Abstract for Invited Talk in Cocoa Beach 2006 International Conference

Robust Joining and Integration Technologies for Advanced Metallic, Ceramic, and Composite Systems

M. Singh, Tarah Shpargel QSS Group, Inc., NASA Glenn Research Center

Cleveland, OH 44135

G.N. Morscher Ohio Aerospace Institute, NASA Glenn Research Center

Cleveland, OH 44135

Michael Halbig US Army Propulsion Directorate NASA Glenn Research Center

Cleveland, OH 44135

Rajiv Asthana University of Wisconsin-Stout

Minomnee, WI

Robust integration and assembly technologies are critical for the successful implementation of advanced metallic, ceramic, carbon-carbon, and ceramic matrix composite components in a wide variety of aerospace, space exploration, and ground based systems. Typically, the operating temperature of these components varies from few hundred to few thousand Kelvin with different working times (few minutes to years). The wide ranging system performance requirements necessitate the use of different integration technologies which includes adhesive bonding, low temperature soldering, active metal brazing, diffusion bonding, ARCJoinT, and ultra high temperature joining technologies. In this presentation, a number of joining examples and test results will be provided related to the adhesive bonding and active metal brazing of titanium to C/C composites, diffusion bonding of silicon carbide to silicon carbide using titanium interlayer, titanium and hastelloy brazing to silicon carbide matrix composites, and ARCJoinT joining of SiC ceramics and SiC matrix composites. Various issues in the joining of metal-ceramic systems including thermal expansion mismatch and resulting residual stresses generated during joining will be discussed. In addition, joint design and testing issues for a wide variety of joints will be presented.

https://ntrs.nasa.gov/search.jsp?R=20070017912 2018-05-22T13:12:25+00:00Z

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910

∆α= α

(Ti)

–α

(C/C

)

∆T =

T (l

iqui

dus

~ pr

oces

sing

) –25

o C

21G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Act

ive

Met

al B

razi

ng o

f C

/C F

ace

Shee

t/Poc

oFo

am/T

itani

um S

yste

m

CuS

il-A

BA

Bra

ze A

lloy

C/C

Poc

oFo

am

Bra

zed

Join

ts

Poc

oFo

amTi

22G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Loca

tions

of P

oten

tial J

oint

Fai

lure

in

C/C

Fac

e Sh

eet/P

oco

Foam

Sad

dle/

Tita

nium

C/C

Sadd

le

Ti

Join

ing

mat

eria

l (JM

)Jo

inin

g m

ater

ial (

JM)

C/C

–JM

inte

rface

JM –

Sad

dle

inte

rface

With

in J

M

With

in J

MC

/C –

JM in

terfa

ce

With

in C

/C

With

in T

i

With

in S

addl

e

In a

dditi

on th

e ge

omet

ry o

f joi

ning

sur

face

s w

ill a

ffect

stre

ngth

of j

oint

and

in

fluen

ce s

prea

ding

of j

oint

mat

eria

l: fla

t to

flat,

flat t

o tu

be, c

urve

d su

rface

s…Th

eref

ore,

kno

win

g th

e lo

catio

n of

join

t fai

lure

is c

ritic

al•W

eake

st li

nk re

quiri

ng fu

rthe

r im

prov

emen

t•A

ffect

s in

terp

reta

tion

of re

sults

(mat

eria

l or t

est-d

epen

dent

pro

pert

y)

Key

fact

or: B

onde

d ar

eadi

ctat

ed b

y br

aze

com

posi

tion

and

appl

ied

pres

sure

, C

/C c

onst

ituen

t com

posi

tion,

fibe

r orie

ntat

ion,

geo

met

ry o

f joi

ned

surfa

ce

23G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Diff

usio

n B

ondi

ng o

f Sili

con

Car

bide

U

sing

Met

allic

Inte

rlaye

rs

24G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Mul

ti-Po

int L

ean

Dire

ct In

ject

or

(Lef

t) M

ulti-

Poi

nt L

ean

Dire

ct In

ject

or a

ccel

erat

es fu

el-a

ir m

ixin

g an

d ha

s sm

all r

ecirc

ulat

ion

zone

s w

ith s

hort

resi

denc

e tim

e th

at re

duce

s N

Ox

emis

sion

. (C

ente

r) 3

-inch

squ

are

met

al M

P-L

DI w

ith 4

5 in

ject

ors.

(Rig

ht) D

etai

l of f

uel a

nd a

irflo

w.

From

Rob

ert T

acin

a, e

t al.,

“A

Low

Lea

n D

irect

In

ject

ion,

Mul

ti-Po

int I

nteg

rate

d M

odul

e Co

mbu

stor

Con

cept

for A

dvan

ced

Airc

raft

Gas

Tur

bine

s,”N

ASA

/TM

-200

2-21

1347

, Apr

il 20

02.

Sw

irler

25G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Lean

Dire

ct In

ject

or F

abric

ated

by

Lam

inat

es

SiC

lam

inat

es c

an b

e us

ed to

cre

ate

intri

cate

and

inte

rlace

d pa

ssag

es to

spe

ed

up fu

el-a

ir m

ixin

g to

allo

w le

an-b

urni

ng, u

ltra-

low

em

issi

ons. K

ey T

echn

olog

ies:

•Bon

ding

of S

iC to

SiC

•Bra

zing

of S

iC to

M

etal

lic (K

ovar

) Fue

l Tu

bes

Ben

efits

of L

amin

ated

Pla

tes

-Pas

sage

s of

any

sha

pe c

an b

e cr

eate

d to

allo

w fo

r mul

tiple

fuel

circ

uits

-Pro

vide

s th

erm

al p

rote

ctio

n of

the

fuel

to p

reve

nt c

hoki

ng-L

ow c

ost f

abric

atio

n of

mod

ules

with

com

plic

ated

inte

rnal

geo

met

ries

thro

ugh

chem

ical

et

chin

g

26G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Mic

ropr

obe

of α

-SiC

Rea

ctio

n B

onde

d U

sing

Ti F

oil

Con

ditio

ns: 1

250 ˚C

, 24

MPa

, 2 h

r, va

cuum

, 5 ˚C

/min

Mic

rocr

acki

ng m

ay b

e du

e to

the

form

atio

n of

two

detri

men

tal p

hase

s:

•Pha

se B

Ti 5S

i 3CX

–Ti

5Si 3

if hi

ghly

ani

sotro

pic

in it

s th

erm

al e

xpan

sion

whe

re

CTE

(c)/C

TE(a

) = 2

.72

(Sch

neib

el e

t al).

•Pha

se E

–Ti

3Al h

as lo

w

duct

ility

at lo

w

tem

pera

ture

s. A

l can

be

in

the

rang

e of

23-

35 a

tm %

(D

jana

rthan

y et

al).

Bot

h ph

ases

can

co

ntrib

ute

to th

erm

al

stre

sses

and

m

icro

crac

king

dur

ing

cool

dow

n.

27G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Mic

ropr

obe

of C

VD S

iC R

eact

ion

Bon

ded

Usi

ng P

VD T

iC

ondi

tions

: 125

0 ˚C

, 31

MPa

, 2 h

r, va

cuum

, 5 ˚C

/min

The

unde

sira

ble

phas

es o

f Ti 5S

i 3an

d Ti

3Al w

ere

not

form

ed.

No

mic

rocr

acks

are

ob

serv

ed.

Iden

tity/

sour

ce o

f th

e bl

ack

phas

e or

vo

ids

still

nee

ds to

be

det

erm

ined

.

28G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Initi

al S

tren

gth

Test

s on

Diff

usio

n B

onde

d C

VD S

iC w

ith a

PVD

Ti I

nter

laye

r

Initi

al p

ull t

est t

ensi

le s

treng

ths:

> 23

.62

MP

a (3

.43

ksi)*

> 28

.38

MP

a (4

.12

ksi)*

* fa

ilure

in th

e ad

hesi

ve

The

inje

ctor

app

licat

ion

requ

ires

a st

reng

th o

f abo

ut 3

.45-

6.89

MP

a (0

.5 -

1.0

ksi).

The

new

1”s

ampl

e de

sign

(par

tially

coa

ted

disk

s) w

ill a

llow

for s

tress

es o

f 62

MP

a (9

ksi

) to

be a

pplie

d (d

ue to

a la

rge

adhe

sive

/pul

l are

a co

mpa

red

to th

e di

ffusi

on b

ond

area

).

29G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Join

ing

of A

dvan

ced

Cer

amic

s an

d C

ompo

site

s-M

onol

ithic

SiC

Cer

amic

s-F

iber

Rei

nfor

ced

Com

posi

tes

30G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Join

ing

of C

eram

ic C

ompo

nent

s U

sing

A

fford

able

, Rob

ust C

eram

ic J

oini

ng T

echn

olog

y(A

RC

Join

T)

Affo

rdab

le a

nd R

obus

t C

eram

ic J

oint

s w

ith

Tailo

rabl

ePr

oper

ties

App

ly S

ilico

n or

Sili

con-

Allo

y(p

aste

, tap

e, o

r slu

rry)

Hea

t at 1

250-

1425

°C

for 1

0 to

15

min

utes

1999

R&

D 1

00 A

war

d 19

99 R

&D

100

Aw

ard

2000

20

00 N

orTe

chN

orTe

chIn

nova

tion

Aw

ard

Inno

vatio

n A

war

d

App

ly C

arbo

nace

ous

Mix

ture

to J

oint

Are

asC

ure

at 1

10-1

20°C

for

10 to

20

min

utes

Adv

anta

ges

•Joi

nt in

terla

yer p

rope

rtie

s ar

e co

mpa

tible

w

ith p

aren

t mat

eria

ls.

•Pro

cess

ing

tem

pera

ture

aro

und

1200

-14

50°C

.•N

o ex

tern

al p

ress

ure

or h

igh

tem

pera

ture

to

olin

g is

requ

ired.

•Loc

aliz

ed h

eatin

g so

urce

s ca

n be

util

ized

.•A

dapt

able

to in

-fiel

d in

stal

latio

n, s

ervi

ce,

and

repa

ir.

31G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

AR

CJo

inT

is C

urre

ntly

Bei

ng U

sed

to J

oin

and

Rep

air

a W

ide

Varie

ty o

f Cer

amic

and

Com

posi

te M

ater

ials

AR

CJo

inT

AR

CJo

inT

SiC

-Bas

ed C

eram

ics

•Rea

ctio

n B

onde

d Si

C•S

inte

red

SiC

•CVD

SiC

, Por

ous

SiC

SiC

/SiC

Com

posi

tes

•Mel

t Inf

iltra

ted

SiC

/SiC

•CVI

SiC

/SiC

Com

posi

tes

•PIP

SiC

/SiC

Com

posi

tes

C/S

iCC

ompo

site

s•M

elt I

nfilt

rate

d C

/SiC

•CVI

C/S

iCC

ompo

site

s•P

IP C

/SiC

Com

posi

tes

C/C

Com

posi

tes

•CVI

C/C

Com

posi

tes

•Res

in D

eriv

ed C

/C•C

-C/S

iCw

ith M

I

•C

ompo

site

s w

ith D

iffer

ent F

iber

Arc

hite

ctur

es a

nd S

hape

s C

ompo

site

s w

ith D

iffer

ent F

iber

Arc

hite

ctur

es a

nd S

hape

s ••

Cer

amic

s w

ith D

iffer

ent S

hape

s an

d Si

zes

Cer

amic

s w

ith D

iffer

ent S

hape

s an

d Si

zes

32G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Tech

nica

l Cha

lleng

es in

Des

ign

and

Sele

ctio

n

of J

oint

s in

Adv

ance

d C

eram

ics

and

Com

posi

tes

Typi

cal

Cer

amic

Joi

nts

will

hav

e C

ombi

natio

n of

St

ress

es U

nder

O

pera

ting

Con

ditio

ns

(a) C

ompr

essi

on; (

b)

Tens

ion;

(c)

She

ar; (

d) P

eel;

(e) C

leav

age

Diff

eren

t Typ

es o

f She

ar T

ests

33G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Tech

nica

l Cha

lleng

es in

Joi

ning

of

Cer

amic

Mat

rix C

ompo

site

s

•Jo

int D

esig

n Jo

int D

esig

n -H

igh

elas

tic m

odul

us o

f cer

amic

join

t mat

eria

ls p

rovi

des

sign

ifica

nt

chal

leng

es to

join

t des

ign

and

char

acte

rizat

ion.

-U

nder

stan

ding

of s

tres

s st

ate

in th

e jo

ints

.

••M

ater

ials

Rel

ated

Issu

esM

ater

ials

Rel

ated

Issu

es-O

ptim

izat

ion

of in

-pla

ne te

nsile

pro

pert

ies

of C

MC

s by

eng

inee

ring

the

fiber

/mat

rix in

terf

ace

is a

ccom

plis

hed

at th

e ex

pens

e of

inte

rlam

inar

pr

oper

ties.

Wea

k in

terf

aces

com

plic

ate

join

t pro

pert

ies

and

perf

orm

ance

-Com

posi

tion

and

mic

rost

ruct

ure

-Bon

ding

and

adh

esio

n-T

estin

g an

d da

ta a

naly

sis

-Hig

h el

astic

mod

ulus

cer

amic

join

t mat

eria

ls.

••Li

fe T

ime

Test

ing

for S

peci

fic A

pplic

atio

nsLi

fe T

ime

Test

ing

for S

peci

fic A

pplic

atio

ns-T

ime

depe

nden

t the

rmom

echa

nica

lpro

pert

ies

of jo

ints

.-E

nviro

nmen

tal e

ffect

s on

join

t pro

pert

ies.

34G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Mic

rost

ruct

ure

ofA

s-Fa

bric

ated

Join

tsin

M

onol

ithic

SiC

Cer

amic

s

Sint

ered

SiC

(Hex

oloy

-SA

)

100

µm

10

0 µ

m

Ecoc

eram

ics

Afr

ican

Bub

inga

CVD

-SiC

200

X

35G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

TEM

Ana

lysi

s of

Rea

ctio

n Fo

rmed

Joi

nts

SiC

SIN

TER

EDSi

CR

B-S

iCJO

INT

JOIN

T

36G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Frac

ture

Str

engt

hD

istr

ibut

ion

ofJo

ined

SiC

(Hex

oloy

-SA

) atD

iffer

entT

empe

ratu

res

37G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

2520

080

010

0012

0013

50

Tem

pera

ture

(C)

0

100

200

300

400

500

600

700

Flexural Strength (MPa)

Join

ed C

VD

SiC

Mor

ton

Dat

a ??

Flex

ural

Str

engt

hs o

f Joi

ned

CVD

SiC

Cer

amic

sFl

exur

al S

tren

gths

of J

oine

d C

VD S

iC C

eram

ics

Ave

rage

dat

a fo

r fiv

e sp

ecim

ens

No.

of s

peci

men

s un

know

n

38G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Effe

ct o

f Sur

face

Rou

ghne

ss o

n th

e

Sh

ear S

tren

gth

of J

oine

d C

VI C

/SiC

Com

posi

tes

CVI

C/S

iCC

ompo

site

s

Join

ts w

ith A

s-Fa

bric

ated

Su

rfac

esJo

ints

with

As-

Fabr

icat

ed/

Mac

hine

d Su

rfac

esJo

ints

with

Mac

hine

d

Surf

aces

39G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Spec

imen

Geo

met

ry a

nd T

est F

ixtu

re U

sed

for

Com

pres

sion

Dou

ble-

Not

ched

She

ar T

ests

com

plia

nt

inte

rpha

se

sem

i-cyl

indr

ical

sp

acer

sem

i-cyl

indr

ical

sp

acer

load

ing

rod

pist

on

tolo

ad c

ell

alig

nmen

t dis

k

spec

imen

load

ing

rod

pist

on

toac

tuat

or

slee

ve(h

ollo

w c

ylin

der)

AST

M C

129

2-95

a (R

T)

and

AST

M C

142

5-99

(HT)

Spec

imen

Dim

ensi

ons

Spec

imen

leng

th (L

) : 3

0 m

m

(±0.

10 m

m)

Dis

tanc

e be

twee

n no

tche

s (h

) : 6

mm

(±0.

10 m

m)

Spec

imen

wid

th (W

) : 1

5 m

m

(±0.

10 m

m)

Not

ch w

idth

(d) :

0.5

0 m

m

(±0.

05 m

m)

Spec

imen

thic

knes

s (t)

: (a

djus

tabl

e)

40G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Typi

cal S

tres

s-St

rain

Beh

avio

r Obt

aine

d D

urin

g th

e

Com

pres

sion

Dou

ble-

Not

ched

She

ar T

ests

05101520253035404550

00.

51

1.5

2

Stra

in, %

Stress, MPa

1200

C - a

RT -

b

800C

- a

1350

C - a

41G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Com

pres

sion

Dou

ble

Not

ch S

hear

Str

engt

h of

Jo

ined

CVI

SiC

Com

posi

tes

at D

iffer

ent T

empe

ratu

res

•She

ar s

tren

gth

of jo

ints

incr

ease

s w

ith te

mpe

ratu

re a

nd is

hig

her t

han

the

CVI

Si

Cco

mpo

site

sub

stra

te.

•

No

appa

rent

influ

ence

of s

urfa

ce c

ondi

tion

on th

e sh

ear s

tren

gth

of jo

ints

.

0

10

20

30

40

50

60

03

00

60

09

00

12

00

15

00

Te

mp

era

ture

(C

)

Shear Strength (MPa)

As-

Fab

rica

ted

Su

rfac

eM

ach

ine

d/A

s-F

abri

cate

dM

ach

ine

d/M

ach

ine

d

CV

I C/S

iC S

ub

stra

te

42G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ld

Exam

ples

of C

ompo

nent

s Jo

ined

Usi

ng A

RC

Join

T

Join

ed S

iCTu

bes

for W

afer

Fa

bric

atio

n Sy

stem

Cab

on-C

arbo

n C

ompo

site

Val

ves

for

Rac

e C

ar E

ngin

es

Join

ed C

/SiC

Com

posi

tes

Atta

chm

ent f

or

Sens

ors

43G

lenn

Res

earc

h C

ente

r at L

ewis

Fie

ldSum

mar

y an

d C

oncl

usio

ns•

Join

ing

and

asse

mbl

y te

chno

logi

es a

re c

ritic

ally

nee

ded

for t

he ro

bust

de

sign

and

man

ufac

turin

g of

com

pone

nts.

•

Bra

ze/S

olde

r effe

ctiv

enes

s is

dic

tate

d by

sev

eral

issu

es: w

ettin

g,

spre

adin

g, b

ondi

ng, a

nd th

erm

al m

ism

atch

.•

Ther

mal

exp

ansi

on m

ism

atch

bet

wee

n C

-C/B

raze

/Tita

nium

and

inte

rlam

inar

prop

ertie

s of

C/C

com

posi

tes

play

a k

ey ro

le in

mec

hani

cal b

ehav

ior o

f jo

int. -C

uSil

AB

A p

aste

was

mos

t suc

cess

ful e

ven

thou

gh n

ot th

e lo

wes

t te

mpe

ratu

re b

raze

-S-B

ond

Sol

der h

ad b

est s

hear

stre

ngth

s du

e to

low

pro

cess

ing

tem

pera

ture

•Th

e pu

rity

cont

rol o

f met

allic

inte

rlaye

r is

also

ver

y cr

itica

l for

goo

d jo

ints

. •

AR

CJo

inT

proc

ess

has

been

use

d to

mak

e se

vera

l typ

es o

f joi

nts

in S

iC,

C/S

iC, a

nd S

iC/S

iCco

mpo

site

s. J

oint

s in

mon

olith

ic c

eram

ics

(CVD

and

Si

nter

ed S

iC) s

how

~75

% o

f the

str

engt

h co

mpa

red

to b

ulk

mat

eria

ls.

•In

C/S

iCco

mpo

site

s, w

heth

er th

e jo

ined

sur

face

s ar

e as

-rec

eive

d (r

ough

) or

mac

hine

d (s

moo

th) h

as n

o ef

fect

on

the

shea

r str

engt

h of

the

join

t. Fu

rthe

rmor

e, th

e sh

ear s

tren

gth

of a

ll jo

ints

exc

eeds

that

of t

he a

s-re

ceiv

ed

C/S

iCat

ele

vate

d te

mpe

ratu

res

up to

135

0 C

. •

Hig

h el

astic

mod

ulus

of c

eram

ic jo

ints

and

wea

k in

terf

aces

in c

ompo

site

m

ater

ials

pro

vide

sig

nific

ant c

halle

nges

to jo

int d

esig

n an

d ar

ecr

itica

l to

join

t pro

pert

ies

and

perf

orm

ance

.•

A c

ombi

natio

n of

tens

ile, s

hear

, and

sub

com

pone

nt te

stin

g of

join

ts

coup

led

with

frac

ture

mec

hani

cs b

ased

des

ign

and

anal

ysis

is n

eede

d to

ge

nera

te u

sefu

l eng

inee

ring

desi

gn d

ata.