FUSED WITH ZIRCONIA COMPOSITES

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International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 7, July 2017, pp. 455 461, Article ID: IJMET_08_07_052 Available online at http://www.ia aeme.com/ijm MET/issues.

1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 7, July 2017, pp , Article ID: IJMET_08_07_052 Available online at aeme.com/ijm MET/issues.as asp?jtype=ijm MET&VType=8&IType= =7 ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed HOT GUARD AND PLASMAA JET EVALUATION OF C-PH AND C-PH FUSED WITH ZIRCONIA COMPOSITES Sravanthi G, Satyaa Sandeep C, Swathi G, Ragha Leena.Ch, Rathan A Assistant Professor, Department of Aeronautical Engineering, Institute of Aeronautical Engineering, Hyderabad, India Praveen B Assistant Professor, Department of Aeronautical Engineering, Marri Lakshman Reddy Institute of Technology, Hyderabad, India ABSTRACT Materials having efficient heat shielding properties are required for machines which operate at very highh temperatures. Carbon fibre composites are well knownn for their mechanical properties. In the present study C-Ph laminates along with C-Ph fused with zirconia weree manufactured. Hot guard test and Plasma jet test were conducted to compare the thermal conductivity and ablation properties of both the composite laminates. The advantage of C-Ph fused with zirconia compared with blank C-Ph in heat shielding was observed and reported. Key words: C-Ph composites, C-Ph with Zirconia Composite, Thermal conductivity, Ablation properties. Cite this Article: Sravanthi G, Satyaa Sandeep C, Swathi G, Ragha Leena.Ch, Rathan A and Praveen B. Hot Guard and Plasma Jet Evaluation of C-Ph and C-Ph Fused with Zirconia Composites. International Journal Technology, 8(7), 2017, pp of Mechanical Engineering and http: :// me.com/ijm MET/issues.a asp?jtype=i IJMET&VType=8&ITy ype=7 1. INTRODUCTION Gas turbine engines operate at very higher temperatures. It is a great challenge to manufacture aircraft engines and the liners guiding nozzles of aircraft which can withstand high temperatures. Thermal conductivity of these materials should be minimumm so that it could not let energy generated in the engines dissipate outside. Composite materials are modern era smart materials which inhabit large strengths and structural properties. Many investigations have been made to come up with different composite materials which can be used as heat shields. In 1970, Kenneth Sutton have conducted experiments to determine the ablative properties of carbon phenol composites. The main aim behind his experimentation was to calculate the 455 editor@iaeme..com

2 Hot Guard and Plasma Jet Evaluation of C-Ph and C-Ph Fused with Zirconia Composites heat shielding of the composites to use them for aerospace applications. He reported that injection of the water has minimum effect on the behaviour of these composites. [9] Carbon phenol composites added with other materials have shown some increased properties in the material characteristics. Srikanth and his group has done investigations and made a conclusion that C-Ph composite with zirconia have less thermal conductivity and more ablation rate. [1] Yaxi Chen and team have done investigations and reported that ZrBr 2 fused into C-Ph composites increase the ablation rate. [2] Carbon phenol composites fabricated with Nano silica have increased ablation resistance. [6] Alessandro Turchi and team developed a computer code to evaluate the ablative properties. E.V. Morozov and team developed a finite element code ADINA to numerically simulate the thermo structural response of the composites. [8] Uncertainty in codes were identified and comparison with the experiments have been done to validate the code. [3] Donghwan cho and his team have done investigations on the oxidation effects on the ablation phenomena of carbon fibre reinforced composites. [4] Experiments were also conducted to determine the friction and wear characteristics of carbon fibre phenol composites is better than composites like asbestos fibre. [5] The heat resistance properties of the composite materials made it flexible to use them for the application of the re-entry vehicle. G.Pulci and the team conducted experiments on C-Ph composites to test their use in space re-entry vehicles and concluded their efficiency. [7] Ahmad Reza Bahramian and his team made investigations on the Ablation and thermal degradation behaviour of a composite based on resol type phenolic resin and came out with observations on the temperature arrangement along the composite thickness, temperature of moving surface, and the rate of moving boundary changes. They found that the values are in a positive agreement with the experimental evaluation got from oxyacetylene flame tests. They came out with conclusion that the model can successfully be used for both material selection and thickness calculation in the design of thermal protection shields. [10] All the above mentioned research and development theories vote for the efficiency in the use of composite materials C-Ph composites with additional materials like zirconia as perfect heat shields. The present article mainly concentrates on the comparison thermal conductivity and ablation properties of the C-Ph and C-Ph with zirconia. 2. PREPARATION OF THE COMPOSITES 2.1. Preparation of Blank Carbon Phenol Composite Carbon fibre of 450 mm X 1 meter thickness was taken and phenolic resin coating was applied on it using the wet layup technique. It was allowed to dry at the room temperature. The phenolic resin coated with carbon fibre were cut into 150mm X 150mm and were stacked into vacuum bagging. Then it was sent for curing with first temperature set to 100 degrees and was soaked till 20 minutes. Next temperature was set up to 115 degrees and load was applied to soak for 15 minutes. The next temperature was set to 160 degrees with load applied and soaked for three hours. The obtained composite was filed using diamond cutting machine. Finally the laminated composite was of length mm, width mm, thickness 5.5 mm and density of 1.21 g/cc. 456 editor@iaeme.com

11 molar ratio (typical composition is 58.

hour with the help of a magnetic stirrer

Prepared sol is applied on the surface of

allowed to dry at room temperature for 96

3 Sravanthi G, Satya Sandeep C, Swathi G, Ragha Leena.Ch, Rathan A and Praveen B Figure 1 Prepared Blank carbon phenolic composite laminates 2.2. Preparation of Carbon Fibre-Zirconia Based Functionally Graded Carbon ph Composite To prepare the zirconia sol, zirconium oxy chloride, ethanol and DM water were mixed in 0.05: 2..38: 1.11 molar ratio (typical composition is g of zirconium oxy chloride: ml of water: ml of ethanol) and stirred for one hour with the help of a magnetic stirrer for 60 minutes at room temperature. Then the sol is allowed to stand for 24 hours. Prepared sol is applied on the surface of the carbon fabric with the help of spray gun at a pressure of 20 40kg/cm². Sol to gel conversion takes place by following reaction The quantity of the sol required to apply on the fabric is decided based on the theoretically expected yield of the zirconia. Theoretically one mole of zirconium chloride will give 38.25g of zirconia. The zirconia coated fabric is allowed to dry at room temperature for 96 hours or till it attains constant weight. The zirconia is applied to the fabric through gun spray as shown in the figure 2. Phenolic resin mixture is applied on the carbon fabrics having 3.5wt% of zirconia coating. These are allowed to dry at room temperature.. Zirconia coated carbon fabric prepegs are cut in to 150mm *150mm pieces, stacked up and curing followed at 180 C. Figure 2 Spray gun to apply zirconia on C-Ph composite 457 editor@iaeme..com

Hot Guard and Plasma Jet Evaluation of C-Ph and C-Ph Fused with Zirconia Composites 3.

sample and an unknown sample and comparing the respective thermal gradients, which will be

Most commonly, the unknown is sandwiched between two known samples, the references, to

Figure 3 shows the schematic diagram of hot guard testing method.

Plasma Arc Jet Test To calculate the ablation resistance using ablative conditions and to

Three samples from each of the laminate are machined in to ϕ10 * 17.6mm (+/- 0.1mm) size.

Figure 4 Plasma arc test Specimens are exposed to plasma arc jet at a flame velocity of

4 Hot Guard and Plasma Jet Evaluation of C-Ph and C-Ph Fused with Zirconia Composites 3. EXPERIMENTAL TECHINQUES TO TEST THERMAL CONDUCTIVITY AND ABLATION PROPERTIES OF THE COMPOSITESS 3.1. Hot Guard Testing Method Hot guard testing method is one of the efficient way to test axial thermal conductivity of materials. In this, the principle of the measurement lies with passing the heat flux through a known sample and an unknown sample and comparing the respective thermal gradients, which will be inversely proportional to their thermal conductivities. Most commonly, the unknown is sandwiched between two known samples, the references, to further account for minor heat losses that are very difficult to eliminate. Figure 3 shows the schematic diagram of hot guard testing method. Figure 3 Hot guard testing method to determine the thermal conductivity of composites 3.2. Plasma Arc Jet Test To calculate the ablation resistance using ablative conditions and to find out the back phase temperature, a test is conducted known as Plasma arc jet test. Three samples from each of the laminate are machined in to ϕ10 * 17.6mm (+/- 0.1mm) size. Samples are encircled with the guard rings which are made up of the same compositions as that of the test specimens. Guard ring ensures unidirectional exposure of test specimen to the plasma arc jet. Figure 4 Plasma arc test Specimens are exposed to plasma arc jet at a flame velocity of about 1 Mach and a stagnant flux of 4..0 MW/m² for 30 seconds. To measure the back face temperature of the specimen during the test duration, K type thermo couples are attached to the specimen face which is away from the plasma arc. Ablation rate is determined by dividing the weight loss during the test with arcing time in seconds. Averagee rate is determined after repeating the test 458 editor@iaeme..com

Sravanthi G, Satya Sandeep C, Swathi G, Ragha Leena.

Figure 4 shows a plasma jet test for determination of the ablation properties. 4.. RESULTS AND DISCUSSIONS DISCUSSIONS 4.

onductivity A sample of 25 mm circular diameter is being cut from the obtained laminate and

To conduct the hot guard testing 25mm sample diameter of blank C-Ph C Ph was taken with fused

00 W/Mk as the reference material. The results obtained are presented in table 1.

compare the results. The data obtaine obtainedd is tabulated in table 2.

Temp Sample Bottom Temp Average Temp Thermal Conductivity (W/Mk) (Degree gree C) 1 60 42.

8 0.525 5 340 175.1 112.4 143.8 0.520 6 380 175.4 112.3 143.9 0.

Sno Time 1 2 3 4 5 6 60 140 200 300 340 380 Sample Top Temp 42.2 56.8 111 173.4 175.1 175.

5 Sravanthi G, Satya Sandeep C, Swathi G, Ragha Leena.Ch, Rathan A and Praveen B for three specimens from each laminate. Figure 4 shows a plasma jet test for determination of the ablation properties. 4.. RESULTS AND DISCUSSIONS DISCUSSIONS 4.1. Results of Hot Guard uard Testing esting to Determine etermine Thermal hermal Conductivity onductivity A sample of 25 mm circular diameter is being cut from the obtained laminate and tested. To conduct the hot guard testing 25mm sample diameter of blank C-Ph C Ph was taken with fused silica ilica of 25 mm diameter and thermal conductivity of 1.00 W/Mk as the reference material. The results obtained are presented in table 1. After this same experiment was repeated by using specimen of C C-Ph Ph with zirconia to compare the results. The data obtaine obtainedd is tabulated in table 2. Table 1 Hot guard test results for blank C C-Ph Ph composite laminate Sno SnoTime Sample Top Temp Sample Bottom Temp Average Temp Thermal Conductivity (W/Mk) (Degree gree C) Table 2 Hot guard test results for blank C C-Ph Ph composite laminate fused with zirconia Sno Time Sample Top Temp Sample Bottom Temp (Degree ree C) Average Temp Thermal Conductivity (W/Mk) Figure 5 Comparison of thermal conductivity of blank C-Ph C Ph and C-Ph C Ph fused with zirconia asp 459 editor@iaeme.com

6 Hot Guard and Plasma Jet Evaluation of C-Ph and C-Ph Fused with Zirconia Composites The comparison clearly shows that the C-ph fused with zirconium is capable of heat shielding than blank C-Ph because it is exhibiting less thermal conductivity Results of Plasma Arc Testing to determine the Ablation Resistance Plasma jet testing was conducted to determine the ablation rate of the blank C-ph and C-ph fused with zirconium for a test duration of 30 seconds. Erosion rate and back wall temperature were calculated and reported in table 3. Reports clearly showed that C-Ph with zirconia had low back wall temperature and high erosion rate when compared with Blank C-Ph. A conclusion can be made that C-Ph with zirconium though having high erosion rate, it can be used for heat shielding than blank C-Ph composite. S.No Specimen Heat flux (W/mm²) Table 3 Test duration (s) Erosion rate (mm/s) Back wall temperature ( C) 1 Blank (C-Ph) 2 C-Ph with Zirconia CONCLUSIONS Carbon fibre was fused with phenol to manufacture C-Ph composite laminate through prepegging and curing processes. After this Zirconium was also fused to C-Ph laminate through spray gun and curing process to make C-Ph-Zirconia laminate. Hot guard testing was performed on both C-Ph and C-Ph-Zirconia laminates at different time periods and a conclusion was made that C-Ph-Zirconia laminates have less thermal conductivity. Apart of this plasma arc jet tests were conducted to determine ablation rates. A conclusion was made that C-Ph fused with zirconia laminates have exhibited less back wall temperatures and more erosion rates when compared with blank C-Ph laminates. An overall observation was made that C-Ph fused with Zirconium can be better heat shielding materials. REFERENCES [1] Srikanth, N. Padmavathi, Suresh Kumar, P. Ghosal, Anil Kumar, Ch. Subrahmanyam, Mechanical, thermal and ablative properties of zirconia, CNT modified carbon/phenolic composites, Composites Science and Technology 80 (2013) 1 7, Elsevier, [2] Yaxi Chen a, Ping Chen, Changqing Hong, Baoxi Zhang, David Hui, Improved ablation resistance of carbon phenolic composites by introducing zirconium diboride particles, Composites: Part B 47 (2013) , [3] Alessandro Turchi, Pietro M. Congedo, Thierry E. Magin, Thermochemical ablation modelling forward uncertainty analysis Part I: Numerical methods and effect of model parameters, International Journal of Thermal Sciences (2017) 1-13, Elsevier, [4] Donghwan cho, Jin yong lee, Byung ilyoon, Microscopic observations of the ablation behaviours of carbon fibre/phenolic composites. Journal of materials science letters 12 (1993) [5] Seong Su Kim, Dong Chang Park, Dai Gil Lee, Characteristics of carbon fibre phenolic composite for journal bearing materials, Composite Structures 66 (2004) doi: /j.compstruct editor@iaeme.com

7 Sravanthi G, Satya Sandeep C, Swathi G, Ragha Leena.Ch, Rathan A and Praveen B [6] Srikanth, Alex Daniel, Suresh Kumar, N. Padmavathi, Vajinder Singh, P. Ghosal, Anil Kumara and G. Rohini Devi, Nano silica modified carbon phenolic composites for enhanced ablation resistance, Scripta Materialia 63 (2010) , doi: /j.scriptamat [7] G. Pulci, J. Tirillò, F. Marra, F. Fossati, C. Bartuli, T. Valente, Carbon phenolic ablative materials for re-entry space vehicles: Manufacturing and properties, Composites: Part a 41 (2010) , doi: /j.compositesa [8] E.V. Morozov, J.F.P. Pitot de la Beaujardiere, Numerical simulation of the dynamic thermo structural response of a composite rocket nozzle throat, Composite Structures 91 (2009) , doi: /j.compstruct [9] Kenneth Sutton, An experimental study of a carbon-phenolic ablation material, NASA technical note TN D [10] Ahmad Reza Bahramian, Mehrdad Kokabi, Mohammad Hossein Navid Famili Mohammad Hossein Beheshty, Ablation and thermal degradation behaviour of a composite based on resol type phenolic resin: Process modelling and experimental, doi: /j.polymer [11] A. Lakshumu Naidu, V. Jagadeesh and M V A Raju Bahubalendruni, A Review on Chemical and Physical Properties of Natural Fiber Reinforced Composites. International Journal of Advanced Research in Engineering and Technology, 8(1), 2017, pp editor@iaeme.com

MODELING AND ANALYSIS OF HEXAGONAL UNIT CELL FOR THE PREDICTION OF EFFECTIVE THERMAL CONDUCTIVITY

MODELING AND ANALYSIS OF HEXAGONAL UNIT CELL FOR THE PREDICTION OF EFFECTIVE THERMAL CONDUCTIVITY International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 5, May 2017, pp. 651 655, Article ID: IJMET_08_05_071 Available online at http://www.iaeme.com/ijmet/issues.asp?jtype=ijmet&vtype=8&itype=5