Michael J. Presby

The utility of laser‐based heating for the rapid synthesis of small quantities of ytterbium aluminum garnet (Yb₃Al₅O₁₂, YbAG), a high‐temperature ceramic material, was demonstrated. YbAG was synthesized in air using a 400 W carbon dioxide (CO₂) laser in a copper hearth, starting from ytterbia (Yb ₂ O ₃ ) and alumina (Al ₂ O ₃ ) powders. The process produced spheroidal YbAG beads in a single step through the direct reaction of the mixed oxides. For comparison, YbAG was also synthesized as a pellet via solid‐state reaction in an electric box furnace. The resulting phases and microstructures of both a laser‐synthesized bead and the furnace‐synthesized pellet were characterized using X‐ray diffraction (XRD) and scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS). The laser‐synthesized beads were predominantly single‐phase YbAG, with minor eutectic formation of Al₂O₃ and YbAG in one bead at grain boundaries and pores. Laser‐based synthesis proved to be a fast and efficient method for producing small quantities of high‐temperature ceramic powders. Although not a novel technique, laser heating is rarely applied in high‐temperature materials synthesis. The rapid reaction observed here suggests the potential for forming YbAG coatings through a combined reaction and deposition process during thermal spray methods.

New materials and component designs are needed to advance gas turbine engine technology and provide the performance and efficiency needs for future applications. In order to advance these materials, testing in combustion environments is a critical step prior to engine testing. In this work, we detail the design and the fabrication of a materials test sector in a flame tube combustor facility. The facility simulates a combustion environment similar to that experienced by components in gas turbine engines. The flow regime is characterized by a combination of high-temperature, high-heat flux, and high-velocity that components experience in gas turbine engines. Exposure of components in this facility allows for the study of combined environmental effects and the impact on both coating and substrate durability. The test facility may operate across a wide range of pressures from 275 to 400 psig (1896–2758 kPa) and an air flowrate of 5 lb/s (2.27 kg/s). While combustion gas temperature is expected in excess of 3000 °F (1649 °C), 900 °F (482 °C) cooling air may be supplied to the backside of components or test articles. The flame tube combustor was previously used to evaluate fuel injectors and combustion products, and the new test configuration will also allow for materials exposure to complex, engine-like conditions. The interior of the test section was additively manufactured from GRCop-84 and cryogenically fit and brazed to a stainless-steel 304 housing. The use of a copper liner minimizes welds and, with active cooling, is expected to provide better durability over traditional hardware using stainless-steel or Inconel with a ceramic liner. The test section has two opposing 9.5 in × 3.125 in (241 mm × 80 mm) removable windows that can accommodate articles up to 3.5 in (89 mm) tall. This modular design allows for custom platforms to hold coupons, panels, or airfoil shapes to be tested with minimal re-engineering or fabrication. The bolted joint and sealing remains consistent, so any new testing only needs to work within the existing design footprint. This paper will provide an overview of the facility capabilities, design considerations, as well as thermal and structural analysis of the hardware. Future testing of ceramic matrix composite (CMC) airfoils and advanced environmental barrier coatings (EBCs) will also be discussed.

The spectral reflectance and transmittance of two free‐standing ytterbium disilicate (Yb₂Si₂O₇)—based environmental barrier coatings (EBCs) were measured from 25°C up to 1270°C. The measurements were collected over the spectral range of approximately 2–20 µm. The spectral emittance was then determined through conservation of energy and Kirchhoff's law of thermal radiation. The spectral emittance measurements for the EBCs were then compared to previous measurements for a thermal barrier coating (TBC).

The integration of ceramic matrix composites (CMCs) into safety-critical applications, such as turbine engines and aerospace structures, necessitates a sound understanding of their expected damage evolution under in-service conditions and real-time health-monitoring methods to assess their damage state. The measurement of acoustic emissions (AEs), the transient elastic waves emitted during damage formation, offers an enhanced capability for evaluating damage evolution and structural health in CMCs due to its high sensitivity, accurate temporal resolution, and relative ease of use compared to other nondestructive evaluation (NDE) techniques. Recent advances in numerical simulation methods and data-driven model development, in combination with improved multimodal experimental characterization methods and sensor hardware, are rapidly advancing AE to a mature technique for damage quantification. This review discusses the fundamental principles of acoustic emissions, provides practical guidelines on their experimental characterization and analysis, and offers perspectives on the current state-of-the-art.

This work outlines the development of a new natural gas/oxygen (NG/O₂) fueled combustion rig located at the NASA Glenn Research Center for high-temperature environmental durability studies of advanced materials and components at atmospheric pressure. The NG/O₂ burner rig can simulate the high-temperature, high-heat flux, and high-velocity thermal environments encountered in gas turbine engines. It also provides the capability to study environmental effects such as water vapor and other foreign contaminants relevant to these applications. The rig is anticipated to bridge the gap between other laboratory methods such as furnaces, jet-fueled burner rigs, high-heat flux lasers, and more expensive engine rig testing. The NG/O₂ rig is expected to have maximum sample temperature capabilities over 3,000°F (1,649°C) and result in higher water vapor content compared to our Mach 0.3 to Mach 1.0 jet-A burner rigs which is important for characterizing current and next-generation environmental barrier coatings. This paper will provide an overview of the development of the NG/O₂ burner rig, initial characterization, and current research and development efforts on environmental barrier coated ceramic matrix composites.

Ceramic matrix composites (CMCs) and environmental barrier coatings (EBCs) are key technologies that can enable improvements in the thermal and propulsive efficiency of gas turbine engines. However, CMCs and EBCs are susceptible to various life limiting damage modes associated with the engine operating environment such as oxidation, recession, thermomechanical stress/strain, corrosion, foreign object damage (FOD), and solid particle erosion (SPE). Despite its importance, there is a limited understanding of the SPE behavior of CMCs and EBCs in the literature. This paper reviews the status of SPE research for CMCs and EBCs and provides a perspective towards future research.

Solid particle erosion (SPE) is a common phenomenon observed in gas turbine engines. Particles entrained in the gas flow impact engine hardware, resulting in micro-scale damage that leads to deleterious effects such as material removal. For protective coatings, damage due to SPE is a key concern, since it can negatively affect the durability of the coating and subsequently the life of the underlying component. In this work, the high-temperature SPE behavior of two state-of-the-art environmental barrier coatings (EBCs) deposited via air plasma spray (APS) is investigated using alumina erodent to understand the effect of particle kinetic energy, impingement angle, and temperature. The SPE behavior of the EBCs is also compared to APS and electron beam–physical vapor deposition (EB-PVD) thermal barrier coatings (TBCs) to elucidate similarities and differences in the erosion response. The EBCs were more susceptible to SPE than the EB-PVD TBC but had greater SPE resistance compared to the APS TBC. Coating microstructure and porosity were shown to have a strong influence on the observed behavior.

Ceramic matrix composites are an enabling propulsion material system that offer weight benefits over current Ni-based superalloys, and have higher temperature capabilities that can reduce cooling requirements. Incorporating ceramic matrix composites into the hot section of gas-turbine engines therefore leads to an increase in engine efficiency. While significant advancements have been made, challenges still remain for current and next-generation gas turbines; particularly when operating in dust laden or erosive environments. Solid particles entrained in the gas flow can impact engine hardware resulting in localized damage and material removal due to repeated, cumulative impacts. In this study, the erosion behavior of a melt-infiltrated (MI) silicon carbide fiber-reinforced silicon carbide (SiC/SiC) ceramic matrix composite is investigated at high temperature (1200 °C) in a simulated combustion environment using 150 μm alumina particles as erodent. Particle impact velocities ranged from 100 to 200 m/s and the angle of impingement varied from 30 to 90 deg. Erosion testing was also performed on α-SiC to elucidate similarities and differences in the erosion response of the composite compared to that of a monolithic ceramic. Scanning electron microscopy was used to study the posterosion damage morphology and the governing mechanisms of material removal.

In this work, we demonstrate that damage mechanism identification from acoustic emission (AE) signals generated in minicomposites with elastically similar constituents is possible. AE waveforms were generated by SiC/SiC ceramic matrix minicomposites (CMCs) loaded under uniaxial tension and recorded by four sensors (two models with each model placed at two ends). Signals were encoded with a modified partial power scheme and subsequently partitioned through spectral clustering. Matrix cracking and fiber failure were identified based on the frequency information contained in the AE event they produced, despite the similar constituent elastic properties of the matrix and fiber. Importantly, the resultant identification of AE events closely followed CMC damage chronology, wherein early matrix cracking is later followed by fiber breaks, even though the approach is fully domain-knowledge agnostic. Additionally, the partitions were highly precise across both the model and location of the sensors, and the partitioning was repeatable. The presented approach is promising for CMCs and other composite systems with elastically similar constituents.

Damage mechanism identification has scientific and practical ramifications for the structural health monitoring, design, and application of composite systems. Recent advances in machine learning uncover pathways to identify the waveform-damage mechanism relationship in higher-dimensional spaces for a comprehensive understanding of damage evolution. This review evaluates the state of the field, beginning with a physics-based understanding of acoustic emission waveform feature extraction, followed by a detailed overview of waveform clustering, labeling, and error analysis strategies. Fundamental requirements for damage mechanism identification in any machine learning framework, including those currently in use, under development, and yet to be explored, are discussed.