Ceramics and Ceramic Matrix Composites in Aerospace ... · 1 Ceramics and Ceramic Matrix Composites in Aerospace Applications - An Overview Suraj Rawal Technical Fellow, Advanced

1

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

2

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

3

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

4

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

5

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

6

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

7

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

8

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

9

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

10

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

11

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

12

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

13

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

14

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

15

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%)

16

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

17

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

18

Thank You

19

Acknowledgements

• Special Thanks to Fellow LMSSC colleagues:

• Connie Henshall

• Gautham Ramachandran

• Scott Smith

• Vadim Khayms

• Dan Lichtin

• Kevin Johnson

• Bill Willcockson