ceramics and ceramic matrix composites in aerospace ... · 1 ceramics and ceramic matrix composites...
TRANSCRIPT
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Ceramics and Ceramic Matrix Composites
in Aerospace Applications
- An Overview
Suraj RawalTechnical Fellow, Advanced Technology Center
Lockheed Martin Space Systems Company
Ceramics Expo 2017
April 25, 2017
2017 Lockheed Martin Corporation. All Rights Reserved
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Outline
• Lockheed Martin Space Systems Company
• Use of Ceramics and CMCs
– Aero-entry Systems• Space Shuttle and other Entry, Descent and Landing Missions
– UHTCs, Insulations and Coatings
– Propulsion Subsystems
– High Temp. Radiators
• Concluding Remarks
– Also Following
• Industry Standards: Uniform reproducible standard products!
• CMC Behavior and Life Prediction Tools, Time Dependent Damage
Progression
• Role of Additive Manufacturing
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Lockheed Martin Business Areas
Missiles and Fire Control
• Air and Missile Defense
• Tactical Missiles
• Fire Control
• Combat Maneuver Systems
• Energy
Space Systems
• Surveillance and Navigation
• Global Communications
• Human Space Flight
• Strategic and Defensive Systems
• Strategic / Operational Command &
Control Systems
Aeronautics
• Tactical Fighters
• Tactical /Strategic Airlift
• Advanced Development
• Sustainment Operations
Rotary and Mission Systems
• Naval Combat Systems
• Radar and Surveillance Systems
• Aviation Systems
• Training and Logistics Solutions
• DOD Cyber Security
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Space Systems Company Portfolio
Special
Programs
Advanced Technology Center
Optics, RF
& Photonics
Adv. Materials
& Nano
Systems
Space
Sciences &
Instruments
Military Space
Protected
Comms
Narrowband
Comms
Early
Warning
Navigation Weather Space
Protection
Commercial Space
Remote
Sensing
Commercial
SATCOM
Wind Energy
Management
Strategic & Missile Defense
Missile DefenseStrategic MissilesAdv Programs
Mission Solutions
End-to-End
Mission
Systems
Geospatial
Technologies
NASA
Civil Space
Weather & Environment
Planetary Exploratio
n
Human Exploration
Subsidiaries
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Shuttle Tile Insulation Invented at
Palo Alto Labs of Lockheed
• 04/79 – LMSC delivered 24,000 Silica
Tiles for the First Shuttle Launch
• 04/12/81 – First Columbia Launch (STS-1)
• 04/04/83 – First Challenger Launch (STS-6)
• 8/30/84 – First Discovery Launch (STS-41)
• 10/03/85 – First Atlantis Launch (STS-51-J)
• 01/28/86 – Challenger Disaster (STS-51-L)
• 05/07/92 – First Endeavour Launch (STS-49)
• 01/11/96 – Endeavor Launch (STS-72)**
• 01/12/97 – Atlantis Launch (STS-81)**
• 02/01/03 – Columbia Disaster (STS-107)
• 7/8-21/11 – Final Launch and Return of Atlantis (STS-135)
• 2012 Atlantis Shuttle Retired
Image courtesy of
http://www2.pictures.zimbio.com/gi/Space+Shuttle+Endeav
our+Launches+Under+Command+U0TBZMF-O_gl.jpg
**Author witnessed launches
View from Cocoa Beach to KSC
Image courtesy of NASA:
http://science.ksc.nasa.gov/shuttle/missio
ns/sts-72/images/high/KSC-96EC-0129.jpg
STS-72 Launch
Image courtesy of NASA:
http://www.nasa.gov/images/content/543367main
_132-launch-m_428-321.jpg
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LI-900 Randomly Oriented Fibers
• 99.9% pure silica fibers
• 94% air by volume
• Overall density is 9pcf
• Fiber diameters range in sizes less than 10 m
• Fiber lengths range from 10’s to several 100 m
• Fibers are “unbonded”
• CTE = 0.5 ppm/ºC
• Tmax = 1250ºC / 2280ºF
• Coating not bonded to substrate
• LI-2200 (22pcf) used in high-stress areas such as landing gear doors and windows
10m
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RCG-Coating on LI-900 Tile
• Glass frit milled with silicon tetraboride and binder in ethanol
• Ball mill 24 hours
• Measure slurry properties
• Apply slurry to tile in continuous, consistent path traces to pre-determined weight (density)
• Dry overnight
• Fuse at 1200ºC for 90 minutes Tiles (also) on
the backshell of
Orion
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Space Shuttle: RCC at LM Facility
• Reinforced Carbon-Carbon (RCC) Developed and
Manufactured at LM facility for Space Shuttle Missions
Space shuttle orbiter leading edge
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Ultra High Temperature Ceramics (UHTCs)
• Collaborated with NASA ARC in the development of UHTCs for Leading Edge applications.
– In-House Developments in Conventional and Eutectic UHTCs
Cracks and Gain Boundary Failure at Indentation
Conventional UHTC
P00081_026
Indentation Creates No Visible Failure Regions
Microstructure of Hot Pressed HfB2-SiC Microstructure of Eutectic HfB2-SiC
10 m 10 m
10 m
Eutectic UHTC
Cracks and Gain Boundary Failure at Indentation
Conventional UHTC
P00081_026
Indentation Creates No Visible Failure Regions
Microstructure of Hot Pressed HfB2-SiC Microstructure of Eutectic HfB2-SiC
10 m 10 m
10 m
Eutectic UHTC
Material Crystal StructureDensity
(gm/cc)
Melting
Temp. (°C)
HfB2 Hexagonal 11.2 3380
HfC Face-Centered Cubic 12.76 3900
HfN Face-Centered Cubic 13.9 3385
ZrB2 Hexagonal 6.1 3245
ZrC Face-Centered Cubic 6.56 3400
ZrN Face-Centered Cubic 7.29 2950
TiB2 Hexagonal 4.52 3225
TaB2 Hexagonal 12.54 3040
TaC Cubic 14.5 3800
TaN Cubic 14.3 2700
SiC Polymorph 3.21Dissociates
2545
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Coatings, Insulations, and Machinable Ceramics
• Evaluated the Family of Damage-Tolerant
Ceramic Materials (Drexel Univ.)
Based on 312, 211 and Other Stoichiometries:
312: Ti3SiC2,
211: Ti2AlC, Ti2AlN
• Often Used Machinable Ceramic
Macor for Insulation Interfaces.
Ceramic
Insulation - Macor
• High Temperature Oxidation Resistant
Coatings on Refractory Composites and
Metals
• UHTC Family Type
• SiC / TEOS (Space Shuttle Heritage)
SiC Coating
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Entry Descent Landing
Extensive History in Entry
Systems
2001
Viking
(SLA)
Mars
Pathfinder
(SLA)
Stardust
(PICA/SLA)
Genesis
(SLA/C-C)
19761999
2003
Mars
Science
Lab
(PICA/SLA)
Mars
Exploration
Rover –
Spirit &
Opportunity
(SLA)
2011
Phoenix
(SLA)
2007
1996
2016
OSIRIS-Rex
(PICA/SLA)
SLA: Superlight Ablator
PICA: Phenolic Impregnated Carbon Ablator
C-C: Carbon-Carbon
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Typical EDL Materials
Heatshield:
• Sandwich Construct
• Gr/Pcn Facesheets
• Aluminum Core
• SLA-561V Ablator
Parachute Cone:
Aluminum Skin Stringer
SLA-220 & SLA-561M
Ablator
Seals:
• HS To BS
• Thrusters
• Sep Fittings
• Vent
Backshell:
• Sandwich
Construct
• Gr/Pcn Facesheets
• Aluminum Core
• SLA-561S Ablator
• White Paint
Heatshield:
• Sandwich Construct
• Gr/Pcn Facesheets
• Aluminum Core
• PICA Tile Ablator
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Propulsion SubSystems:
• Hall Current Thrusters
• Ion Propulsion: Ions created and accelerated in an
Electrostatic Field
• Cathode must be efficient Electron Source
• Anode must be an efficient Electron Sink
• Insulator/Walls: Must maintain Properties
(mechanical, electrical, thermal), Erosion Resistance
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Benefits to (XSS-11 Type) spacecraft:Description:• Cost Effective and Robust Warm Gas
Radiator for Multiple Small Spacecraft • Improved Propulsion (2X) Performance for
Microspacecraft Attitude Control
• 2X Reduction in Weight (Compared to Baseline),
• M&P Validation of Critical Interfaces (Foam/Metal, Foam/ Facesheet, and Foam/Foam)
• C-Foam Core Design: an Enabling
Technology Solution for Plenum Radiator
• High Thermal Conductivity C-Foam
Provides Lightweight and Efficient
Thermal Performance
• Low Conductivity C-Foams at Mounting
Sites
C-Foam Core Radiator for Microspacecrafts
Carbon Foam
925C
300C
High Temp Steel Tubing
ACS
Thruster
@ 150C
Carbon Foam
925C
300C
High Temp Steel Tubing
ACS
Thruster
@ 150C
ACS
Thruster
ACS
Thruster
@ 150C
Technology:
Technology Transition:
• Transitioned to XSS-11, GRAIL, and others
Warm Gas Thruster:Multifunctional Plenum Radiator
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Electrostatic Propulsion: Ion Engine Thrusters
Accomplishments:• Successfully Designed, Fabricated and
Tested 8 cm, 20 cm, and 30 cm. C-C Grids.
• Precision Laser Machining.
• Performed Random Vibration Tests
(@20Grms) 8 cm grids: No Damage,
Perveance Performance Identical to
NSTAR-DS1 Mo-Grids.
Potential USER Systems:
Future High Power NASA Missions (NEXT,
CBIO, NEXIS, JIMO, and NSI programs, and
DoD programs)
Integrated C-C Ion-
Engine Grid System
Objective:
Develop and Demonstrate C-C as a
High-Performance, Cost-Effective,
Erosion-Resistant Grid Material
Benefits:
• Significant increased life (7x)
• Improved ion beam extraction capabilities
• Ease of Alignment and Assembly
• Cost savings (15%)
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TPS Panels For Structural Health Monitoring
TPS-NASP
C-C Panels
- 24” x 24”
- Vertical stiffeners
-- C/SiC Brackets
TPS-Modular CCAT Panel
-12” x 12”
-- Grid Stiffened
-- C/C Brackets
GrafoilGrafoil
Incorporated Impact Damage Sensors
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Concluding Remarks
• Lockheed Martin Uses Ceramics and
CMCs in Different Subsystem
Application
– Aero-entry Systems
– UHTCs, Insulations and Coatings
– Propulsion Subsystems
– Structures and High Temp. Radiators
• In Pace with the advancements in– Industry Standards: Uniform reproducible standard
products!
– Understanding CMC Behavior and Life Prediction
Tools, Time Dependent Damage Progression
– Additive Manufacturing of Ceramics and Challenges
of Insertion
C-C Structural
Radiator [EO-1]
C-C Standard Arc Jet Sample 913 W/cm2C-C Standard Arc Jet Sample 913 W/cm2