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NASA NTRS1989

Heat transfer to throat tubes in a square-chambered rocket engine at the NASA Lewis Research Center

A gaseous H2/O2 rocket engine was constructed at the NASA-Lewis to provide a high heat flux source representative of the heat flux to the blades in the high pressure fuel turbopump (HPFTP) during startup of the space shuttle main engines. The high heat flux source was required to evaluate the durability of thermal barrier coatings being investigated for use on these blades. The heat transfer, and specifically, the heat flux to tubes located at the throat of the test rocket engine was evaluated and compared to the heat flux to the blades in the HPFTP during engine startup. Gas temperatures, pressures and heat transfer coefficients in the test rocket engine were measured. Near surface metal temperatures below thin thermal barrier coatings were also measured at various angular orientations around the throat tube to indicate the angular dependence of the heat transfer coefficients. A finite difference model for a throat tube was developed and a thermal analysis was performed using the measured gas temperatures and the derived heat transfer coefficients to predict metal temperatures in the tube. Near surface metal temperatures of an uncoated throat tube were measured at the stagnation point and showed good agreement with temperatures predicted by the thermal model. The maximum heat flux to the throat tube was calculated and compared to that predicted for the leading edge of an HPFTP blade. It is shown that the heat flux to an uncooled throat tube is slightly greater than the heat flux to an HPFTP blade during engine startup.

Nesbitt, James A.↗

NASA NTRS1996

Internal Radiation Effects in Zirconia Thermal Barrier Coatings

Using thermal barrier coatings on combustor liners, turbine vanes, and rotating blades is important for reducing metal temperatures in current and advanced aircraft engines. Zirconia is a common coating material, and it is partially transparent to thermal radiation. Radiation becomes more significant as temperatures are raised for higher efficiency in advanced engines. Calculations are often made with radiation effects neglected inside the coating. The effect of radiation is illustrated here, where an analytical procedure is provided by using the two-flux method for the radiative contribution. A detailed study was made of ceramic thermal barrier coatings for diesel engines, and a two-flux analysis was developed for radiation in semitransparent multilayer composites. These efforts provide the basis for the present analysis where illustrative solutions are obtained for typical conditions in an aircraft engine. The formulation and solution of the exact spectral radiative transfer equations including large scattering, as is characteristic of zirconia, are rather complicated. The two-flux method is used here to provide a simplified method.

Siegel, Robert↗

NASA NTRSDate not supplied

Varying Processing Parameters in the Development of Slurry-Based Oxide Bond Coat for Environmental Barrier Coatings

Silicon carbide (SiC)-based ceramic matrix composites (CMCs) are replacing nickel-base superalloys in some hot-section aircraft engine materials due to their lower density and higher working temperature. CMCs require an environmental barrier coating (EBC) for protection from corrosive combustion species. Current-generation EBCs consist of a rare earth silicate topcoat and a silicon bond coat; however, the relatively low melting point of silicon (1414°C) limits the upper use temperature of these coatings. To extend the capability of next-generation EBCs, an oxide-based bond coat capable of withstanding temperatures of up to 1480°C has been developed at NASA Glenn Research Center. In this study, the oxide-based bond coat was applied to monolithic SiC via a slurry coating process. Parameters including slurry particle size and viscosity were varied, and coating performance was evaluated after steam cycling at 1480°C. The effect of including different rare earth constituents in the bond coat was also explored.

R. I. Webster↗

NASA NTRS1981

Automated Plasma Spray (APS) process feasibility study

An automated plasma spray (APS) process was developed to apply two layer (NiCrAlY and ZrO2-12Y2O3) thermal barrier coatings to aircraft and stationary gas turbine engine blade airfoils. The APS process hardware consists of four subsystems: a mechanical positioning subsystem incorporating two interlaced six degree of freedom assemblies (one for coating deposition and one for coating thickness monitoring); a noncoherent optical metrology subsystem (for in process gaging of the coating thickness buildup at specified points on the specimen); a microprocessor based adaptive system controller (to achieve the desired overall thickness profile on the specimen); and commerical plasma spray equipment. Over fifty JT9D first stage aircraft turbine blade specimens, ten W501B utility turbine blade specimens and dozens of cylindrical specimens were coated with the APS process in preliminary checkout and evaluation studies. The best of the preliminary turbine blade specimens achieved an overall coating thickness uniformity of 53 micrometers (2.1 mils), much better than is achievable manually. Comparative evaluations of coating thickness uniformity for manually sprayed and APS coated specimens were performed. One of the preliminary turbine blade evaluation specimens was subjected to a torch test and metallographic evaluation. Some cylindrical specimens coated with the APS process survived up to 2000 cycles in subsequent burner rig testing.

Fetheroff, C. W.↗

NASA NTRS1993

Technical paper contest for women 1992. Space challenges: Earth and beyond

Two of the major concerns of the NASA Ames Research Center (NASA ARC) Advisory Committee for Women (ACW) are that recruitment of women scientists, engineers, and technicians needs to increase and that barriers to advancement need to be removed for improved representation of women in middle and upper management and scientific positions. One strategy that addressed this concern was the ACW sponsorship of a Technical Paper Contest for Women at Ames Research Center. Other sponsors of the Contest were the Ames Equal Opportunity Council and the Ames Contractor Council. The Technical Paper Contest for Women greatly increased the visibility of both the civil service women and the women who work for contractors at Ames. The women had the opportunity to hone their written and oral presentation skills. Networking among Ames women increased.

Orans, Robin↗

NASA NTRS1999

The Trailblazer Program

This paper presents the "Three Pillars of Success" for the Trailblazer Program. The topics include: 1) The "Rocket Equation" for SSTO (Single Stage To Orbit); 2) The Rocket I* Barrier; 3) Rocket-Based Combined-Cycle Engine; 4) Potential for Reusability; 5) Factors Mitigating RBCC Performance; 6) The "Trailblazer" Program; 7) Trailblazer Performance Goals; 8) Trailblazer Reference Vehicle; and 9) Trailblazer Program Architecture.

Trefney, Charles J.↗

NASA NTRS2003

Small Engine Technology (SET) - Task 4, Regional Turboprop/Turbofan Engine Advanced Combustor Study

Under the SET Program Task 4 - Regional Turboprop/Turbofan Engine Advanced Combustor Study, a total of ten low-emissions combustion system concepts were evaluated analytically for three different gas turbine engine geometries and three different levels of oxides of nitrogen (NOx) reduction technology, using an existing AlliedSignal three-dimensional (3-D) Computational Fluid Dynamics (CFD) code to predict Landing and Takeoff (LTO) engine cycle emission values. A list of potential Barrier Technologies to the successful implementation of these low-NOx combustor designs was created and assessed. A trade study was performed that ranked each of the ten study configurations on the basis of a number of manufacturing and durability factors, in addition to emissions levels. The results of the trade study identified three basic NOx-emissions reduction concepts that could be incorporated in proposed follow-on combustor technology development programs aimed at demonstrating low-NOx combustor hardware. These concepts are: high-flow swirlers and primary orifices, fuel-preparation cans, and double-dome swirlers.

Reynolds, Robert↗

NASA NTRS1990

Thermal Conductivity and Temperature Limits of Electron-Beam Physical-Vapor-Deposited ZrO2-7wt%Y2O3 Thermal Barrier Coating

The electron-beam physical-vapor-deposited (EB-PVD) ZrO2-7wt%Y2O3 thermal barrier coating has been widely used to protect engine hot section components in modem aircraft engines. Thermal conductivity and the conductivity increases due to sintering and phase changes are important coating design parameters. There is a need to characterize the coating thermal conductivity behavior and temperature limits, in order to potentially take full advantage of the coating capability. In addition, since the ZrO2-7wt%Y2O3 coating is often used as a baseline coating for the development of advanced lower thermal conductivity and higher temperature capability coatings, a thorough evaluation of the coating conductivity behavior at future higher engine operating temperatures will be useful for more accurately assessing the benefit gained from the new coating systems. In this study, thermal conductivity behavior of EB-PVD ZrO2-7wt%Y2O3 coating has been systematically investigated as a function of temperature (up to 2600 F) and time under steady-state and cyclic test conditions using a laser heat-flux technique. Thermal conductivity change kinetics were determined under realistic engine high temperature thermal gradient conditions, and correlated to the coating microstructural and phase changes. The thermal conductivity prediction models have been established in terms of heat flux, time, and testing temperatures.

Zhu, Dongming↗

NASA NTRS2017

CMC Research at NASA Glenn in 2017: Recent Progress and Plans

As part of NASA's Aeronautics research mission, Glenn Research Center has developed advanced constituents for 2700F CMC turbine engine applications. In this presentation, fiber and matrix development and characterization for SiCSiC composites will be reviewed and resulting improvements in CMC durability and mechanical properties will be summarized. Progress toward the development and validation of models predicting the effects of the engine environment on durability of CMC and Environmental Barrier Coatings will be summarized and plans for research and collaborations in 2017 will be summarized.

propulsion↗

NASA NTRS2017

CMAS Interactions with Advanced Environmental Barrier Coatings Deposited via Plasma Spray- Physical Vapor Deposition

Materials for advanced turbine engines are expected to have temperature capabilities in the range of 1370-1500C. At these temperatures the ingestion of sand and dust particulate can result in the formation of corrosive glass deposits referred to as CMAS. The presence of this glass can both thermomechanically and thermochemically significantly degrade protective coatings on metallic and ceramic components. Plasma Spray- Physical Vapor Deposition (PS-PVD) was used to deposit advanced environmental barrier coating (EBC) systems for investigation on their interaction with CMAS compositions. Coatings were exposed to CMAS and furnace tested in air from 1 to 50 hours at temperatures ranging from 1200-1500C. Coating composition and crystal structure were tracked with X-ray diffraction and microstructure with electron microscopy.

Coatings↗

NASA NTRS2019

Materials and Processes for New Propulsion Systems with Reduced Environmental Impact

Aeronautics research at NASA Glenn Research Center includes development, characterization and modeling of high temperature, lightweight materials and fabrication processes for aircraft propulsion systems with increased efficiency and reduced emissions, fuel burn and noise. Current propulsion materials research includes Ceramic Matrix Composites and Environmental Barrier Coatings, Polymer Matrix Composites and Additive Manufacturing processes. This presentation will summarize recent progress and plans in these areas. Ceramic Matrix Composites for Turbine Components: As part of NASA's Aeronautics research, Glenn Research Center has developed Ceramic Matrix Composites for 2700 degrees Fahrenheit turbine engine applications in the next generation of ultra-efficient aircraft. In this presentation, the development of advanced fiber and matrix constituents that enabled this advancement will be reviewed, and characterization of the resulting improvements in mechanical properties and durability will be summarized. Progress toward the development and validation of models predicting the effects of the engine environment on durability of Ceramic Matrix Composites and Environmental Barrier Coatings will be summarized. Progress and plans for collaborative research with industry and other government agencies will be reviewed. Polymer Matrix Composites for Powertrain and Impact Protection: A lightweight, hybrid polymer matrix composite/steel gear concept for rotorcraft power transmission applications was evaluated at realistic speed, torque, and power conditions. Dynamic testing was performed at 5000 horsepower and 5400 revolutions per minute with no performance degradation. Test results demonstrated the potential of hybrid composite / metal gears to reduce gear weight by approximately 15 percent, enabling the implementation of multi-speed drive systems, which would otherwise have a weight penalty, for increased speed and efficiency. Results of post-test inspection and endurance tests will be presented. Separately, ballistic impact tests demonstrated improved damage tolerance in polymer matrix composites by incorporating lightweight, thermoplastic veil materials between selected composite plies during the composite fabrication process. Results of impact tests and post-test inspection will be presented. Additive Manufacturing for Electric Propulsion: Additive Manufacturing processes offer the potential to fabricate new, high power density electric motor designs with complex geometries, multi-material components and optimally designed components that would not be feasible with traditional manufacturing processes. High performance stator components using advanced 3-phase conductive coils were fabricated using direct printing with optimized silver pastes. Additional additive manufacturing methods are being used to fabricate rotors and motor housing components. Systems studies show that the higher performance and lower weight motors offer improved energy efficiency and reduced emissions. Improvements to motor performance resulting from optimized materials and component designs will be presented.

Additive Manufacturing↗

NASA NTRSDate not supplied

Development of Luminescence Lifetime-Based Surface Temperature Mapping for Environmental Barrier Coatings

Luminescence lifetime-based temperature mapping for thermal barrier coatings (TBCs) has been previously demonstrated up to temperatures approaching 1200 °C. Advantages of this method include insensitivities to reflected radiation and emissivity uncertainties. Because of a push towards greater efficiency turbine engine operation using higher turbine inlet temperatures, there is an ongoing movement from TBC-coated superalloy turbine engine components to SiC/SiC ceramic matrix composite components protected by environmental barrier coatings (EBCs). The useful application of luminescence lifetime-based temperature mapping to EBCs requires a significant increase in high temperature capability from below 1200 °C up into the 1300 to 1500 °C temperature range where the much higher background thermal radiation is a challenging issue. In addition, the luminescing sensing layer must exhibit thermochemical compatibility with the EBC. To meet these requirements, Er-doped Y 2 SiO 5 was selected as the luminescing sensor layer material both for its enhanced temperature sensitivity above 1300 °C and its compatibility with rare-earth disilicate EBC topcoats. Both localized spot temperature measurements as well as luminescence lifetime imaging-based temperature mapping were demonstrated up to 1560 °C for Er-doped Y 2 SiO 5 disks. In addition, temperature mapping capability was demonstrated from a 15 µm thick Er-doped Y 2 SiO 5 layer at the surface of a Sc 2 Si 2 O 7 based EBC topcoat. Both localized spot and temperature mapping by luminescence lifetime imaging were demonstrated up to 1380 °C (upper temperature limit of this slurry-based layered EBC) with excellent suppression of background thermal radiation and no degradation of the Er-doped Y 2 SiO 5 temperature sensing surface layer. The source of the novel enhanced temperature sensitivity above 1300 °C will be discussed as well as a path towards compatibility between sensing layer and EBC topcoat to higher temperatures.

temperature measurement↗

NASA NTRS2005

Advanced Environmental Barrier Coatings Development for Si-Based Ceramics

Advanced environmental barrier coating concepts based on multi-component HfO2 (ZrO2) and modified mullite systems are developed for monolithic Si3N4 and SiC/SiC ceramic matrix composite (CMC) applications. Comprehensive testing approaches were established using the water vapor cyclic furnace, high pressure burner rig and laser heat flux steam rig to evaluate the coating water vapor stability, cyclic durability, radiation and erosion resistance under simulated engine environments. Test results demonstrated the feasibility and durability of the environmental barrier coating systems for 2700 to 3000 F monolithic Si3N4 and SiC/SiC CMC component applications. The high-temperature-capable environmental barrier coating systems are being further developed and optimized in collaboration with engine companies for advanced turbine engine applications.

Zhu, Dong-Ming↗

NASA NTRS2002

Furnace Cyclic Behavior of Plasma-Sprayed Zirconia-Yttria and Multi-Component Rare Earth Oxide Doped Thermal Barrier Coatings

Ceramic thermal barrier coatings will play an increasingly important role in advanced gas turbine engines because of their ability to enable further increases in engine temperatures. However, the coating performance and durability become a major concern under the increasingly harsh thermal cycling conditions. Advanced zirconia- and hafnia-based cluster oxide thermal barrier coatings with lower thermal conductivity and improved thermal stability are being developed using a high-heat-flux laser-rig based test approach. Although the new composition coatings were not yet optimized for cyclic durability, an initial durability screening of numerous candidate coating materials was carried out using conventional furnace cyclic tests. In this paper, furnace thermal cyclic behavior of the advanced plasma-sprayed zirconia-yttria-based thermal barrier coatings that were co-doped with multi-component rare earth oxides was investigated at 1163 C using 45 min hot cycles. The ceramic coating failure mechanisms were studied by using scanning electron microscopy combined with X-ray diffraction phase analysis after the furnace tests. The coating cyclic lifetime will be discussed in relation to coating phase structures, total dopant concentrations, and other properties.

Zhu, Dongming↗

NASA NTRS2023

High Temperature Solid Particle Erosion of Environmental and Thermal Barrier Coatings

Solid particle erosion (SPE) is a common phenomenon observed in gas turbine engines. Particles entrained in the gas flow impact engine hardware resulting in micro-scale damage that leads to deleterious effects such as material removal. For protective coatings, damage due to SPE is a key concern since it can negatively affect the durability of the coating and subsequently the life of the underlying component. In this work, the high temperature SPE behavior of two state-of-the-art environmental barrier coatings (EBCs) deposited via air plasma spray (APS) is investigated using alumina erodent to understand the effect of particle kinetic energy, impingement angle and temperature. The SPE behavior of the EBCs is also compared to APS and electron beam – physical vapor deposition (EB-PVD) thermal barrier coatings (TBCs) to elucidate similarities and differences in the erosion response. The EBCs were more susceptible to SPE than the EB-PVD TBC but had greater SPE resistance compared to the APS TBC. Coating microstructure and porosity were shown to have a strong influence on the observed behavior.

Solid particle erosion↗

NASA NTRS2016

Performance and Durability of Environmental Barrier Coatings on SiC/SiC Ceramic Matrix Composites

This presentation highlights advanced environmental barrier coating (EBC) and SiC-SiC Ceramic Matrix Composites (CMC) systems for next generation turbine engines. The emphasis will be placed on fundamental coating and CMC property evaluations; and the integrated system performance and degradation mechanisms in simulated laboratory turbine engine testing environments. Long term durability tests in laser rig simulated high heat flux the rmomechanical creep and fatigue loading conditions will also be presented. The results can help improve the future EBC-CMC system designs, validating the advanced EBC-CMC technologies for hot section turbine engine applications.

Environment and Fatigue↗

NASA NTRS2004

Thermal Conductivity of Advanced Ceramic Thermal Barrier Coatings Determined by a Steady-state Laser Heat-flux Approach

The development of low conductivity and high temperature capable thermal barrier coatings requires advanced testing techniques that can accurately and effectively evaluate coating thermal conductivity under future high-performance and low-emission engine heat-flux conditions. In this paper, a unique steady-state CO2 laser (wavelength 10.6 microns) heat-flux approach is described for determining the thermal conductivity and conductivity deduced cyclic durability of ceramic thermal and environmental barrier coating systems at very high temperatures (up to 1700 C) under large thermal gradients. The thermal conductivity behavior of advanced thermal and environmental barrier coatings for metallic and Si-based ceramic matrix composite (CMC) component applications has also been investigated using the laser conductivity approach. The relationships between the lattice and radiation conductivities as a function of heat flux and thermal gradient at high temperatures have been examined for the ceramic coating systems. The steady-state laser heat-flux conductivity approach has been demonstrated as a viable means for the development and life prediction of advanced thermal barrier coatings for future turbine engine applications.

Zhu, Dong-Ming↗

NASA NTRS1981

Abradable dual-density ceramic turbine seal system

A plasma sprayed dual density ceramic abradable seal system for direct application to the HPT seal shroud of small gas turbine engines. The system concept is based on the thermal barrier coating and depends upon an additional layer of modified density ceramic material adjacent to the gas flow path to provide the desired abradability. This is achieved by codeposition of inert fillers with yttria stabilized zirconia (YSZ) to interrupt the continuity of the zirconia struture. The investigation of a variety of candidate fillers, with hardness values as low as 2 on Moh's scale, led to the conclusion that solid filler materials in combination with a YSZ matrix, regardless of their hardness values, have a propensity for compacting rather than shearing as originally expected. The observed compaction is accompanied by high energy dissipation in the rub interaction, usually resulting in the adhesive transfer of blade material to the stationary seal member. Two YSZ based coating systems which incorported hollow alumino silicate spheres as density reducing agents were surveyed over the entire range of compositions from 100 percent filler to 100 percent YSZ. Abradability and erosion characteristics were determined, hardness and permeability characterized, and engine experience acquired with several system configurations.

Clingman, D. L.↗