AAWSAP DIRD, Materials for Advanced Aerospace Platforms, January 2010

UNCLASSIFIED/f FQR 8FFI@Itltt tJ91! ertt I Defense Intelligence Reference Document Acquisition Threat Support 12 January 2010 !COD: 1 December 2009 DIA-08-0912-008 Materials for Advanced Aerospace Platforms UNCLASSIFIED/I f8R 8fFIEilAI: W6& Qtlb¥ UNCLASSIFIED/ /Pel\ OPPICIAL USE ONLY Materials for Advanced Aerospace Platforms Prepared by: Acquisition Support Division (DW0-3) Defense warning Office Directorate for Analysis Defense Intelligence Agency Author: AAP Person 66 Administrative Note COPYRIGHT WARNING: Further dissemination of the photographs in this publication is not authorized. This product is one in a series of advanced technology reports produced in FY 2009 under the Defense Intelligence Agency, Defense Warning Office's Advanced Aerospace Weapon System Applications (AAWSA i Program. Comments or questions pertaining to this document should be addressed to MP Person 1 ! AAWSA Program Manager, Defense Intelligence Agency, ATTN: CLAR/DW0-3, Bldg 6000, Washington, DC 20340-5100. ii UNCLASSIFIED/ /liOA OFFIOIAL li91!! ertt I UNCLASSIFIED//FOR OFFI@IAl W&lii 9PU.Y Contents Introduction ...........................................................................................................iv Launch Vehicles ................................................................................................. 1 Reusable Crew Modules...................................................................................... 9 Reusable Single-Stage-to-Orbit Vehicles ...................................................... 10 Advanced Al Alloys ....................................................................................... 11 Polymer Matrix Composites.......................................................................... 11 Al Matrix Composites.................................................................................... 12 Ti Alloys ....................................................................................................... 12 Ti Matrix Composites.................................................................................... 14 Ni-base Alloys .............................................................................................. 16 Refractory Metal Alloys ................................................................................ 18 Ceramic Matrix Composites .......................................................................... 18 Carbon-Carbon Composites .......................................................................... 19 Titanium Aluminides .................................................................................... 20 Propulsion Systems.......................................................................................... 21 Summary and Recommendations ..................................................................... 22 Figures 1. Schematic Diagram of Friction Stir Welding ....................................................... 2 2. Specially Modified 747 Transporter Unloading a Boeing 787 Composite Fuselage Barrel Section ..................................................................................... 4 3. Micrograph Showing Phase Formation at the Surface of a Ti Alloy That has Been Exposed to Air at Elevated Temperature ................................................. 13 4. Cross-Section Micrograph of a Ti Matrix Composite.......................................... 15 Tables 1. Potential Materials by Use Temperature Regime and Property ......................... 10 2. Example of Properties of Ti Matrix Composites ................................................ 14 iii UNCLASSIFIED//FOR 0FFI€1Ak Uili ,u1k¥ UNCLASSIFIED//FOA OFFI€1Ak Ulilii ONkY Materials for Advanced Aerospace Platforms Introduction "Advanced aerospace platforms" is a broad topic that can be divided into several narrower subtopics to enable a more concise discussion of materials advances, challenges, and opportunities. Consequently, this document discusses the areas of launch vehicles, space vehicles, and space propulsion systems separately because their key requirements are often application specific, which affects materials selection decisions. In addition, single-use and reusable boosters have different durability requirements that directly impinge on design and materials selection. Furthermore, current engineering practice has evolved to the point that design synthesis must integrate the structure and construction materials to achieve optimum product performance. For example, the space shuttle was designed to meet customer-imposed mission requirements (range, payload, empty weight, landing capability, and so forth) without significant real-time consideration of materials capability. This approach led to significant compromises at later stages in the shuttle's development and maturation. (Arguably, the shuttle could be designed as a more efficient vehicle today.) In the extreme, a spectacular engineering failure was the National Aerospace Plane (also dubbed the Orient Express), which was launched as a military project and was intended to be a mach 12 reusable strike vehicle. This project rapidly became materials limited and was canceled in 1993, after about $750 million in federal R&D expenditures and a substantial private sector investment. The point is that any "clean sheet of paper design" must start with an assessment of the requirements for construction materials and be accompanied by a realistic assessment of the capability of currently available materials to meet these needs. If these two assessments indicate a gap between requirements and existing materials capability, a risk assessment and a risk-mitigation plan must be developed before expending engineering hours and funds. Since the inception of manned space flight, the approach to design has changed to include the concept of damage tolerance. This shift in design philosophy was prompted by the (eventual) recognition that complex structures cannot be designed and produced with zero defects. With the maturation of fracture mechanics and means of reducing these concepts to practice, the transition from zero defects to defect tolerance became the norm. This new approach in turn led to recognition that high-performance materials required not only high specific strength and stiffness but pacing increases in strength with simultaneous improvements in fracture toughness and fatigue crack growth resistance. The introduction of damage tolerance was accompanied by a renewed emphasis on nondestructive inspection capabilities. This latter thrust was driven by the need to demonstrate the capability to reproducibly locate small flaws that could become failure initiation sites, either because of static or because of cyclic loading conditions. In the case of atmospheric flight, the U.S. Air Force has introduced standards for airframes (the Aircraft Structural Integrity Program) and propulsion systems (the Engine Structural Integrity Program) that tie structural life and reliability to iv UNCLASSIFIED//FOA OFFl&IAI:: U&li &Ptl::lf UNCLASSIFIED//FOR OFFl@IAL l:ISl!!! 9HtY this demonstrated inspections capability. Implementation of these standards, starting with the B-1 bomber and the F-100 and F-110 engines, has dramatically reduced (but not eliminated) the incidence of catastrophic failures of critical components that endanger crews, vehicles, or both. Taking these changes into account, this document outlines the current situation regarding the design and production of high-performance structures for aerospace platforms, including launch vehicles, space vehicles, and propulsion systems for transporting space vehicles (and payloads) into orbit. V UNCLASSIFIED/ /FOR. OFFISIAI: YSE OHL\« UNCLASSIFIED//FOR 8FFI@IAL t:191!! l>flt I Materials for Advanced Aerospace Platforms LAUNCH VEHICLES For the purposes of this document, launch vehicles are defined as the structure that supports and/or encloses the propulsion system, the fuel supply, and the crew or payload module. Launch vehicles today are either single use or multiple use after recovery and extensive refurbishment. This approach adds considerably to the cost of transporting a pound of payload into earth orbit, regardless of whether an unmanned satellite or a manned orbiting crew module that must withstand the temperatures and loads associated with safe reentry to earth. Furthermore, the larger the payloads are, the greater are the reaction forces the launch vehicle must withstand during launch. With the total weight of the payload, the empty weight of the launch vehicle, and fuel all needing to be lifted initially, fuel-efficient propulsion and lightweight launch vehicles are essential to maximizing the payload. Except in the area around the propulsion system exhaust, the temperatures experienced by launch vehicles during launch are not demanding. Therefore, advanced, high-strength aluminum (Al} alloys and polymer matrix carbon fiber composites (PMCs) are prime candidates for the parts of the structure that experience aerodynamic loads and where aerodynamic heating does not exceed about 125 °Celsius. One class of advanced Al alloys is the lithium (Li)-bearing alloys, such as Al alloy 2090. This alloy contains enough Li to reduce its density by 8 percent while increasing the elastic modulus (E) by 10 percent. Other, newer advanced Al alloys, such as 7050 and 2050, have been developed to have improved damage tolerance. These alloys have excellent specific strength at or near room temperature and experience no major loss of ductility at cryogenic temperatures. The newer variants of the 2000 and 7000 Al alloys also have substantially improved resistance to most types of corrosion, including exfoliation and stress corrosion cracking. This can be important in a reusable vehicle. Perhaps the most important aspect of the improved Al alloys is their higher fracture toughness, accomplished through a combination of alloy composition control and improved processing. In alloy composition control, the concentrations of the residual elements iron (Fe), chromium (Cr), manganese (Mn), and silicon (Si) are reduced at the ingot stage. These elements combine with Al to form hard, brittle intermetallic compounds known as constituent phases. The advanced alloys contain fewer, smaller constituent phases, leading to improved fracture resista nce and higher fracture toughness values. In applications such as body skins for commercial aircraft, this improved toughness has enabled an increase in the spacing of the circumferential fuselage frames, or "hat sections," that serve both as stiffeners and as crack stoppers to prevent a catastrophic failure during pressurization. For any given operating stress­ in this case the pressurization stress-the spacing of the frames is directly related to the critical crack size of the body skin . Higher toughness alloys have larger critical crack sizes, and the frames can be spaced further apart without increasing the risk of catastrophic failure. The increased spacing ultimately allows a fuselage design that requires fewer frames. Consequently, the airplane benefits from a commensurate reduction both in weight and in manufacturing cost. Similar possibilities exist for the design of a fail-safe launch vehicle that has a lower empty weight. Clearly, the advanced Al alloys offer intrinsic improvements over the alloys used in the Saturn launch vehicle and introduce the prospect of new, more efficient launch vehicle designs. 1 UNCLASSIFIED/,'FOR 8FFI&i1Ak Uili ODIL\' UNCLASSIFIED/} FOR OFFICil<L l:191!!! 8HL1/ The newer Al alloys also can be specially processed to render them superplastically formable. This capability opens a realm of possibilities to replace structures that, in the absence of this capability, are machined from thick plate. Very large structures are produced in sections that must be joined. Conventional fusion welding techniques do not work for high-strength Al alloys such as 7075, 7050, 2024, or 2050 because either the welds lead to cracks or the welds made under conditions that avoid cracking have greatly reduced tensile properties. Because these alloys are not amenable to welding, heavier, fatigue-prone mechanically fastened joints must be used. Recently, scientists developed a joining process that permits joining of Al alloys such as 7050. This process, called friction stir welding (FSW), allows joint designs in a variety of configurations that were not considered possible when fusion welding was the only alternative. In FSW, a rotating steel tool is inserted into the seam between the two Al alloy pieces to be joined. As the rotating tool is driven forward, the friction between the tool and the work piece generates enough heat to soften the Al alloy without melting it. A schematic of this process is shown in Figure 1. retreating side Tool / Figure 1. Schematic Diagram of Friction Stir Welding The combined action of the rotation and the traversing of the tool essentially kneads the two pieces together, leaving a mechanically sound joint. Although the weld properties may be somewhat inferior to those of the base metal, they are good enough that a relatively small increase in thickness at the joint position can compensate. Although substantial development of the FSW process is ongoing, FSW already has been put into practice. For example, the current external propellant tank on the space shuttle is made from an Al-Li alloy fabricated through FSW. The weight advantage of using welded as opposed to bolted joints in a large structure such as a launch vehicle is considerable. With earlier high-strength alloys such as 7075, concerns about fracture toughness in conjunction with monolithic structures would have caused a welded 2 UNCLASSIFIED/ /FOR. OFFl&IAI:: W&li &Ptl::lf UNCLASSIFIED//POlt OPPl@IAL YSI!! 8HLY construction to be considered too risky. Today, the combination of higher toughness alloys and FSW opens up the possibility of greater design flexibility resulting in lighter large structures with equal or greater reliability than earlier ones. In sum, metallic, nonreusable (at least nominally so) launch vehicles made from advanced Al alloys and fabricated through FSW constitute an incremental but significant improvement over earlier versions. In recent years, PMCs have matured significantly. For many components that are not exposed to elevated temperatures, PMCs provide a degree of design flexibility not readily available in metals. Consequently, PMC materials have begun to supplant Al alloys in the construction of commercial subsonic aircraft. The use of PMCs in the empennage of the Boeing 777 was one of the first examples of Al alloys being displaced. Subsequently, the new Boeing 787 has more structure made from composites than from metallic materials. Once PMCs are introduced into a structure in significant quantities, a constraint related to galvanic incompatibility between the PMC structure and any adjoining Al alloys also is introduced. When a PMC structure is in direct contact with an Al alloy structure, catastrophic corrosion of the Al alloy components can occur. In the Boeing 787, the remedy for this concern is the use of titanium (Ti) alloys in areas where there is direct contact between the metallic and the PMC structures. This is directly analogous to the plastic bushing a plumber puts in the j oint between copper and iron piping. Notwithstanding this constraint, the specific strength and stiffness of PMC structures make a compelling argument for their application in high-performance structures, such as launch vehicles . Composite structures can be manufactured using one of three methods: hand layup of pre-preg, automated tow placement, and resin transfer molding. • The most rudimentary of these, but also the most flexible, is hand layup of pre-preg. This method uses sheets of material that contain both the fiber and the polymeric matrix (called pre-preg). The polymeric matrix can be either a thermoset (for example, epoxy) or a thermoplastic. Individual plies are cut from the pre-preg typically using a numerically controlled laser or mechanical cutting device and are laid up to form the desired shape. Areas that have heavier loads contain more plies locally, and the plies are cut in an orientation with respect to the fiber direction in the pre-preg to achieve the desired strength relative to the principal load path. These plies are carefully placed according to a drawing (blueprint), making hand layup a labor-intensive process and, therefore, making parts made using this method expensive. During ply placement, it is critical that no ply wrinkles are introduced, as these create severe reductions in the local load-bearing capability of the final component. Once all the plies are in their proper places, the article is placed in a vacuum-tight bag that is evacuated and placed in an autoclave for curing of the epoxy matrix or fusing of the thermoplastic. A disadvantage of a pre-preg whose matrix is a thermoset is limited shelf life. In practice, this is managed to a degree by storing the pre-preg in a freezer to slow the rate of chemical reaction that sets the epoxy. However, this does not completely halt the reaction, causing these materials to have a shelf life beyond which they are not easily manipulated during layup and do not develop full strength after curing in the autoclave. An additional issue is out time-the time the pre-preg can be out of the freezer during layup before the reaction proceeds at an accelerated rate and reaches a point at which the 3 UNCLASSIFIED//F8R 8FFUiil>I. 11&5 ON! X UNCLASSIFIED// FOR OFFICll<L l:l!H!! 8PtLY material is not suitable for the reasons stated earlier. Clearly, the time required for layup places practical limitations on component size. • In automated tow placement, thin ribbons of a pre-preg are fed off a drum or rolled into a computer numerically controlled machine that places them in the desired position. In principle, this process trades recurring labor cost for up-front capital investment (the tow placement machine) and programming time. If the anticipated volume of identical parts is high enough to amortize the capital investment and, particularly, the programming cost, this can be an attractive means of reducing manufacturing costs. For axisymmetric shapes, such as cylinders, this essentially becomes a winding process and is quite efficient. An example of a finished composite fuselage barrel section for the Boeing 787 is shown in Figure 2. For more irregular three-dimensional shapes, such as a spar or a strut, placing the tows becomes much more difficult and presents a fundamental limitation. Consequently, PMC structures with complex shapes are still for the most part made using the hand layup process. A variant of automated tow placement is compression, whereby a preform, made by automated tow placement, is forced by a press into a preshaped die. This process allows fabrication of more complex shapes, but the rigidity of the fiber and the extreme anisotropy of the tows can lead to wrinkles, which are not acceptable because of the reductions in properties these cause. Figure 2. Specially Modified 747 Transporter Unloading a Boeing 787 Composite Fuselage Barrel Section • The third main composite fabrication method, resin transfer molding (RTM), begins with a woven fiber mat or preform. The polymeric matrix is injected into this mat to create a fully dense composite. The major benefit of RTM is that it permits use of a three-dimensional weave that minimizes the risk of delamination between plies. Note that, with the other two methods, the material is reinforced in only two dimensions (the plane of the pre-preg or tows). RTM's limitations include the viscosity of the resins used. If the resin is too viscous, injecting it will either distort the fiber architecture of the woven preform or not fully penetrate the preform, 4 UNCLASSIFIED//FOR 8FFI@IAL YSE erttl/ UNCLASSIFIED/ /POI': OPPlelAL l:ISE 8PtLY leaving voids. This limitation makes it difficult to use many thermoplastic resins that are otherwise attractive because they are recyclable and have much longer shelf lives than thermosets (epoxies). Another, more obvious limitation of RTM is component size. This is in part because weaving of very large fiber preforms is challenging and requires a very large weaving machine. It also requires a large injection machine capable of multiple injection sites to ensure the complete infiltration necessary to avoid formation of voids. In practice, there are several significant challenges associated with manufacturing large PMC structures today. Among these, perhaps the most significant are manufacturing cost and the difficulty associated with making large, nonaxisymmetric components. Large axisymmetric components that can be produced by winding tows of pre-preg are clearly possible today, as demonstrated by the Boeing 787 fuselage whose section is shown in Figure 2. For other shapes, because the load-bearing capability of PMCs depends on the transfer of externally imposed loads to the strong, stiff fibers, joints that intersect the principal load path become problematic. This is because the fibers and, as a direct consequence, the load path are discontinuous, requiring local section size adjustments to offset this local structural inefficiency. Thus, achieving the most structurally efficient use of PMCs requires monolithic structures with continuous fibers. In large structures, this is at best a challenge. Even in the Boeing 787's PMC fuselage, mechanically fastened joints are used to connect adjacent barrel sections. In the fuselage, as in any cylindrical pressure vessel, the principal stresses are hoop stresses stemming from pressurization during flight. However, the compromise in structural efficiency is minimized by the circumferential orientation of the joints. Although these bolted joints add weight, the overall structural efficiency of the PMC structure is still better, albeit considerably more expensive, than a longitudinally and circumferentially stiffened Al structure. The circumferential joints also create discontinuous longitudinal crack paths that improve the structure's damage tolerance. Some of the added expense of the PMC fuselage stems from the use of Ti alloy fasteners because of the galvanic coupling issues that would accompany Al or steel fasteners. For other applications, which are limited by different material properties, the PMC system can be tailored to optimize structural performance. This is possible because both the matrix and the fiber can be independently selected. Moreover, the fiber "architecture" (fiber orientation, weave geometry, and fiber volume fraction) can be varied spatially to optimize load-bearing capability under complex stress states. For example, again drawing on recent applications in commercial aircraft, the fan blades of the large, high-bypass-ratio turbofan engine {GE90) produced by General Electric for the Boeing 777 are made from PMCs. The limiting design consideration for these fan blades is resistance to bird strikes. To optimize the PMCs' impact resistance, a medium­ modulus, high-tensile-strength carbon fiber was selected in combination with a thermoplastic toughened epoxy matrix. Furthermore, the fiber architecture was set to optimize the bending strength under the impact of a bird. The GE90 fan blades are produced by hand layup and are quite costly to produce. In the 10-plus years that these fan blades have been in service, not a single unscheduled engine removal related to the PMC fan blades has occurred. The competitive fan blade technology for B-777­ class engines is hollow Ti, which is used by both Pratt & Whitney and Rolls Royce. By all informal accounts, these blades are cost intensive. This example supports the unwritten rule that the pathways leading to high-performance, high-value structures typically are 5 UNCLASSIFIED/,sroR. OFFl&IAL W&li 8Ptllf UNCLASSIFIED// POI': OPPlelAL l:ISE 8PtLY not technology dependent but are cost intensive, no matter what technology is employed to meet the requirements. An additional characteristic of PMC structures-one related to the laminated construction of components made by hand layup or automated tow placement methods-is their susceptibility to formation of delaminations when impacted perpendicular to the plane of the plies. This is due to the mismatch in bending stiffness between adjacent plies that have different unidirectional fiber orientations. This mismatch causes shear stresses to develop that can exceed the shear strength of the interlaminate bonds, causing small, embedded cracks to form. Under subsequent inplane compression loading, the laminates bow because of the Poisson stresses and separate because of the lack of an interlaminar bond to hold them together. In significant compression loads, the laminates buckle, and this leads to structural failure. This phenomenon, called compression after impact, is an insidious failure mode because the delaminations are not externally detectable unless ultrasonic inspection methods are used. Sources of such an impact include dropped tools, foreign objects (for example, meteorites), and, perhaps most commonly, hail storms. Ultrasonic inspection, if required, is expensive and time consuming. The latter concern in turn affects vehicle availability and turnaround time. PMC parts made using RTM typically have reinforcing fibers in the through-thickness direction, so concerns about compression after impact are minimal. The maximum temperature at which PMCs can be used is limited by PMCs' susceptibility to oxygen degradation of the polymeric matrix. The maximum-use temperature for prolonged exposure is determined by the thermal oxidative stability (TOS) of a particular resin. The TOS, like any chemical reaction, is determined by both time and temperature. The glass transition temperature (T9) of the polymeric matrix also imposes strength and dimensional stability limitations independent of the TOS limits. This is particularly true for thermoplastics. However, the TOS limits usually impose lower temperature limits than T9 if prolonged thermal exposure is contemplated. Three distinct classes or groups of resins exist, each with a successively higher temperature capability. These are conventional epoxies and most thermal plastics, bismaleimides (BMis), and linear polyimides. The first class is limited by TOS to about 125° Celsius. BMis can be used to about 175° Celsius. Linear polyimides, such as the in situ polymerization of monomer reactants (PMR) group of thermosetting formulations, can be used to about 300° Celsius. Many of the PMR resins contain the hazardous compound methylenedianiline, which requires special care during use, including protective clothing to limit personnel exposure (for example, during ply cutting and hand layup). This requirement reduces productivity, adds cost, and creates a degree of liability concern for the manufacturer of the PMC components. For RTM, the BMis and PMR resins typically have higher viscosity and require commensurately higher injection temperatures to reduce the viscosity to manageable levels for reasons discussed earlier. New resins are constantly being developed, including some with attractive properties. However, many of the sources of these resins are startup companies that exist on R&D funding, often in the form of U.S. government SBIR (Small Business Innovative Research) projects. Such companies are good at innovation but often have limited experience transitioning new products from the laboratory to large-scale production. Furthermore, in the current economic climate, access to sufficient capital to set up production-scale capacity can be a formidable problem for a small company. Larger companies (for example, BASF, DuPont, GE Plastics) typically are not interested 6 UNCLASSIFIED/.{FOR OFFICilAL l:ISE 8HLY UNCLASSIFIED// POI\ OPPICl"L U.!I! Oflt I in materials with small annual sales volume, so even licensing the new material to one of these companies may not be commercially feasible . This foregoing discussion highlights a commonly encountered inconsistency between technical innovation and commercial progress. Until a production-scale source exists, pricing of new materials is at best highly uncertain and potentially unstable over time. This is in part due to the uncertainty surrounding demand and the associated volume of material that will be required. Taken together, these factors act as a clear deterrent to the adoption of new materials of literally all classes (polymers, metals, and ceramics). For heavily loaded structures or structures that will experience temperatures higher than about 200 °Celsius, Ti alloys are the preferred material class. Ti alloys are about half as dense as steel or Ni-base alloys and possess a density-corrected strength and stiffness competitive with that of other metallic materials. Numerous grades of Ti alloys are in use today, and a strong domestic industrial base of suppliers exists for nearly all these grades. Ti alloys for structural applications can be divided into three groups based on their metallurgy: near a alloys, a+p alloys, and metastable p alloys (commonly called p alloys for short). Both the aircraft and propulsion original equipment manufacturers and several private engineering firms have extensive design experience with Ti alloys. Although most of this experience is with Ti-6Al-4V (Ti-6-4 ), other alloys also are widely used, particularly in jet engines and liquid-fueled rocket engines. The alloy most likely to be used in a launch vehicle, Ti-6-4, has been available and in use for more than 40 years but is still highly competitive with newer grades in large part because of its versatility. Potential applications of other alloys that have particularly attractive characteristics, such as a higher temperature capability, are discussed in the Reusable Reentry Vehicle and Propulsion Systems sections of this document. The most commonly used structural grade of Ti alloy today, Ti-6-4, can be readily fusion welded, formed both by forging and as a sheet product, and conventionally machined, although each of these operations requires special precautions. In addition, the feasibility of friction stir welding has been demonstrated. Ti-6-4 also can be superplastically formed and diffusion bonded, enabling synthesis of innovatively shaped components. For launch vehicles, the most likely application for Ti alloys is in the structure that carries the reactions from the propulsion system to the vehicle itself. These applications typically involve heavy sections to accommodate the large loads, and the main property requirements are high strength, fatigue resistance, and fracture toughness. Ti alloys have been used in both military and commercial aircralt. Heavily loaded components in service today include the wing box of the B-1B bomber (Ti-6-4), the landing gear beam in the B-747 (Ti-6-4), and the landing gear truck beam in the B­ 777 (higher strength Ti-10V-2Fe-3AI [Ti-10-2-3]). The choice of Ti-10-2-3 for the landing gear truck beam reflects the time-based maturation of the newer p-Ti alloys, such as Ti-10-2-3. These alloys have the advantage of being "deep hardenable"­ compared with Ti-6-4, they can develop full strength in thicker sections during heat treatment. For example, that the B-777's truck beam is up to 6 inches thick in some locations factored significantly in the choice of Ti-10-2-3. Because Ti alloys are about half as dense as steel, they are very competitive on a density-corrected basis. However, mass is not the only driver for some applications; the volume of a component also must be compatible with the space available for it. This factor also is a consideration in the choice ofTi-10-2-3 for the B-777 truck beam. And it also applies to an application such as landing gear, because it is retracted into the fuselage for aerodynamic reasons. 7 UNCLASSIFIED/ f FOR. OFFl&IAI:: W&li &Ptl::lf UNCLASSIFIED/JFOR OFFICIAL USE 014[ I 13-Ti alloys would be an attractive option for a launch vehicle with a very heavy payload. These alloys can be processed and heat-treated to ultimate tensile strengths greater than 1,300 mega-Pascals (MPa), making them very efficient structural alloys. However, at these strength levels, the fracture toughness is decreased to about 40 MPa-m0 •5 , making damage tolerance marginal. For example, using a design stress that is two­ thirds that of ultimate tensile strength, the critical crack size for an alloy with these properties is about 4 millimeters. Such a small critical crack size poses a challenge to any required field inspections associated with reusability requirements. p-Ti alloys' stiffness also is as much as 10 percent lower than that of a+J3 alloys. Ten percent lower stiffness generally is not an issue in a tension-loaded structure, but it can be an issue for a compression-loaded structure because of the potential for buckling. Designs with a higher section modulus can eliminate this concern, but the additional shape complexity will almost certainly add cost. In extreme circumstances, Ti alloys can be reinforced with ceramic fibers (typically silicon carbide) to increase their intrinsic stiffness, as will be discussed later. Ti alloys are reactive when exposed to air at temperatures of 550 °Celsius or above. Consequently, any manufacturing operations that exceed this temperature limit must be performed in a protective atmosphere of argon (Ar) or helium (He) gas. An exception occurs during forging if enough excess material is left on the raw forging to contain the oxygen-contaminated layer so it can be machined away during the final machining of the finished component. How to deal with this reactivity issue is well understood, and it poses no concern other than the additional costs associated with the excess material and additional machining. In other operations, such as welding, use of specially designed fixtures incorporating inert shielding gas also effectively eliminates concerns about oxygen contamination. In hot-forming applications, the as-formed part is typically chemically milled to remove the oxygen-rich surface layer because this layer typically has lower ductility and can cause fatigue cracking in service. The practice of eliminating all oxygen-contaminated material has served the aerospace industry well over the years but is quite conservative and restrictive. This matter is discussed in greater detail in the Reusable Reentry Vehicle section of this document. In summary, although the choices of materials for launch vehicles are in principle numerous, in practice these choices are reduced by a variety of application-specific considerations that include manufacturing capability for large components and manufacturing cost. The foregoing discussion has attempted to examine the prospects for advanced Al alloys, PMCs, and Ti alloys in light of these perceived practical constraints. On a case-by-case basis, a variety of requirements are imposed by design constraints, which some materials meet more readily than others. In all cases, discussion of available material options was constrained by the assumption that the maximum service temperatures would be relatively low. Consequently, the material classes discussed here are all intended for relatively low-temperature use. The separate case of a reusable single-stage-to-orbit vehicle, where operating temperature requirements are considerably higher, is discussed in a later section of this document. Ultimately, materials are selected to optimize structural performance, and a coordinated approach of materials selection and geometric design is essential to this. Going forward, a design using a synthesis process that treats form, fit, function, and materials capability as equal constraints is needed to achieve true optimum structural efficiency. 8 UNCLASSIFIED/ /570A OFFl&IAk W&E 8HL\« UNCLASSIFIED//FOR 8FFI@IAL l:l!H! 8HL'I REUSABLE CREW MODULES The concept of manned orbital crew modules has evolved from the Mercury capsules to the Gemini and Apollo programs to the space shuttle, the first fully reusable crew module. The shuttle also has a combined payload bay used for transporting satellites into orbit and hardware for developing the International Space Station and for repairing and refurbishing the Hubble telescope, among other uses. The reusable nature of the shuttle crew module introduced a number of design and materials selection challenges. Perhaps foremost among these is the requirement for a thermal protection system (TPS) that would protect the crew during reentry and also minimize the intermission refurbishment requirements of the spacecraft itself. During the early days of the shuttle development program, there was much initial interest in a metallic TPS because it appeared to better meet the program's needs. Ultimately, however, ceramic tiles were used on the underbody and carbon-carbon composites (C-CCs) were used on the leading edges of the wings. The shuttle design itself can therefore be characterized as a "cold structure" with an insulating TPS. For example, much of the shuttle load-bearing structure is made of the Al alloy 2219, in part because it is fusion weldable and in part because it retains its strength at moderately elevated temperatures better than other high-strength Al alloys can. The refurbishment needs of the ceramic shuttle tiles after each flight reputedly are considerable and increase with vehicle age. The C-CC wing leading edges are basically not repairable but require scrutiny. Hindsight shows that C­ CCs "age" and lose much of their fracture toughness during repeated thermal exposure. (This loss of toughness was a prime factor in the Columbia disaster. Had a metallic heat shield that included the wing leading edges been used, this disaster arguably could have been avoided.) If the discussion of a metallic TPS were held today, the outcome might not be much different. Certainly any serious consideration of a reusable single­ stage-to-orbit vehicle today would need to reopen the discussion of a metallic TPS. The challenges and opportunities associated with a metallic TPS are discussed later. The design efficiency of an integrated TPS and load-bearing structure is extremely attractive. Such a design requires availability of high-temperature alloys that also have good strength at the moderate temperatures to withstand the aerodynamic and vibrational loads encountered during launch and orbital insertion. Any attractive alloy also must have reasonable intrinsic resistance to oxidation at the reentry temperatures and should be capable of being fabricated into sheet gauges at reasonable cost. Meeting these various requirements in combination becomes quite daunting. Earlier programs such as the DynaSoar reusable reentry glider devoted considerable time and resources to examining the use of refractory alloys such as Mo-0.5%Ti (Moly half Ti) and several Columbia-based alloys for the TPS and some hot structure. All the refractory metal alloys are solid solution strengthened and, consequently, have relatively low ambient temperature strengths. They also are quite dense, making the density-corrected strength even less attractive. Refractory metals and their alloys react extensively when exposed to air at elevated temperatures. Therefore, even if the mechanical property limitations could be overcome, any hot structure would require an oxidation-resistant protective coating. In the case of the DynaSoar program, scientists extensively investigated a surface conversion coating of MoSi2 formed by reacting the Moly half-Ti alloy with Si powder in a high-temperature fluidized bed. With the benefit of hindsight, it is now unclear how a large structure could have been successfully coated in this manner. This is particularly true when the brittle nature of MoSii is 9 UNCLASSIFIED/ 6FOA. OFFICI0L Pili 011! X • UNCLASSIFIED//Pelt OfFI61Ak WIiii ,u1L¥ considered in light of the thermal stresses that were certain to develop in a large structure placed in the fluidized bed. Reusable Single-Stage-to-Orbit Vehicles A reusable single-stage-to-orbit (SSO) vehicle will require metallic materials for the TPS and for much of the other hot structure. This will be challenging from the standpoint of an empty vehicle weight. With the exception of military applications, which are outside the scope of this document, empty vehicle weight is a critical metric because every additional pound of empty weight reduces the payload by the same amount (assuming a fixed propulsion capability). As mentioned earlier, the key to a lightweight vehicle is the use of design methods that integrate the TPS and the load-bearing structure to minimize structural redundancy and single-function structure (for example, a TPS that is not load bearing). Achieving this goal will require new design paradigms that incorporate true synthesis of new structural concepts. In reality, such designs can be completed only if they are based on a detailed set of mission requirements, including the number of missions and expectations for turnaround time between missions. Furthermore, operational parameters such as the value of inserting a pound of payload into orbit are needed to bound the cost of the initial vehicle and the maintenance cost per mission (translated into cost per pound of payload). Absent such specific data, the following discusses possibilities for materials systems that can enable a reusable SSO vehicle. It is perhaps more efficient to discuss these materials according to their principal capability and the anticipated temperature regime in which they can be used most productively. This categorization method is illustrated in Table 1. Table 1. Potential Materials by Use Temperature Regime and Property Temperature Specific Specific Fatigue Fracture Creep Regime Strength Stiffness Resistance Toughness Resistance PMCs; Ambient up to 250 °C Advanced Al alloys; AMCs* ; Ti alloys; PMCs; AMCs; TMCs PMCs; AMCs; Ti Alloys; TMCs PMCs; Ti alloys Ti alloys; TMCs TMCs* 250 °Cup to 550 °C Ti alloys; TMCs TMCs Ti alloys; TMCs Ti alloys Ti alloys; TMCs Above 550 °C Ni-base alloys; Ti aluminides; Refractory metal alloys; CMCs* ; C-C Cs* Ti aluminides; CMCs; c-ccs Ni-base alloys; Refractory metal alloys Ni-base alloys; CMCs; Refractory metal alloys Ni-base alloys; Ti aluminides; CMCs; Refractory metal alloys; C-C Cs AMCs = Al matrix composites; TMCs = titanium matrix composites; CMCs = ceramic matrix composites; C-CCs = carbon-carbon composites 10 UNCLASSIFIED//FOR. OFFl&IAk WIiii &Ptklf UNCLASSIFIED//FOR OFFl@IAL l!ISI!!! 9HLY Table 1 shows there are essentially 10 distinct classes of candidate materials for use in a reusable 550 vehicle. Their usefulness for specific applications and components depends on the operating temperature regime and the design -limiting material property. Some background and characteristics of each of these materials are described in this section. Applications of some of these materials have already been addressed, so the discussion here is limited to applications for a reusable S5O vehicle. Advanced Al Alloys This class of materials is limited by its temperature capability because, even if used in an embedded structure, the thermal soakback from the hot external structure can lead to softening in real time or averaging during extended exposure (that is, after several missions). Scientists have worked to develop high-temperature powder-metallurgy Al alloys, mainly alloys containing Fe, cobalt (Co) and cesium (Ce) or Mn and Si. These alloys are not routinely produced today owing to a lack of demand stemming in part from their cost and their relative lack of maturity as judged by the high variability in mechanical properties between lots of material. Consequently, the main application for Al alloys is in the crew compartment itself, where temperatures must be maintained at levels that are tolerable for the human occupants. Al alloys have marginal stiffness, even on a density-corrected basis. However, using fabricated panels with Al face sheets and a lightweight core can minimize this limitation. Such panels have a high section modulus, which increases the structural stiffness without adding much weight. Earlier uses of phenolic honeycomb cores experienced only limited success because of the tendency of the core to absorb water from the environment if a breach of the face sheet or the face sheet core bond occurred . Today, Al phenolic honeycomb sandwich construction is unpopular among aircraft and spacecraft designers because of this earlier, unfavorable experience. However, a new possibility for lightweight stiff structures-Al face sheets with a foamed Al alloy core-is worthy of consideration. Considerable progress in making uniform-density Al and other metallic foams has been realized in the past 10 years. This new class of sandwich materials is sufficiently different from the earlier versions to merit a careful evaluation. Polymer Matrix Composites As described in the Launch Vehicle section, polymer matrix composites have excellent strength, stiffness, fatigue resistance, and fracture toughness. All polymeric materials are to some degree susceptible to degradation when exposed to ultraviolet (UV) radiation. For an orbiting vehicle, a major limitation is the effects of UV radiation on the polymer matrix. Given their limited time at altitude, this vulnerability is not an issue for launch vehicles; however, it is a concern for structures that remain in orbit for an extended time at altitudes where the UV intensity is much greater. Although there are coatings that protect substrates (PMCs in this case) from UV radiation, the risk of these coatings being breached and the uncertainty about their effectiveness in orbit make UV exposure an ongoing concern. Any consideration of using PMCs for exterior applications would need to include an evaluation of their effectiveness. As discussed for Al alloys, PMCs also could be considered for interior applications where temperatures are within the material capabilities. As discussed earlier, some polyimide resins are usable up to about 300 °Celsius; therefore, the low density and excellent specific stiffness of PMCs make them viable candidates for some components. As also discussed, some polyimides, such as PMR-15, contain methylenedianiline, and care must be taken to 11 UNCLASSIFIED//FOR OFFIQl.\k Uili QPlk¥ UNCLASSIFIED/fFOA OFFI€1Ak Ulilii ONkY ensure that any outgassing that occurs in space would not liberate any of this toxic material-at least not where it could be ingested by the crew. Al Matrix Composites Al matrix composites (AMCs) are typically made by mixing short fibers or even particulate silicon carbide (SiC) with Al alloy powder and hot-pressing or mechanically consolidating the mixture by extrusion or forging. AMCs have higher modulus and strength but suffer ductility losses owing to the hard, nondeforming SiC second phase. They also are much better in fatigue because the SiC particles or short fibers mitigate the effects of planar slip in precipitation-hardening alloy matrices. Machining, fusion­ welding, or cold-forming AMCs is difficult. Mechanical fastening is possible, but drilling fastener holes is difficult and expensive because the wear caused by the hard, reinforcing phases shortens tool life. Most of the AMCs produced to date have used relatively simple Al matrix alloys such as 6061 and 5083. This presumably is because of the conventional wisdom that AMCs are not heat treatable and the perception that no benefit is gained by using more complex alloy matrices. This is probably the case for a conventional solution treat-and-age approach. Consequently, there has been little effort to optimize AMC systems. For the right application where AMCs could provide a significant benefit, this could present an opportunity. For example, using the high-temperature Al-Fe-Co-Ce alloy powder as the matrix could prove interesting and might permit use of AMCs at up to 200 °Celsius-a temperature at which Ti alloys do not provide any significant advantage, but one that is too high for conventional Al alloys to be suitable. In sum, while AMCs are not really a commercial materials system today, sufficient research has been performed to establish proof of concept. If an adequate market for AMCs were to emerge, the time and cost to make them commercially available could prove acceptable. Ti Alloys Ti alloys also have been discussed earlier, but mainly in the context of heavy-section, large-load-bearing applications for launch vehicles. Here, the potential of Ti alloys for lighter gauge applications in the warm structure and the TPS is considered. Table 1 shows that at intermediate temperatures, Ti alloys are attractive in all aspects except for specific stiffness. What this table does not capture is Ti alloys' propensity to react with oxygen in the air to form an oxygen-stabilized a phase layer on the surface known as a case. An example of a case is shown in Figure 3. 12 UNCLASSIFIED//FOA OFFICiI>k n&'lii ODIL¥ UNCLASSIFIED/;'FOR OFFl&IAl W&IE 9fslllf Figure 3. Micrograph Showing a Phase Formation at the Surface of a Ti Alloy That has Been Exposed to Air at Elevated Temperature The a case is harder than the matrix because oxygen is a potent a-phase solid-solution strengthener. As with almost all other strengthening reactions, the increased strength is accompanied by reduced ductility. Again, drawing on conventional wisdom, the presence of a case in sheet structures has been forbidden by specification, design practice, or whatever means a company uses to manage its hardware. Less clear is how truly detrimental a case is to properties. Essentially no effort has been made to determine whether it can be tolerated if the affected hardware is allowed to operate at a modestly reduced stress. The industry standard for a case has essentially been one of zero tolerance. Given the significant potential weight advantage associated with use of Ti alloys in portions of the TPS and warm structure, this conservative approach needs to be revisited. Several key questions related to this are: • Is a case truly detrimental to the load-bearing capability of Ti alloy sheet structures? • If so, is there a limiting amount that can be tolerated without significantly degrading the structural capability? • Which properties are the most severely degraded? • Are a case formation and property degradation alloy dependent? • If so, which alloys are the most tolerant of a case formation? 13 UNCLASSIFIED/ /FOR OFFI&IAl Wliliii QfslL¥ UNCLASSIFIED//FOil OFFl@IAL YSli 8Ptllf • Once a case is present, can the structure be repaired (for example, by fusion or friction stir welding)? The Air Force Materials and Manufacturing Directorate is starting a new project intended to address these questions. The motivation for this program is hypersonic flight vehicles. The results from this U.S. Air Force program should prove highly useful to the design of future reusable SSO vehicles. Earlier uses of Ti alloys at high temperatures included the skin and much of the load­ bearing structure of the SR-71 Blackbird. This airplane flew successfully at peak speeds in excess of mach 3.2 for 34 years (1964-1998). While the maximum skin temperatures are not readily available, they were in excess of 300 °Celsius. There were no known issues involving a case during the SR-71's service. Notably, the primary alloy used for the SR-71 was one of the original ~-Ti alloys, B-120 VCA, the composition of which is Ti-13V-11Cr-3AI. The primary reason for choosing this alloy was that it is much easier than any of the a +~ Ti alloys are to roll into sheet gauges. Today there are newer ~-Ti sheet alloys featuring a better balance of properties that could be used in the same way as B-120 VCA. The most common of these is Ti-15V-3Cr-3Sn-3AI. However, the successful use of B-120 VCA raises the question of whether ~- Ti alloys are more resistant than a+ ~ alloys such as Ti-6-4 are to a case formation. The attraction to using Ti alloys, in addition to their structural efficiency, is the extensive industrial base for making the material in a variety of product forms and the extensive knowledge base resulting from the many successful applications of Ti alloys in high-performance products. For example, the ability to superplastically form Ti alloys such as Ti-6-4 creates the opportunity for design of a structure that functions both as load bearing and as thermal protection. Ti Matrix Composites As Table 1 showed, Ti alloys are not especially attractive for their specific stiffness. One way to overcome this limitation is to reinforce a Ti alloy matrix with SiC fibers. In this case, the fibers are "long" fibers-they have sufficient length for the matrix to transfer the maximum possible fraction of the external load to the fiber. The fibers are essentially monofilaments and must be carefully placed so adjacent fibers do not touch one another. Areas of contact between fibers essentially are incipient cracks that degrade the mechanical strength. As Table 2 shows, TMCs have excellent properties. Table 2. Example of Properties of Ti Matrix Composites Property Property Value (English /Metric Units) Ultimate tensile strenqth 276 ksi / 1902 MPa Young's modulus 32.8 msi / 226 GPa Strain to fracture 0.95% Density 0.16 lb/in 3 / 4.43 q/cm3 Fiber Volume fraction 0.39 14 UNCLASSIFIED/;SFOR. OFFl&IAL Y&li 8Ptllf UNCLASSIFIED/ fFOR 8FFI@IAL YSI!! f>HLY Figure 4 shows an example of a TI matrix composite (TMC) cross section. Figure 4. Cross-Section Micrograph of a Ti Matrix Composite. Small, dark centers of fibers are C monofilament substrates for deposition of SiC (light micrograph). Material system: Matrix alloy - Ti-6242; Fiber - SiC about 5.6-mil-diameter SCS-6 Table 2 shows that the strength and stiffness properties of TMCs can exceed those of the Ti matrix (or other a.+13 Ti alloys) by more than a factor of two with no increase in density. So why are TMCs not in widespread use? The foremost reason is cost. Another reason is the availability of SiC fiber for TMCs. • During the 1990s, when the U.S. government (mainly DoD) was interested in and provided development money for TMC R&D, the most attractive reinforcing fiber was SCS-6™, which was produced exclusively by Textron Specialty Materials (TSM) in Lowell, MA. • Unfortunately (at least in hindsight), TSM made a business decision not to sell fiber and to instead forward-integrate and sell TMC components or finished TMC mill products. This decision stemmed in part from TSM's negative business experience with development of B-based fiber (Boro-SiC™) for first-generation TMCs. • Prior to making this business decision, TSM did not develop sufficient TMC­ manufacturing expertise to properly position itself as a producer of TMC products with consistent properties. 15 UNCLASSIFIED/ f FOR OFFIQl.\k Uili Qfslk¥ UNCLASSIFIED/,'FOR OFFl@IAL YSE OHL¥ • A couple of costly and highly visible TMC component test failures using TSM materials called into question the viability of TMCs. In truth, the real issue was one of quality and not the fundamental viability of the TMC material concept. • These failures led to extreme caution by the government, which promptly imposed stringent quality requirements on TSM. Consequently, TSM became a serious bottleneck for availability of TMCs with acceptable quality. As a result, numerous large, government-funded R&D programs fell behind schedule to the point that some were canceled and others were abandoned. • Other, less attractive SiC fibers were being developed during this period, including Nicalon in Japan and Sigma in the United Kingdom. Because SiC fiber and TMCs were deemed strategic materials and neither of these alternate fibers was produced in the United States, there was reluctance to experiment with them, and the U.S. government occasionally prohibited their use in federally funded R&D programs. • The issue of fiber availability became a major distraction from the real business at hand-that is, improving the consistency and reducing the cost of the TMC product. • In the end, TSM partially relented, but by then such limited interest in TMCs existed that the original opportunity was lost. Furthermore, there still was no concrete evidence that TMCs could be produced with sufficiently consistent properties that they could be considered an engineering material (at any cost). • In the mid-1990s, a cost study that assumed fiber availability showed that TMCs that meet specification properties could be manufactured for about $500/lb (in 1995 $) if the use volume was about 10,000 lb/year. Finding enough low-risk, high-value applications to consume this quantity of TMCs was not deemed possible. • Consequently, work on TMCs halted after an investment of about $500 million of U.S. government funds and a (presumably) comparable, but less well known private sector (mostly independent R&D $) investment. • One lesson from this is that a credible market and cost study should be undertaken before embarking on a major R&D program to develop revolutionary materials such as TMCs. The foregoing discussion exemplifies the challenges associated with developing and commercializing a revolutionary new materials system. New material concepts originating from nonproduction sources such as national laboratories or research universities should be approached with caution and never be put on the critical path of product design. Even if a new material is vetted through an established production source, the timing of full commercialization should be carefully examined. Ni-base Alloys Ni-base alloys have been considered real engineering materials for at least 40 years. Because of their relatively low rate of strength loss with increasing temperature, Ni­ base alloys are also called "superalloys." They are commonly used at temperatures well in excess of half of their melting point (Tm), which is the accepted useful limit for most structural metallic materials. There is no other class of structural alloys for which this is true. Ni-base alloys have been used in turbine engines of all types almost since their 16 UNCLASSIFIED//FOA OFFICiIAk Wlilii 0PU.¥ UNCLASSIFIED//PO" orr1e11tt U.!I! l>flt I inception. In fact, Ni-base alloys are a prime enabler of the modern gas turbine engine. As a result, this class of materials has a well-established industrial base for the production of literally all product forms. There is a second class of Ni-base alloys that has excellent resistance to attack in aggressive environments, such as those encountered in petroleum recovery, but these alloys are not of interest for high­ temperature applications. To avoid any confusion, the term Ni-base alloys is used in this document to mean high-temperature Ni-base alloys. Ni-base alloys have a high elevated temperature strength because they typically contain Al and Ti, which enable them to be precipitation strengthened. The alloys with the highest temperature capability are strengthened by precipitates of Ni3AI (called y'), which have a positive temperature coefficient of strength up to about 1,000 °Celsius. This unusual characteristic accounts for Ni-base alloys' elevated temperature capability. In combination with the ordinary temperature dependence of the matrix strength, the overall temperature dependence is quite low compared with that of any other class of structural alloys. Ni-base alloys also contain alloying additions of refractory elements such as tungsten (W), tantalum (Ta), and niobium (Nb). These additions also improve the elevated temperature strength because they diffuse slowly and strengthen the matrix. Because Ni-base alloys are used at elevated temperatures, they contain Cr additions in significant concentrations to improve their oxidation resistance. The t