Propulsion System Materials Program semiannual progress report for April 1995 through September 1995

Significant accomplishments in fabricating ceramic components for the DOE, NASA, and DOD advanced heat engine programs have provided evidence that the operation of ceramic parts in high-temperature engine environments is feasible. These programs have also demonstrated that additional research is needed in materials and processing development, design methodology, and data base and life prediction before industry will have a sufficient technology base from which to produce reliable cost-effective ceramic engine components commercially. An assessment of needs was completed, and a 5-year program plan was developed with extensive input from private industry. During the course of the Propulsion System Materials Program, remarkable progress has been made in the development of reliable structural ceramics. However, further work is needed to reduce the cost of ceramics to facilitate their commercial introduction, especially in the highly cost-sensitive automotive market. To this end, the direction of the Propulsion System Materials Program is now shifting toward reducing the cost of ceramics to facilitate commercial introduction of ceramic components for near-term engine applications. In response to extensive input from industry, the plan is to extend the engine types which were previously supported to include near-term (5--10 years) applications in conventional automobile and diesel truck engines. To facilitate the rapid transfer of this technology to US industry, the major portion of the work is being done in the ceramic industry, with technological support from government laboratories, other industrial laboratories, and universities. A systematic approach to reducing the cost of components is envisioned. The work elements are as follows: economic cost modeling, ceramic machining, powder synthesis, alternative forming and densification processes, yield improvement, system design studies, standards development, low-expansion ceramics, and testing and data base development