Research Papers: Gas Turbines: Structures and Dynamics

Quantification of Foreign Object Damage and Electrical Resistivity for Ceramic Matrix Composites and Tensile Residual Strength Prediction

[+] Author and Article Information
Frank Abdi

AlphaSTAR Corporation,
5150 East Pacific Coast Highway,
Suite 650,
Long Beach, CA 90804
e-mail: fabdi@alphastarcorp.com

Gregory N. Morscher

University of Akron,
Auburn Science and Engineering Center 101,
Akron, OH 44325-3903
e-mail: gm33@uakron.edu

Yibin Xue

AlphaSTAR Corporation,
5150 East Pacific Coast Highway,
Suite 650,
Long Beach, CA 90804
e-mail: annayxue@gmail.com

Sung Choi

Materials Engineering,
48066 Shaw Road,
Unit 5, CODE 4341, BLDG 2188,
Patuxent River, MD 20670-1908
e-mail: sung.choi1@navy.mil

Contributed by the Structures and Dynamics Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received July 21, 2014; final manuscript received August 29, 2014; published online November 18, 2014. Editor: David Wisler.

J. Eng. Gas Turbines Power 137(5), 052503 (May 01, 2015) (8 pages) Paper No: GTP-14-1421; doi: 10.1115/1.4028677 History: Received July 21, 2014; Revised August 29, 2014; Online November 18, 2014

SiC-based ceramic matrix composites (CMC) in turbine engine applications must sustain certain foreign object impacts (FOIs) that might occur in services. Experiments and nondestructive evaluation (NDE) have illustrated good correlations between impact energy and foreign object damage (FOD) assessed using electrical resistivity (ER), acoustic emission (AE), and microscopy. A progressive failure dynamic analysis (PFDA) method is explored in understanding and predicting the damage states, ER, and residual strength after impact of CMCs. To accurately correlate the damage state with ER, the PFDA tool has been improved to incorporate the physical damage mechanisms in CMCs, which are matrix microcrack density due to both longitudinal and transverse tensile loads and the fiber breakage due to probabilistic fiber strength distribution. The predicted damage states and ER are correlated with the measurement of FOD and validated with tension after impact tests using high temperature ER. The PFDA tool has demonstrated a great potential for CMCs' FOD and residual strength predictions.

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Fig. 1

Impact dynamic explicit analysis versus PFDA

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Fig. 2

Analysis procedure of multiscaled FEM progressive failure method

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Fig. 3

Damage tracking expressed in terms of load versus displacement

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Fig. 4

MCQ-Ceramics for SiC/SiC composites (a) stress–strain curve for (0 deg/90 deg) SiC-SiC composites test (red) and model correlation, and (b) predicted microcrack density in the matrix and the total electrical resistance as a function of the remote axial strain

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Fig. 5

PFDA predictions for impact test (a) impact force and (b) impactor displacement as a function of impact duration

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Fig. 6

Contact forces as a function of the simulated impacting time, with the boundary condition as: (a) cantilever, (b) simply supported and (c) fully supported, and (d) comparison of simply and fully supported CMCs under impact velocity of 300 m/s

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Fig. 7

PFDA for impact test: (a) damage volume fraction and (b) the microcrack density at the 90 deg plies, and (c)–(f) the damage mechanisms including fiber and matrix damage and delamination in the 0 deg plies at 10 μs (red is for damaged elements and blue is for undamaged elements)

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Fig. 8

(a) PFA results for damage evolution (fraction of damage volume fraction) as the remote tensile stress, (b) simulated matrix microcrack density versus laminate average stress, and (c) experimental NDE tests using ER and the acoustic energy for damage state estimation

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Fig. 9

The fracture states of the (0 deg/90 deg) SiC/SiC laminate under tension after the high speed impacts: (a) top view and (b) side view with 30 deg tilt

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Fig. 10

The experimental fracture states of the (0 deg/90 deg) SiC/SiC laminate under tension after the high speed impacts: (a) top view and (b) side view with 30 deg tilt




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