p e c i a l l y w i t h t h e h i g h l y r e a c t i v e i n t e r -
m e t a l l i c compounds such as t h e aluminides. Because o f the many v a r i a b l e s i n
t h i s process such as t o r c h design, t o r c h o p e r a t i o n , and powder c h a r a c t e r i s -
t i c s , automation and process c o n t r o l a r e needed t o i n s u r e u n i f o r m r e p r o d u c i b l e
compos1t e s .
Each o f these processes a r e f o l l o w e d by a c o n s o l i d a t i o n process such as
h o t p r e s s i n g or HIPing. I t i s normal to prepare f l a t p l a t e s o f u n i d i r e c -
t i o n a l , c r o s s p l y , or a n g l e p l y composites. I n a d d i t i o n , tubes and more compl i-
cated geometries can be produced by t h e H I P technique. Composite f a b r i c a t i o n
holds the key t o producing a successful composite m a t e r i a l . C o n s o l i d a t i o n i s
. a time-temperature-pressure process ( f i g . 9) where t h e f a b r i c a t i o n parameters
must be s u f f i c i e n t t o c o n s o l i d a t e and completely f i l l t h e m a t r i x around t h e
f i b e r and to bond the f i b e r t o t h e m a t r i x . I n s u f f i c i e n t time, temperature, or
pressure w i l l n o t a l l o w c o n s o l i d a t i o n o f the composite. Excessive time or tem-
p e r a t u r e can cause increased f i b e r - m a t r i x r e a c t i o n and thus f i b e r s t r e n g t h deg-
r a d a t i o n , w h i l e excessive pressure can cause f i b e r breakage and m a t r i x
squeeze-out. O p t i m i z a t i o n o f the process chosen f o r each composite m a t e r i a l
p l a y s a major p a r t of our research program.
A f i n a l area t h a t we our beginning t o address i n o u r research programs i s
the j o i n i n g o f composite m a t e r i a l s . I n o r d e r t o a p p l y advanced composites,
a c t u a l s t r u c t u r e s w i l l have t o be f a b r i c a t e d . Figure 10 s e t s f o r t h t h e prob-
l e m i f proper design o f t h e j o i n t i s n o t taken i n t o c o n s i d e r a t i o n . Several
techniques a r e shown t h a t a r e being explored t o overcome t h i s problem.

FUNDAMENTAL RESEARCH

Advanced f i b e r s . - Since the f i b e r provides t h e c h a r a c t e r i s t i c s t h a t dom-

i n a t e the s t r e n g t h , s t i f f n e s s , and c o n d u c t i v i t y o f a composite, s u p e r i o r
f i b e r s need t o be developed. Two p a r t i c u l a r concerns are the chemical compati-
b i l i t y between f i b e r and m a t r i x and t h e i r thermal expansion mismatch ( f i g . 1 1 ) .
We p l a n t o i n v e s t i g a t e new h i g h temperature f i b e r s by growing s i n g l e c r y s t a l s
u s i n g a l a s e r f l o a t i n g zone apparatus which operates as shown i n f i g u r e 12.
F i b e r s w i t h h i g h m e l t i n g p o i n t s and thermal expansions s i m i l a r t o those o f the
matrices t h a t are o f i n t e r e s t w i l l be grown and evaluated f o r h i g h temperature
s t r e n g t h , modulus, and c o m p a t i b i l i t y w i t h v a r i o u s matrices.

M a t r i c e s . - I n t e r m e t a l l i c compounds o f f e r h i g h m e l t i n g p o i n t s , l i g h t
weight, and i n the case o f aluminides and s i l i c i d e s good o x i d a t i o n r e s i s t a n c e
f o r aero p r o p u l s i o n systems as i l l u s t r a t e d f o r n i c k e l aluminide i n f i g u r e 13.

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Alloying and thermomechanical processing a r e underway t o understand f a c t o r s
t h a t may improve the low temperature d u c t i 11 t y and h i g h temperature s t r e n g t h
o f these m a t e r i a l s . Figure 14 shows t h a t strengthening o f N i A l can be
achieved by a l l o y i n g t o form a second phase w i t h i n the aluminide g r a i n s .
Other m a t r i c e s t h a t are c u r r e n t l y being explored i n c l u d e FeA1, Ti3A1 + NbA13.
For space power and p r o p u l s i o n copper, n i c k e l , and i r o n a l l o y s along w i t h t h e
r e f r a c t o r y metals are being explored as matrices. I n p a r t i c u l a r molybdenum-
base a1 loys are under i n v e s t i g a t i o n t o improve t h e i r h i g h temperature s t r e n g t h
and increase t h e i r f a b r i c a b i l i t y so t h a t they may be used as e i t h e r f i b e r s or
m a t r i ces.
F i b e r - m a t r i x i n t e r a c t i o n s . - Chemical r e a c t i o n s or i n t e r d i f f u s i o n between
f i b e r and m a t r i x can degrade composite p r o p e r t i e s due t o the f o r m a t i o n o f b r i t -
t l e phases a t the i n t e r f a c e or the l o s s o f e f f e c t i v e f i b e r diameter w i t h
extended exposure t i m e s . Figure 15 shows the r e a c t i o n zone i n S I C r e i n f o r c e d
FeAl composi t e . Determination o f r e a c t i o n k i n e t i c s as i l l u s t r a t e d i n f i g u r e
16 and e f f e c t on p r o p e r t i e s i s c u r r e n t l y underway in-house and v i a o f a Unlver-
s i t y Grant. Modeling o f the i n t e r a c t i o n s i s a l s o being conducted and the
e f f e c t s on p r o p e r t i e s w i l l be p r e d i c t e d from these models. S i m i l a r s t u d i e s
a r e underway on r e f r a c t o r y metal composi t e s .

Environmental r e s i s t a n c e . - As mentioned p r e v i o u s l y , the aluminides and

s i l i c i d e s have e x c e l l e n t o x i d a t i o n r e s i s t a n c e due t o t h e f o r m a t i o n o f adherent
A1203 and S i 0 2 scales, r e s p e c t i v e l y . However, even t h e s e m a t e r i a l s are l i m -
i t e d by temperature and c y c l i c c o n d i t i o n s such t h a t Improvement i n o x i d a t i o n
r e s i s t a n c e i s d e s i r a b l e so t h a t these m a t e r i a l s can be used i n advanced aero
p r o p u l s i o n systems. A l l o y i n g t o improve o x i d a t i o n r e s i s t a n c e i s underway as
shown i n f i g u r e 17. Fundamental o x i d e mapping s t u d i e s w i l l a i d i n the develop-
ment o f t e r t i a r y a d d i t i v e s t o s t a b i l i z e the o x i d e scales. Dopants such as Zr,
H f , and Y may h e l p reduce oxide s p a l l i n g . External o x i d a t i o n r e s i s t a n t coat-
i n g s and thermal b a r r i e r coatings w i l l be explored t o f u r t h e r improve the oxi-
dation resistance o f the matrix materials.

APPLIED RESEARCH ,

Tungsten/niobium composi t e s . - Space power systems f o r f u t u r e NASA m i s -

sions a r e under develoDment t h a t w i l l r e q u i r e hundreds o f k l l o w a t t s o f elec-
t r i c i t y . To meet these demands o p e r a t i n g temperatures f o r the power sources
a r e contemplated t o be near 1500 O C (2700 O F ) . To achieve the l o n g l i f e o f 7
t o 10 years r e f r a c t o r y metal composites appear t o h o l d promise. Figure 18
i l l u s t r a t e s t h i s p o t e n t i a l based on h i g h temperature t e n s i l e t e s t s o f 40 v o l X
f i b e r s . Long-term creep r u p t u r e t e s t i n g i s underway on these composites and
f i b e r - m a t r i x i n t e r a c t i o n s t u d i e s a r e being modeled.

Tungsten/copper composites. - Copper i s a t t r a c t i v e f o r heat t r a n s f e r

a m l i c a t i o n s because o f i t s h i g h thermal c o n d u c t i v i t y . However, i t s low
s t i e n g t h a t elevated temperatuies 1 i m i t s i t s u t i 11 ty-. Reinforcement w i t h h i g h
s t r e n g t h tungsten f i b e r s can overcome the l a c k o f s t r e n g t h problem and i f h e l d
t o a low volume percent, loss i n thermal c o n d u c t i v i t y w i l l be minimized. An
a p p l i c a t i o n for t h i s composite i s i n the Space S h u t t l e combustion l i n e r as
i l l u s t r a t e d i n f i g u r e 19. A p r o t o t y p e combustion l i n e r has been t e s t e d i n one
o f our r o c k e t engine t e s t f a c i l i t i e s and survived over 400 f i r i n g s o f the
r o c k e t engine which i s over t w i c e the l i f e o f OFHC copper and equal t o t h a t o f

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the c u r r e n t copper a l l o y now I n use on t h e Space S h u t t l e Main Engine. We hope
t o f u r t h e r improve upon t h i s r e s u l t by m o d i f i c a t i o n s o f t h e processing of the
composite m a t e r i a l and a redesign of t h e t e s t chamber.

S i l i c o n c a r b i d e / t i t a n i u m aluminide composites. - The l i g h t weight, h i g h

m e l t i n g p o i n t o f Ti3Al makes i t an a t t r a c t i v e candidate m a t e r i a l f o r a i r c r a f t
p r o p u l s i o n systems. Research by the A i r Force has shown t h a t Nb a d d i t i o n s
improve t h e room temperature d u c t i l i t y of t h i s m a t e r i a l . Reinforcement by a
h i g h - s t r e n g t h l i g h t - w e i g h t f i b e r o f f e r s the p o t e n t i a l o f f u r t h e r i n c r e a s i n g
t h e use temperature o f t h i s m a t e r i a l . Results o f t e n s i l e t e s t i n g n a i r have
shown t h e advantage of t h i s composite over s u p e r a l l o y s as shown i n f i g u r e 20.
Again f i b e r - m a t r i x I n t e r a c t i o n I s o f concern for l o n g t e r m use and as shown i n
f i g u r e 21 t h i s composite may be l i m i t e d t o about 980 O C (1800 O F ) . Thermal
expansion mismatch between f i b e r and m a t r i x may f u r t h e r be a l i m i t ng
c r i t e r i o n for the aluminide composite m a t e r i a l .

CONCLUDING REMARKS

Metal m a t r i x and i n t e r m e t a l 1 i c m a t r i x composites o f f e r some unique

combinations of m a t e r i a l p r o p e r t i e s for f u t u r e aerospace power and p r o p u l s i o n
systems. NASA Lewis along w i t h o t h e r government l a b o r a t o r i e s , n a t i o n a l
l a b o r a t o r i e s , and i n d u s t r i a l l a b o r a t o r i e s are addressing t h e issues t h a t may
be c r l t i c a l to t h e i r appl i c a t i o n as h i g h temperature s t r u c t u r a l m a t e r i a l s .
C e r t a i n l y advanced f i b e r development i s a t t h e t o p o f t h i s l i s t . Thermal
expansion mismatch, f i b e r - m a t r i x c o m p a t i b i l i t y , thermal c y c l i n g , and environ-
mental r e s i s t a n c e a l l have to be addressed f o r each MMC and I M C under condi-
t i o n s a n t i c i p a t e d f o r t h e i r use. Our research i s focused on these issues for
a v a r i e t y of composite m a t e r i a l s under a broad range o f proposed o p e r a t i n g
cond it i ons .

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 FIGURE 1. - ARTIST'S CONCEPTION OF THE SP-100 NUCLEAR POWER SOURCE FOR THE SPACE STATION.

CS-80-2107

FIGURE 2. - SCHEMATIC REPRESENTATION OF THE SPACE SHUTTLE MAIN ENGINE.

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 P
6-
R
P

FIGURE 3. - ARTIST’S RENDERING OF THE NATIONAL AEROSPACE PLANE.

SPACE SPACE AERO

REQUIREMENT POWER PROPULSION PROPULSION
LIFE >SEVEN YEARS MINUTES THOUSAND(S) HOURS
CYCLES <TEN > FIFTY THOUSANDS
ENVIRONMENT VACUUM REDUClNGlOXlDlZlNG OXIDIZING
TEMPERATURE HIGH, SUSTAINED BURST VARIABLE
WEIGHT LOW LOW LOW
LIFE CONTROLLED CREEP FATlGUE CREEP-FATIGUE
BY STRESS

CD-87-28892
FIGURE 4. - FUTURE REQUIREMENTS IMPOSED UPON METAL MATRIX COMPOSITES.

7
 uuuuu
FIBERS

HIGH STRENGTH
HIGH MODULUS
HIGH TEMPERATURE
CAPABILITY
+ El
MATRIX

PROCESSABLE
BONDS WELL
TO FIBERS
ENVIRONMENTAL
=o COMPOSITE

ADVANTAGES
CAN TAILOR PROPERTIES
HIGH STRENGTH
HIGH STIFFNESS
RESISTANCE
DUCTILITY
DUCTILE
DISADVANTAGES
SOMETIMES DEGRADED BY
INTERDIFFUSION
CAN NOT ALWAYS MATCH
THERMAL EXPANSIONS

FIGURE 5. - PYTAL MTRIX COMPOSITES CONCEPT LISTING THEIR ADVANTAGES AND DISADVANTAGES.

TITAN IUM
ALUM1N I DE
POWDER

+ TEFLON POWDER

+ STODDARD SOLUTION

MIX - PRESSURE
HEAT
HEAT ROLL = POWDER CLOTH

POWDER
CLOTH
TEFLON AND

ORIE:NTED
Sic FIBERS
ISTODDARD
DRIVEN OFF
IN VACUUM S i C/T i jA I +N b COMPOSITE

4 CD-87-27598

FIGURE 6. - POWDER CLOTH TECHNIQUE USED TO PRODUCE INTERHETALL IC MTR IX COMPOSITES,

8
 ARC SPRAY HEAD

OVERALL VIEW SCHEMATIC OF OPERATION

(30-87-26390

FIGURE 7. - ARC SPRAY TECHNIQUE USED TO PRODUCE METAL MATRIX COMPOSITES.

r ANODE
/

GAS

-.
WATER COOLING-’ {/ y,/;
I /
I
POWER A’
WORK PIECE^
FIGURE 8. - PLASMA SPRAY TECHNIQUE PLANNED FOR PREPARING METAL
MATRIX AND INTERMETALLIC MATRIX COMPOSITES.

OPTIMUM
INSUFFICIENT CoNDITloNSEXCESSIVE

PROCESSING PARAMETER
(TEMPERATURE, TIME, PRESSURE)

CD-87-26403

FIGURE 9. - OPTIMIZATION OF FABRICATION PARAMETERS I S CRITICAL TO

ACHIEVING MAXIMUM PROPERTIES.

9
 FIBER
PROBLEM
FIBERS CARRY MAJOR PORTION OF LOAD
IN COMPOSITES. JOINT CAN REPRESENT A
LINE OF DISCONTINUITY IN FIBERS THAT A
CAN RESULT IN LOW STRENGTH JOINT

SOLUTION
LOCATE JOINTS IN LOWER STRESS AREAS.
DESIGN JOINT TO PROVIDE TRANSFER OF LOAD FROM FIBER TO FIBER
ACROSS JOINT SUCH AS:

I
J
SCARF TONGUE IN GROOVE
DOUBLER PLATES

CD-87-26402

FIGURE 10. - SUGGESTED JOINING SCHEMES TO ACHIEVE A STRONG BOND IN COMPOSITE MATERIALS.

THERMAL CYCLING EFFECTS INCREASED BY

THERMAL EXPANSION MISMATCH
ADDITIONAL STRAIN = (cYM-cYF) AT
(30-87-26412

FIGURE 11. - THERMAL EXPANSION fiISMATCH BETWEEN FIBER AND

MATRIX WILL LIMIT THERMAL CYCLIC RESISTANCE OF NETAL MATRIX
COMPOSITES.

10
 ,rFEED ROD

c
F,BER40440fi
MOLTEN
SEED ZONE
CRYSTAL SEED CRY
TOUCHES MOLTEN DROP
It1 TO START CRYSTAL
1 ' 1 GROWTH
FEED ROD INTERSECTS SINGLE CRYSTAL FIBER
LASER BEAMS TO INITIATE PULLED FROM MOLTEN
MELTING CD-87-26399 ZONE BY SEED FIBER
FIGURE 12. - LASER FIBER GROWTH FACILITY WILL BE USED TO GROW ADVANCED FIBERS.

ALUMINUM-NICKEL PHASE DIAGRAM

WEIGHT PERCENT NICKEL
10203040 50 80 70 8 0 8 5 90 95 ADVANTAGES
3Ooo 0 HIGH MELTING POINT
2800
LIGHT WEIGHT
2600
0 OXIDATION RESISTANT
2100
WIDE COMPOSITION RANGE
2200
0 ALLOYING POTENTIAL
Zoo0
TEMPERA- TEMPERA.
1800 TURE,
TURE,
F 1600
OF DISADVANTAGES
1100 0 LACK OF ROOM TEMPERATURE
1200 DUCTILITY
. ..

300 LACK OF HIGH TEMPERATURE

2w 400 STRENGTH
100 2w

'0 10 20 30 40 50 80 70 80 90 100
AI Ni
ATOMIC PERCENT NICKEL

FIGURE 13. - PHASE DIAGRAM FOR THE NICKEL ALUMINUM SYSTEM SHOWING THE HIGH K L T I N G
TEWERATURE OF THE EQUIATOMIC INTERMETALLIC COMPOUND.

11
 250 I-

V BEST NIAL ALLOY

W
\

a 150

E
z
L
100-

\ ,
W
n
2 NIAL BINARY
5 50 -
0

HIGH CARBON ’;’ LREACTION ZONE

FIBER REACTION IN MATRIX
COATING J‘ ZONE
I N FIBER CD-87-26392

FIGURE 15. - FIBER-MATRIX INTERACTION CAN OCCUR

DURING PROCESSING OF A COMPOSITE.

12
 REACTION DEGRADES EFFECTS OF I / T3
PROPERTIES TIME I /
TEMPERATUREE
T3>T2>T1
7n.m

THE^ I T1
I
EXPOSURE TIME -w
FIBER REACTION MATRIX
COMPOSITION 1 #GA” 1 ‘ONE 1
/
REACTION
ZONE
\

FIBER

COMPOSITION, 1 1 “X”

,,y,,
TO MINIMIZE REACTION
46
TAILOR MATRIX COMPOSITION
INCREASE FIBER DIAMETER
LOWER FABRICATION TEMPERATURE LdG!z&
DISTANCE FROM FIBER CENTER -+
CD 85-17554

FIGURE 16. - UNDERSTANDING OF FIBER-MATRIX INTERDIFFUSION CAN HELP TO MINIMIZE INTERACTIONS.

50
Cr iNON PROTECTIVE OXIDES
\
’
100
Ni,Fe,Co
CD-87-26409

FIGURE 17. -UNDERSTANDING OF ALLOYING EFFECTS ON OXIDATION

OF INTERMETALLICS I S ESSENTIAL TO THEIR USE AT HIGH TEMPERA-
TURES I N GAS TURBINE ENGINES.

13
 FABRICATED USING ARCSPRAY PROCESS INVENTED AT NASA-LEWISRESEARCH CENTER
-

-
ST300-W HIGH STRENGTH TUNGSTEN WIRE WH .5% Tho2
-
218CS-W COMMERCIAL TUNGSTEN LAMP FILAMENT WIRE
MICROSTRUCTURE OF 35 vlo ST300-WINb-lZr COMPARISON OF TENSILE STRENGTHlDENSlTY
COMPOSITE AT 50X MAGNIFICATION RATIOS OF WlUNALLOYED Nb COMPOSITES
WITH CONVENTIONAL Nb ALLOYS
200x103
ST3WWNb

UTSIDENS, 100
in.

-
UNALLOYED Nb
0
1200 1400 1600
TEMPERATURE, K
I I I

1800 2000 2200

TEMPERATURE, OF

CD-86-18%4

FIGURE 18. - REFRACTORY METAL COMPOSITES HOLD PROMISE FOR SPACE POWER SYSTEMS.

THE PROBLEM PROPOSED FIX

ENLARGE0 SECTION OF FAILURE TUNGSTENKOPPER COMPOSITE
COMPOSITE COMBINES 1.8 x STRENGTH WITH
SIMILAR THERMAL CONDUCTIVITY

I
I
n
1

'4

I PURE

-TUNGSTEN
FIBER

CD-S-I7%4

FIGURE 19. - TUNGSTEN REINFORCED COPPER MAY HELP SOLVE COMBUSTION LINER FAILURES I N THE SPACE SHUTTLE
MAIN ENGINE.

14
 SiC/TijAI+Nb
1400
---- (40 VOL X SIC)
NASAIR (100)
1200 SINGLE CRYSTAL
274 SUPERALLOYS RANGE (WROUGHT)
1000

800

600

400 .

200 .

0 400 800 1200 1600 2000

TEMPERATURE, OF
CD-87-27597

FIGURE 20. - LIGHT-WEIGHT SILICON CARBIDE REINFORCED TITANIUM ALUMINIDE

COMPOSITES OFFER STRENGTH ADVANTAGES OVER CONVENTIONAL MATERIALS.

RESULTS INDICATE FIBERAATRIX INTERACTION

WILL PROBABLY LIMIT USE TEMPERATURE TO
1800 OF FOR EXTENDED-LIFE APPLICATIONS

FIGURE 21. - UNDERSTANDING FIBER-MATRIX COMPATIBILITY CAN HELP DEFINE MAXIMUM USE TEMPERATURES OF COMPOSITES.

15
 Report Documentation Page
1. Report No. 2. Government Accession No. 3. Recipient's Catalog No.

NASA TM-100212
4. Title and Subtitle 5. Report Date

Hlgh Temperature Metal Matrlx Composites

for Future Aerospace Systems 6. Performing Organization Code

7. Author(s) 8. Performing Organization Report No.

Joseph R. Stephens E-382 1

10. Work Unit No.

505-63-01
! 9. Performing Organization Name and Address
' National Aeronautics and Space Administration
11. Contract or Grant No.

Lewis Research Center

Cleveland, Ohio 441 35-31 91 13. Type of Report and Period Covered

12. Sponsoring Agency Name and Address

Technical Memorandum
National Aeronautics and Space Administration 14. Sponsoring Agency Code
Washington, D.C. 20546-0001

15. Supplementary No=

Prepared for the ASM International Composite Session, Cincinnati, Ohio,

October 13-15, 1987.

16. Abstract
The objective o f our research o n metal matrix composites and intermetallic matrix
composites is t o understand their behavior under anticipated future operating con
ditions envisioned for aerospace power and propulsion systems of the 21st century
Extremes in environmental conditions, high temperature, long operating lives, and
cyclic conditions dictate that our test evaluations not only include laboratory
testing, but simulated flight conditions. This paper will discuss the various
processing techniques we employ t o fabricate composites, the basic research under
way t o understand the behavior of high temperature composites, and relate some of
this research t o future aerospace systems.

17. Key Words (Suggested by Author@)) 18. Distribution Statement

Metal matrix composites; Processing; Unclassified - Unlimited
Space power ; Space propul s ion ; Subject Category 26
Aeropropulsion

19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No of pages 22. Price'
Uncl ass if i e'd Unclassified 76 A02
NASA FORM 1626 OCT 86
'For sale by the National Technical Information Service, Springfield, Virginia 22161