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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS1994

Plasma sprayed ceramic thermal barrier coating for NiAl-based intermetallic alloys

A thermal barrier coating system consists of two layers of a zirconia-yttria ceramic. The first layer is applied by low pressure plasma spraying. The second layer is applied by conventional atmospheric pressure plasma spraying. This facilitates the attachment of a durable thermally insulating ceramic coating directly to the surface of a highly oxidation resistant NiAl-based intermetallic alloy after the alloy has been preoxidized to promote the formation of a desirable Al2O3 scale.

Miller, Robert A.↗
NASA NTRS2007

High-Heat-Flux Cyclic Durability of Thermal and Environmental Barrier Coatings

Advanced ceramic thermal and environmental barrier coatings will play an increasingly important role in future gas turbine engines because of their ability to protect the engine components and further raise engine temperatures. For the supersonic vehicles currently envisioned in the NASA fundamental aeronautics program, advanced gas turbine engines will be used to provide high power density thrust during the extended supersonic flight of the aircraft, while meeting stringent low emission requirements. Advanced ceramic coating systems are critical to the performance, life and durability of the hot-section components of the engine systems. In this work, the laser and burner rig based high-heat-flux testing approaches were developed to investigate the coating cyclic response and failure mechanisms under simulated supersonic long-duration cruise mission. The accelerated coating cracking and delamination mechanism under the engine high-heat-flux, and extended supersonic cruise time conditions will be addressed. A coating life prediction framework may be realized by examining the crack initiation and propagation in conjunction with environmental degradation under high-heat-flux test conditions.

Zhu, Dongming↗
DOE OSTI2020

Preparation, analysis, and application of coated glass targets for the Wendelstein 7-X laser blow-off system

Coated glass targets are a key component of the Wendelstein 7-X laser blow-off system that is used for impurity transport studies. The preparation and analysis of these glass targets as well as their performance is examined in this paper. The glass targets have a high laser damage threshold and are coated via physical vapor deposition with μm thick films. In addition, nm-thin layers of Ti are used as an interface layer for improved ablation efficiency and reduced coating stress. Hence, the metallic or ceramic coating has a lateral homogeneity within 2% and contaminants less than 5%, being optimal for laser ablation processing. With this method, a short (few ms) and well defined pulse of impurities with about 1017 particles can be injected close to the last closed flux surface of Wendelstein 7-X. In particular, a significant amount of atoms with a velocity of about 1 km/s enters the plasma within 1 ms. The atoms are followed by a negligible concentration of slower clusters and macro-particles. This qualifies the use of the targets and applied laser settings for impurity transport studies with the laser blow-off system in Wendelstein 7-X.

47 OTHER INSTRUMENTATION↗
NASA NTRS1983

Mechanical and physical properties of plasma-sprayed stabilized zirconia

Physical and mechanical properties were determined for plasma-sprayed MgO- or Y2O3-stabilized ZrO2 thermal barrier coatings. Properties were determined for the ceramic coating in both the freestanding condition and as-bonded to a metal substrate. The properties of the NiCrAlY bond coating were also investigated.

Siemers, P. A.↗
NASA NTRS1996

Evaluation of Oxidation Damage in Thermal Barrier Coating Systems

A method based on the technique of dilatometry has been established to quantitatively evaluate the interfacial damage due to the oxidation in a thermal barrier coating system. Strain isolation and adhesion coefficients have been proposed to characterize the thermal barrier coating (TBC) performance based on its thermal expansion behavior. It has been found that, for a thermal barrier coating system consisting of ZrO2-8%Y2O3/FeCrAlY/4140 steel substrate, the oxidation of the bond coat and substrate significantly reduced the ceramic coating adherence, as inferred from the dilatometry measurements. The in-situ thermal expansion measurements under 30 deg C to 700 deg C thermal cycling in air showed that the adhesion coefficient, A(sub i) decreased by 25% during the first 35 oxidation cycles. Metallography showed that delamination occurred at both the ceramic/bond coat and bond coat/substrate interfaces. In addition, the strain isolation effect has been improved by increasing the FeCrAlY bond coat thickness. The strain isolation coefficient, Si, increased from about 0.04 to 0.25, as the bond coat thickness changed from 0.1 mm to 1.0 mm. It may be possible to design optimum values of strain isolation and interface adhesion coefficients to achieve the best TBC performance.

THERMAL PROPERTIES↗
NASA NTRS1985

Top-Coating Silicon Onto Ceramic

Polycrystalline silicon for solar cells produced at low cost. Molten silicon poured from quartz trough onto moving carbon-coated ceramic substrate. Doctor blade spreads liquid silicon evenly over substrate. Molten material solidifies to form sheet of polycrystalline silicon having photovoltaic conversion efficiency greater than 10 percent. Method produces 100-um-thick silicon coatings at speed 0.15 centimeter per second.

Heaps, J. D.↗
NASA NTRS2003

NASA Glenn/AADC-Rolls Royce Collaborated to Measure Erosion Resistance on Coated Polymer Matrix Composites

Polymer matrix composites (PMCs) are increasingly used in aerospace and automotive applications because of their light weight and high strength-to-weight ratio relative to metals. However, a major drawback of PMCs is poor abrasion resistance, which restricts their use, especially at high temperatures. Simply applying a hard coating on PMCs to improve abrasion and erosion resistance is not effective since coating durability is short lived (ref. 1). Generally, PMCs have higher coefficients of thermal expansion than metallic or ceramic coatings have, and coating adhesion suffers because of poor interfacial adhesion strength. One technique commonly used to improve coating adhesion or durability is the use of bond coats that are interleaved between a coating and a substrate with vastly different coefficients of thermal expansion. An example of this remedy is the use of bondcoats for ceramic thermal barrier coatings on metallic turbine components (ref. 2). Prior collaborative research between the NASA Glenn Research Center and the Allison Advanced Development Company (AADC) demonstrated that bond coats sandwiched between PMCs and high-quality plasma-sprayed, erosion-resistant coatings substantially improved the erosion resistance of PMCs (ref. 3). One unresolved problem in this earlier collaboration was that there was no easy, accurate way to measure the coating erosion wear scar. Coating wear was determined by both profilometry and optical microscopy. Both techniques are time consuming. Wear measurement by optical microscopy requires sample destruction and does not provide a comprehensive measure of the entire wear volume. An even more subtle, yet critical, problem is that these erosion coatings contain two or more materials with different densities. Therefore, simply measuring specimen mass loss before and after erosion will not provide an accurate gauge for coating and/or substrate volume loss. By using a noncontact technique called scanning optical interferometry, which was recently developed at Glenn, researchers can accurately determine the wear performance of erosion-coated PMCs while preserving the sample. An example of this interferometry technique is shown in the preceding figure for an erosion-coated inlet guide vane from a Rolls Royce AE3007 regional gas turbine jet engine. Erosion was conducted with coated and uncoated PMC vanes, with the abrasive material moving at a velocity of 229 m/s at impingement angles of 20 and 90 degrees. The coatings for PMCs remarkably reduced the erosion volume loss by a factor of approximately 10. Currently, several erosion coatings for PMCs are being compared and downselected for engine testing at Rolls Royce.

Miyoshi, Kazuhisa↗
NASA NTRS1994

High-temperature behavior of advanced spacecraft TPS

The objective of this work has been to develop more efficient, lighter weight, and higher temperature thermal protection systems (TPS) for future reentry space vehicles. The research carried out during this funding period involved the design, analysis, testing, fabrication, and characterization of thermal protection materials to be used on future hypersonic vehicles. This work is important for the prediction of material performance at high temperature and aids in the design of thermal protection systems for a number of programs including programs such as the National Aerospace Plane (NASP), Pegasus and Pegasus/SWERVE, the Comet Rendezvous and Flyby Vehicle (CRAF), and the Mars mission entry vehicles. Research has been performed in two main areas including development and testing of thermal protection systems (TPS) and computational research. A variety of TPS materials and coatings have been developed during this funding period. Ceramic coatings were developed for flexible insulations as well as for low density ceramic insulators. Chemical vapor deposition processes were established for the fabrication of ceramic matrix composites. Experimental testing and characterization of these materials has been carried out in the NASA Ames Research Center Thermophysics Facilities and in the Ames time-of-flight mass spectrometer facility. By means of computation, we have been better able to understand the flow structure and properties of the TPS components and to estimate the aerothermal heating, stress, ablation rate, thermal response, and shape change on the surfaces of TPS. In addition, work for the computational surface thermochemistry project has included modification of existing computer codes and creating new codes to model material response and shape change on atmospheric entry vehicles in a variety of environments (e.g., earth and Mars atmospheres).

Pallix, Joan↗
NASA NTRS2011

Phase Stability and Thermal Conductivity of Composite Environmental Barrier Coatings on SiC/SiC Ceramic Matrix Composites

Advanced environmental barrier coatings are being developed to protect SiC/SiC ceramic matrix composites in harsh combustion environments. The current coating development emphasis has been placed on the significantly improved cyclic durability and combustion environment stability in high-heat-flux and high velocity gas turbine engine environments. Environmental barrier coating systems based on hafnia (HfO2) and ytterbium silicate, HfO2-Si nano-composite bond coat systems have been processed and their stability and thermal conductivity behavior have been evaluated in simulated turbine environments. The incorporation of Silicon Carbide Nanotubes (SiCNT) into high stability (HfO2) and/or HfO2-silicon composite bond coats, along with ZrO2, HfO2 and rare earth silicate composite top coat systems, showed promise as excellent environmental barriers to protect the SiC/SiC ceramic matrix composites.

Benkel, Samantha↗
NASA NTRS1959

Lubricating Properties of Lead-Monoxide-Base Coatings of Various Compositions at Temperatures to 1250 F

A number of ceramic coatings of different compositions containing lead monoxide (PbO) were studied to determine their relative merits as dry-film lubricants. Lead monoxide is known to be an effective solid lubricant at elevated temperatures, and this oxide was the main component in all compositions studied. Friction and wear properties were determined at temperatures from 750 to 1250 F, at a sliding velocity of 430 feet per minute, and at a normal load of 1 kilogram. In all of the coatings, PbO was the component primarily responsible for the lubricating properties. Oxides other than PbO had an indirect effect on lubrication by influencing such properties as adhesion, hardness, vitrifying or glaze-forming tendency, melting or softening point, and chemical stability of the coatings. Notable among these oxides were magnetite (Fe3O4.), which had generally a beneficial influence on ceramic- to-metal adhesion, and silica (SiO2), which inhibited the oxidation of PbO and enhanced the tendency for glaze formation on the sliding surfaces. Several of the compositions studied provided protection against metal-to-metal adhesive wear, galling, or seizure at test temperatures from 750 to 1250 F. Coating friction coefficients ranged from 0.20 to 0.37 at 75 F but were around 0.08 to 0.20 at temperatures of 1250 F.

Sliney, Harold E.↗
NASA NTRS1999

Thermal Protective Coating for High Temperature Polymer Composites

The central theme of this research is the application of carboxylate-alumoxane nanoparticles as precursors to thermally protective coatings for high temperature polymer composites. In addition, we will investigate the application of carboxylate-alumoxane nanoparticle as a component to polymer composites. The objective of this research was the high temperature protection of polymer composites via novel chemistry. The significance of this research is the development of a low cost and highly flexible synthetic methodology, with a compatible processing technique, for the fabrication of high temperature polymer composites. We proposed to accomplish this broad goal through the use of a class of ceramic precursor material, alumoxanes. Alumoxanes are nano-particles with a boehmite-like structure and an organic periphery. The technical goals of this program are to prepare and evaluate water soluble carboxylate-alumoxane for the preparation of ceramic coatings on polymer substrates. Our proposed approach is attractive since proof of concept has been demonstrated under the NRA 96-LeRC-1 Technology for Advanced High Temperature Gas Turbine Engines, HITEMP Program. For example, carbon and Kevlar(tm) fibers and matting have been successfully coated with ceramic thermally protective layers.

Barron, Andrew R.↗
NASA NTRS2014

The Development of Environmental Barrier Coatings for SiCSiC Ceramic Matrix Composites: Challenges and Opportunities

Environmental barrier coatings (EBCs) and SiC/SiC ceramic matrix composites (CMCs) systems will play a crucial role in future turbine engines for hot-section component applications because of their ability to significantly increase engine operating temperatures, reduce engine weight and cooling requirements. The development of prime-reliant environmental barrier coatings is a key to enable the applications of the envisioned CMC components to help achieve next generation engine performance and durability goals. This paper will primarily address the performance requirements and design considerations of environmental barrier coatings for turbine engine applications. The emphasis is placed on current candidate environmental barrier coating systems for SiCSiC CMCs, their performance benefits and design limitations in long-term operation and combustion environments. Major technical barriers in developing advanced environmental barrier coating systems, the coating integrations with next generation CMC turbine components having improved environmental stability, cyclic durability and system performance will be described. The development trends for turbine environmental barrier coating systems by utilizing improved compositions, state-of-the-art processing methods, and simulated environment testing and durability modeling will be discussed.

Environmental Barrier Coatings↗
NASA NTRS2015

The Development of 2700-3000 F Environmental Barrier Coatings for SiC/SiC Ceramic Matrix Composites: Challenges and Opportunities

Environmental barrier coatings (EBCs) and SiCSiC ceramic matrix composites (CMCs) systems will play a crucial role in future turbine engines for hot-section component applications because of their ability to significantly increase engine operating temperatures, reduce engine weight and cooling requirements. The development of prime-reliant environmental barrier coatings is a key to enable the applications of the envisioned 2700-3000F EBC - CMC systems to help achieve next generation engine performance and durability goals. This paper will primarily address the performance requirements and design considerations of environmental barrier coatings for turbine engine applications. The emphasis is placed on current NASA candidate environmental barrier coating systems for SiCSiC CMCs, their performance benefits and design limitations in long-term operation and combustion environments. The efforts have been also directed to developing prime-reliant, self-healing 2700F EBC bond coat; and high stability, lower thermal conductivity, and durable EBC top coats. Major technical barriers in developing environmental barrier coating systems, the coating integrations with next generation CMCs having the improved environmental stability, cyclic durability, erosion-impact resistance, and long-term system performance will be described. The research and development opportunities for turbine engine environmental barrier coating systems by utilizing improved compositions, state-of-the-art processing methods, and simulated environment testing and durability modeling will be discussed.

CMAS Resistance↗
DOE OSTI2023

Testing and Processing of Pre-production 325 MHz Single Spoke Resonator Power Couplers for PIP-II Project

Fundamental 325 MHz power couplers are designed, built and tested for SSR cavities in PIP-II project. Couplers should work in CW mode at power level 7.5kW w/o beam and ~15 kW with the 2 mA beam. At pre-production stage we built and tested 6 couplers, produced by CPI (FNAL) and PMB (IJCLab) and 4 more couplers will be tested soon. Two of tested couplers had TiN coated ceramic window. In warm test stand two couplers were mounted on the coupling chamber and tested in SW regime at full reflection with phase controlled by position of short and reflection insert. Couplers were tested at pulse mode (up to 25kW) and cw mode (12kW) with HV bias or without bias. Test results demonstrated that 3.5 kV DC bias completely suppresses multipactor in coupler. Vacuum activity in coupler was controlled by e-pickups and build-in vacuum gauges, located near the vacuum side of window. Power processing without DC bias was done for several couplers with and without TiN coating on ceramic window. Test results are presented and discussing in paper.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

TESTING AND PROCESSING OF PRE-PRODUCTION 325 MHZ SINGLE SPOKE RESONATOR POWER COUPLERS FOR PIP-II PROJECT

Fundamental 325 MHz power couplers are designed, built and tested for SSR cavities in PIP-II project [1]. Couplers should work in CW mode at power level 7.5kW w/o beam and ~15 kW with the 2 mA beam. At pre-production stage we built and tested 6 couplers, produced by CPI (FNAL) and PMB (IJCLab) and 4 more couplers will be tested soon. Two of tested couplers had TiN coated ceramic window. In warm test stand two couplers were mounted on the coupling chamber and tested in SW regime at full reflection with phase controlled by position of short and reflection insert. Couplers were tested at pulse mode (up to 25kW) and cw mode (12kW) with HV bias or without bias. Test results demonstrated that 3.5 kV DC bias completely suppresses multipactor in coupler. Vacuum activity in coupler was controlled by e-pickups and build-in vacuum gauges, located near the vacuum side of window. Power processing without DC bias was done for several couplers with and without TiN coating on ceramic window. Test results are presented and discussing in paper.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
NASA NTRS1984

Heat transfer in thermal barrier coated rods with circumferential and radial temperature gradients

To study the heat transfer in ceramic coatings applied to the heated side of internally cooled hot section components of the gas turbine engine, a mathematical model is developed for the thermal response of plasma-sprayed ZrO2-Y2O3 ceramic materials with a Ni-Cr-AL-Y bond coat on a Rene 41 rod substrate subject to thermal cycling. This multilayered cylinder with temperature dependent thermal properties is heated in a cross-flow by a high velocity flame and then cooled by ambient air. Due to high temperature and high velocity of the flame, both gas radiation and forced convection are taken into consideration. Furthermore, the local turbulent heat transfer coefficient is employed which varies with angular position as well as the surface temperature. The transient two-dimensional (heat transfer along axial direction is neglected) temperature distribution of the composite cylinder is determined numerically.

Chung, B. T. F.↗
DOE OSTI2024

Investigating Soil Organic Matter Complexation using Spectral Induced Polarization

Spectral induced polarization (SIP) laboratory experiments were conducted to determine the sensitivity of this method to the formation of soil organic matter (SOM) complexes, with a long-term goal of field-scale monitoring. There are few SIP experiments that have explored this topic, yet understanding the dynamic behavior and interactions of SOM at the field scale could provide insight into soil fertility and health which influences crop yields, microorganisms that degrade organic pollutants, and carbon stabilization. We present the results of three experiments where the iron oxide, ferrihydrite (Fhy), was used to coat different media, and then the OM compound pentaglycine (PG) was pulse injected to form SOM complexes. SIP data was collected during these injections to capture any surface complexation changes. These experiments were performed in 1) a fluidic cell containing a micromodel, 2) a column containing Fhy coated ceramic beads and 3) a column containing Fhy coated Accusand®. Our results show a higher frequency response (defined here as > 1 Hz) in all three experiments, with the largest amplitude response after the first PG injection (Figure S.1). The repeatability of this response is encouraging and supporting data collected on the Accusand® experiment provides preliminary insight into the mechanisms controlling the SIP signatures. Sampling of fluid conductivity $σ_w$ and pH may indicate deprotonation of SOM occurring or rapid adsorption and release of protons from the Fhy sites. However additional experiments are needed to identify and confirm the primary and secondary reactions impacting the SIP response. We are looking towards other opportunities to continue this work, particularly to repeat experiments while collecting supporting datasets.

58 GEOSCIENCES↗