SEARCH · Search NASA

Results for “CERAMIC COATING”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 235 records · Page 13

All sources NASA NTRS DOE OSTI

NASA NTRS1987

Ceramic honeycomb structures and the method thereof

The subject invention pertains to a method of producing an improved composite-composite honeycomb structure for aircraft or aerospace use. Specifically, the subject invention relates to a method for the production of a lightweight ceramic-ceramic composite honeycomb structure, which method comprises: (1) pyrolyzing a loosely woven fabric/binder having a honeycomb shape and having a high char yield and geometric integrity after pyrolysis at between about 700 and 1,100 C; (2) substantially evenly depositing at least one layer of ceramic material on the pyrolyzed fabric/binder of step (1); (3) recovering the coated ceramic honeycomb structure; (4) removing the pyrolyzed fabric/binder of the structure of step (3) by slow pyrolysis at between 700 and 1000 C in between about a 2 to 5% by volume oxygen atmosphere for between about 0.5 and 5 hr.; and (5) substantially evenly depositing on and within the rigid hollow honeycomb structure at least one additional layer of the same or a different ceramic material by chemical vapor deposition and chemical vapor infiltration. The honeycomb shaped ceramic articles have enhanced physical properties and are useful in aircraft and aerospace uses.

Riccitiello, Salvatore R.↗

NASA NTRS1996

Cryogenic Brush Seal Test Results

Brush seals are compliant, contact seals that have long-life, low-leakage characteristics desirable for use in rocket engine turbopumps. 50.8-mm (2.0 inch) diameter brush seals with a nominal initial radial interference of 0.127-mm (0.005 inch) were tested in liquid nitrogen at shaft speeds up to 35,000 rpm and differential pressure loads up to 1.21 MPa (175 psi) per brush. The measured leakage rate of a single brush was 2-3 times less than that measured for a 12-tooth, 0.127-mm (0.005 inch) radial clearance labyrinth seal used as a baseline. Stage effects were studied and it was found that two brush seals with a large separation distance leaked less than two brushes tightly packed together. The maximum measured groove depth on the Inconel 718 rotor was 25.4 (mu)m (0.001 inch) after 4.31 hours of shaft rotation. The Haynes-25 bristles wore approximately 25.4-76.2 (mu)m (0.001-0.003 inch) under the same conditions. Three seal runner coatings, chromium carbide, Teflon impregnated chromium, and zirconium oxide, were tested in liquid hydrogen at 35,000 and 65,000 rpm with separate 50.8 mm diameter brush seals made of Haynes-25 bristles and having a nominal initial radial interference of 129 rpm. Two bare Inconel-718 rotors were also tested as a baseline. The test results revealed significant differences between the wear characteristics of the uncoated and coated seal runners. At both speeds the brush seal with the bare Inconel-718 seal runner exhibited significant bristle wear with excessive material transferring to the runner surface. In contrast, the coated seal runners inhibited the transfer and deposit of bristle material. The chromium carbide coating showed only small quantities of bristle material transferring to its surface. The Teflon impregnated chromium coating also inhibited material transfer and provided some lubrication. This coating, however, is self-sacrificing. The Teflon remained present on the low speed runner, but it was completely removed from the high speed brush seal, which was tested considerably longer. The tests of the Teflon coating revealed the importance of using a lubricating and low friction coating for brush seals to reduce bristle and seal runner wear. The zirconium oxide coating exhibited the greatest amount of coating wear, while the brushes incurred only slight wear. Further testing of ceramics is recommended before making a final judgement on the viability of ceramic coatings for brush seals because of the contrast between the results reported by Carlile and the results presented herein. Strictly based on the results presented hereinabove, the chromium carbide and Teflon impregnated chromium coatings were considered preferable to the uncoated Inconel-718 and zirconium oxide coatings because of their good wear resistance and characteristics to inhibit bristle material wear and transfer to the seal runner.

Proctor, Margaret P.↗

DOE OSTI2024

Simulation and measurement of beam-induced heating of ceramic vacuum chambers

In this article, we summarize recent theoretical and experimental studies of the impedance and beam-induced heating of titanium-coated ceramic vacuum chambers used in the NSLS-II injection kickers. The impedance was calculated using the field matching theory assuming planar approximation and compared with the mpedanceake2 code. For the coating thickness of a few microns, we demonstrated that the beam-induced power is dissipated in the titanium coating and that the longitudinally averaged two-dimensional power density is approximated by an analytical expression, thus allowing the use of a simplified model of the power density as input for the code to simulate the temperature distribution with realistic nonuniform thickness of the Ti coating. For a few values of the NSLS-II beam current, we measured the beam-induced heating of two ceramic chambers using thermal sensors installed along the chamber and compared the measurement results with the simulations. Published by the American Physical Society 2024

36 MATERIALS SCIENCE↗

NASA NTRS1984

Degradation mechanisms of ceramic thermal barrier coatings in corrosive environments

Chemical as well as thermal-mechanical interactions between the ceramics and gas turbine combustion gases/condensates are found to play critical roles in the degradation of porous plasma-sprayed ceramic thermal barrier coatings. The detailed degradation mechanisms of several state-of-the-art ceramic thermal barrier coatings, including several zirconia compositions and a calcium silicate, in corrosive environments are examined in this paper. Approaches to extend coating lifetime are also described.

Lau, S. K.↗

NASA NTRS2000

Thermal Conductivity Change Kinetics of Ceramic Thermal Barrier Coatings Determined by the Steady-State Laser Heat Flux Technique

A steady-state laser heat flux technique has been developed at the NASA Glenn Research Center at Lewis Field to obtain critical thermal conductivity data of ceramic thermal barrier coatings under the temperature and thermal gradients that are realistically expected to be encountered in advanced engine systems. In this study, thermal conductivity change kinetics of a plasma-sprayed, 254-mm-thick ZrO2-8 wt % Y2O3 ceramic coating were obtained at high temperatures. During the testing, the temperature gradients across the coating system were carefully measured by the surface and back pyrometers and an embedded miniature thermocouple in the substrate. The actual heat flux passing through the coating system was determined from the metal substrate temperature drop (measured by the embedded miniature thermocouple and the back pyrometer) combined with one-dimensional heat transfer models.

Zhu, Dongming↗

NASA NTRS1979

A continuous silicon-coating facility

Automatic continuous silicon-coating facility is used to process 100 by 10 cm graphite-coated ceramic substrates for silicon solar cells. Process reduces contamination associated with conventional dip-coating processes, improving material service life.

Butter, C.↗

NASA NTRS1980

Thermal barrier coatings for aircraft gas turbines

Improvements in gas turbine performance are approaching the limits imposed by alloy properties and excessive cooling air requirements. Thin ceramic coatings can increase the difference between gas temperature and metal temperature by several hundred degrees. Thus, they are potentially a major step forward in surface protection. These coatings offer the potential to reduce fuel consumption by permitting reduced coolant flow or higher turbine inlet temperature or to improve durability by reducing metal temperatures and transient thermal stresses. At NASA Lewis, in-house and contractual programs are in place to bring this promising technology to engine readiness in the early 1980's. Progress towards this goal is summarized in this paper.

Miller, R. A.↗

NASA NTRS2001

Thermal Fatigue and Fracture Behavior of Ceramic Thermal Barrier Coatings

Thermal fatigue and fracture behavior of plasma-sprayed ceramic thermal barrier coatings has been investigated under high heat flux and thermal cyclic conditions. The coating crack propagation is studied under laser heat flux cyclic thermal loading, and is correlated with dynamic fatigue and strength test results. The coating stress response and inelasticity, fatigue and creep interactions, and interface damage mechanisms during dynamic thermal fatigue processes are emphasized.

Zhu, Dong-Ming↗

NASA NTRS1976

Some considerations of the dynamics of Space Shuttle vehicle thermal protection system

Two types of reusable surface insulation under consideration for Space Shuttle applications have been analyzed for flutter stability. The first consisted of silicone rubber-coated Nomex felt bonded to the skin of the vehicle; the second consisted of silicone tiles with ceramic coating on five faces, bonded to Nomex felt which was then attached to the vehicle skin. The piston theory was used to compute the aerodynamic forces on the basis of simple models on the two systems. Exact solutions were obtained, and the effect of different parameters of the flutter stability boundary was investigated. Possible reasons for the slow convergence of the Galerkin technique for analyzing membrane flutter are suggested, and a consistent set of nondimensional parameters convenient for flutter studies is introduced.

Kuo, C.-C.↗

NASA NTRS1985

Rocket thrust chamber thermal barrier coatings

Subscale rocket thrust chamber tests were conducted to evaluate the effectiveness and durability of thin yttria stabilized zirconium oxide coatings applied to the thrust chamber hot-gas side wall. The fabrication consisted of arc plasma spraying the ceramic coating and bond coat onto a mandrell and then electrodepositing the copper thrust chamber wall around the coating. Chambers were fabricated with coatings .008, and .005 and .003 inches thick. The chambers were thermally cycled at a chamber pressure of 600 psia using oxygen-hydrogen as propellants and liquid hydrogen as the coolant. The thicker coatings tended to delaminate, early in the cyclic testing, down to a uniform sublayer which remained well adhered during the remaining cycles. Two chambers with .003 inch coatings were subjected to 1500 thermal cycles with no coating loss in the throat region, which represents a tenfold increase in life over identical chambers having no coatings. An analysis is presented which shows that the heat lost to the coolant due to the coating, in a rocket thrust chamber design having a coating only in the throat region, can be recovered by adding only one inch to the combustion chamber length.

Quentmeyer, R. J.↗

NASA NTRS1995

The Wide Field/Planetary Camera 2 (WFPC-2) molecular adsorber

A device has been developed at the Jet Propulsion Laboratory, California Institute of Technology, for the adsorption of contaminants inside a space instrument during flight. The molecular adsorber was developed for use on the Wide Field Planetary Camera 2, and it has been shown to perform at its design specifications in the WFPC-2. The basic principle of the molecular adsorber is a zeolite-coated ceramic honeycomb. The arrangement is efficient for adsorption and also provides the needed rigidity to retain the special zeolite coating during the launch vibrational environment. The adsorber, on other forms, is expected to be useful for all flight instruments sensitive to internal sources of contamination. Typically, some internal contamination is unavoidable. A common design solution is to increase the venting to the exterior. However, for truly sensitive instruments, the external contamination environment is more severe. The molecular adsorber acts as a one-way vent to solve this problem. Continued development is planned for this device.

Barengoltz, Jack↗

NASA NTRS2005

Crack Driving Forces in a Multilayered Coating System for Ceramic Matrix Composite Substrates

The effects of the top coating thickness, modulus and shrinkage strains on the crack driving forces for a baseline multilayer Yttria-Stabilized-Zirconia/Mullite/Si thermal and environment barrier coating (TEBC) system for SiC/SiC ceramic matrix composite substrates are determined for gas turbine applications. The crack driving forces increase with increasing modulus, and a low modulus thermal barrier coating material (below 10 GPa) will have no cracking issues under the thermal gradient condition analyzed. Since top coating sintering increases the crack driving forces with time, highly sintering resistant coatings are desirable to maintain a low tensile modulus and maintain a low crack driving force with time. Finite element results demonstrated that an advanced TEBC system, such as ZrO2/HfO2, which possesses improved sintering resistance and high temperature stability, exhibited excellent durability. A multi-vertical cracked structure with fine columnar spacing is an ideal strain tolerant coating capable of reducing the crack driving forces to an acceptable level even with a high modulus of 50 GPa.

Ghosn, Louis J.↗

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 NTRS1991

Thermal barrier coating life prediction model development, phase 2

The objective of this program was to generate a life prediction model for electron-beam-physical vapor deposited (EB-PVD) zirconia thermal barrier coating (TBC) on gas turbine engine components. Specific activities involved in development of the EB-PVD life prediction model included measurement of EB-PVD ceramic physical and mechanical properties and adherence strength, measurement of the thermally grown oxide (TGO) growth kinetics, generation of quantitative cyclic thermal spallation life data, and development of a spallation life prediction model. Life data useful for model development was obtained by exposing instrumented, EB-PVD ceramic coated cylindrical specimens in a jet fueled burner rig. Monotonic compression and tensile mechanical tests and physical property tests were conducted to obtain the EB-PVD ceramic behavior required for burner rig specimen analysis. As part of that effort, a nonlinear constitutive model was developed for the EB-PVD ceramic. Spallation failure of the EB-PVD TBC system consistently occurred at the TGO-metal interface. Calculated out-of-plane stresses were a small fraction of that required to statically fail the TGO. Thus, EB-PVD spallation was attributed to the interfacial cracking caused by in-plane TGO strains. Since TGO mechanical properties were not measured in this program, calculation of the burner rig specimen TGO in-plane strains was performed by using alumina properties. A life model based on maximum in-plane TGO tensile mechanical strain and TGO thickness correlated the burner rig specimen EB-PVD ceramic spallation lives within a factor of about plus or minus 2X.

Meier, Susan Manning↗

NASA NTRS2000

Thermal Conductivity of EB-PVD Thermal Barrier Coatings Evaluated by a Steady-State Laser Heat Flux Technique

The thermal conductivity of electron beam-physical vapor deposited (EB-PVD) Zr02-8wt%Y2O3 thermal barrier coatings was determined by a steady-state heat flux laser technique. Thermal conductivity change kinetics of the EB-PVD ceramic coatings were also obtained in real time, at high temperatures, under the laser high heat flux, long term test conditions. The thermal conductivity increase due to micro-pore sintering and the decrease due to coating micro-delaminations in the EB-PVD coatings were evaluated for grooved and non-grooved EB-PVD coating systems under isothermal and thermal cycling conditions. The coating failure modes under the high heat flux test conditions were also investigated. The test technique provides a viable means for obtaining coating thermal conductivity data for use in design, development, and life prediction for engine applications.

Zhu, Dongming↗

NASA NTRS2005

Very Tough, Erosion-Resistant Turbine Airfoil Thermal Barrier Coatings Developed

Ceramic thermal barrier coatings (TBCs) are receiving increased attention for advanced gas turbine engine applications. These coatings are considered to be technologically important because of their ability to further increase engine operating temperatures and reduce cooling requirements, thus achieving higher engine efficiency, lower emissions, and increased performance goals. To take full advantage of the capabilities of these coatings, researchers need to use an aggressive design approach whenever possible--one that allows greater temperature reductions through the coating systems and less cooling air to the components. Advanced TBCs that have significantly lower thermal conductivity and better thermal stability than current coatings have been developed for future ultra-efficient, low-emission engine systems. Multicomponent-doped, defect-clustered TBCs have been shown to offer the low conductivity and high stability required for future high-temperature engine applications.

Zhu, Dong-Ming↗

NASA NTRS1976

Ceramic thermal-barrier coatings for cooled turbines

Ceramic thermal-barrier coatings on hot engine parts have the potential to reduce metal temperatures, coolant requirements, cost, and complexity of the cooling configuration, and to increase life, turbine efficiency and gas temperature. Coating systems consisting of a plasma-sprayed layer of zirconia stabilized with either yttria, magnesia or calcia over a thin alloy bond coat have been developed, their potential analyzed and their durability and benefits evaluated in a turbojet engine. The coatings on air-cooled rotating blades were in good condition after completing as many as 500 two-minute cycles of engine operation between full power at a gas temperature of 1644 K and flameout, or as much as 150 hours of steady-state operation on cooled vanes and blades at gas temperatures as high as 1644 K witn 35 start and stop cycles. On the basis of durability and processing cost, the yttria-stabilized zirconia was considered the best of the three coatings investigated.

Liebert, C. H.↗

NASA NTRS1978

Analysis of metal temperature and coolant flow with a thermal-barrier coating on a full-coverage-film-cooled turbine vane

The potential benefits of combining full-coverage film cooling with a thermal-barrier coating were investigated analytically for sections on the suction and pressure sides a high-temperature, high-pressure turbine vane. Metal and ceramic coating temperatures were calculated as a function of coating thickness and coolant flow. With a thermal-barrier coating, the coolant flows required for the chosen sections were half those of an uncoated design, and the metal outer temperatures were simultaneously reduced by over 111 K (200 F). For comparison, transpiration cooling was also investigated. Full-coverage film cooling of a coated vane required more coolant flow than did transpiration cooling.

Meitner, P. L.↗