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All sourcesNASA NTRSDOE OSTI
NASA NTRS2020

Challenges of Testing EB Coated CMC under SPLCF Conditions in Steam Environment at High Temperatures

Environmental barrier (EB) coated monolithic SiC (Hexoloy) and 3D woven SiC/SiC composite specimens were tested under sustained peak low cycle fatigue (SPLCF) conditions at 1204°C at 69 MPa (maximum stress) in steam environment up to 200hrs. Both types of specimens were coated with a multilayer EB coating (Mullite + rare earth disilicate (RED) bond coat and RED top coat) by slurry method. The coated Hexoloy specimen survived 200hrs testing of testing, but the coating showed through-the-thickness cracks and delamination. In contrast, the coated 3D woven SiC/SiC composite specimens failed between 48 and 160 hrs and showed extensive damage in the coating as well as within the CMC substrate.

R T Bhatt↗
NASA NTRSDate not supplied

Mitigation of Silver Ion Loss from Solution by Polymer Coating of Metal Surfaces, Part IV

“Spacecraft potable water systems require a biocidal agent that effectively provides both immediate and residual disinfection over long periods of time. Ionic silver (Ag+) is a leading candidate for this application, but suffers from rapid concentration loss due to interactions with the metallic storage containers and tubing. In order to maintain biocidal efficacy in systems with long periods of dormancy and to reduce the required rate of Ag+ injection, it is necessary to develop alternative materials and coatings for certified metal alloys that significantly reduce the Ag+ loss.” In previous reports, we have described our investigations addressing Ag+ loss mitigation and adhesion performance of parylene barrier coatings on coupons of several metal alloys and 316L tubing under static immersion. In such conditions, parylene-C and AF4 coatings have shown excellent Ag+ loss mitigation performance, and mixed long-term adhesion performance, depending on parylene species and substrate surface chemistry/structure. In Part IV of this series, we begin to address the performance of parylene-C barrier coatings under more challenging and realistic conditions, in order to evaluate potential suitability in flight systems. Using two testbeds, we characterized coating performance under dynamic mechanical operation. In the Flow/Pressure Testbed System, Ag+ solution is pumped through internally coated 316L tubing, with optional pressure cycling. In the Bellows Tank Testbed System, an internally coated edge-welded 316L bellows containing Ag+ solution is cyclically extended and compressed, analogous to the operation of bellows tanks used for potable water storage and delivery on the International Space Station. Periodic determinations of Ag+ loss with testbed cycling/time and visual observation of the parylene-C coatings were conducted. In addition, we characterized parylene-C coating resilience and Ag+ loss with 316L tubing and multiple fitting types under long-term immersion and repeated fitting dis/reassembly.

Lance Dean Delzeit↗
NASA NTRSDate not supplied

Mitigation of Silver Ion Loss from Solution by Polymer Coating of Metal Surfaces, Part IV

Ionic silver (Ag+) biocide is a leading candidate to provide residual microbial control in spacecraft potable water systems, but suffers from rapid concentration loss due to interactions with the metallic storage containers and tubing. One approach to resolve this problem is the coating of metal surfaces with an inert barrier film. In previous reports, we have described our investigations addressing Ag+ loss mitigation and adhesion performance of parylene barrier coatings on coupons of several metal alloys and 316Ltubing under static immersion. In such conditions, parylene-C and -AF4 coatings have shown excellent Ag+loss mitigation and mixed long-term adhesion performance, depending on parylene species and substrate surface chemistry/structure. In Part IV of this series, we report on our work to investigate the performance of parylene-C barrier coatings, under more challenging and realistic conditions, in order to evaluate potential suitability for use. The resilience and associated Ag+ loss with Parylene-C coating on½” (12.7 mm)316L tubing and fittings under medium-term immersion and repeated fitting dis/reassembly were investigated. Potential mechanical challenges to barrier coatings in spacecraft potable water systems were investigated, with two main focuses being identified: liquid flow/pressure cycling in tubing and cyclic operation of bellows in positive-expulsion storage tanks. Two corresponding testbeds for experimental characterization of coating performance were developed. In the Flow/Pressure Testbed System, Ag+ solution will be pumped through internally coated 316L tubing, with optional pressure cycling. In the Bellows Tank Testbed System, an internally coated edge-welded 316L bellows containing Ag+ solution will be cyclically extended and compressed, analogous to the operation of bellows tanks used for potable water storage and delivery on the International Space Station. The design and operation of these testbeds are described. Finally, the Ag+ adsorption and saturation behaviors of Kalrez and Viton, for potential use as seal materials in fittings and other connections, were characterized in limited experiments.

mitigation↗
NASA NTRS2022

Optical properties of morphologically complex black carbon aerosols: Effects of coatings

Optical properties are computed for fractal-like aggregate black carbon (BC) aerosols coated with different substances. Two models are used for these aerosols: (i) the coated aggregate model (model I), where coating is added to the voids and surroundings of BC fractal-like aggregates; and (ii) the closed-cell aggregate model (model II), where coating is added concentrically to each monomer of BC fractal-like aggregates. Our results favor choosing the coated aggregate model (model I) to simulate scattering and absorption by coated BC aerosols because this model is morphologically more realistic, and because this model yields mass absorption cross section (MAC) and backscattering linear depolarization ratio (LDR) values that are consistent with field measurements. Moreover the corresponding computed degree of linear polarization (DoLP) and LDR values are very sensitive to changes in the coating volume fraction (fvol) and the coating refractive index (m). With the same absorbing BC core, the MAC value increases steadily with increasing fvol and m values. For example, using a density of 1.8 g/cm 3 and BC refractive index 1.95 + i0.79, the calculated MAC values for uncoated BC aggregates range from 6.2 to 6.8 m 2 /g at 0.55 µm. When coating material is applied to the BC aggregates, the calculated MAC values for model I particles increase to between 9.8 and 13.2 m 2 /g (depending on m) when fvol = 87.5%. The backscattering LDR values also tend to increase with the increasing m values for the shapes and sizes considered in our study. For model I particles, the backscattering LDR values span a wide range of 4.2–27.8% at a wavelength of 0.35 µm at fvol = 87.5% when m increases from 1.33 to 1.55. Our results are relevant to analyses of polarimetric and lidar observations of smoke particles, especially when these particles undergo hygroscopic growth.

Black carbon aerosols↗
NASA NTRS2024

Wear and Neutron Shielding Resilience of Titanium-Hexagonal Boron Nitride Coatings Against Extreme Lunar Radiation and Thermal Cycles

Ti6Al4V and Al6061 are aerospace alloys used in lunar structural components and rovers owing to their high specific strength. However, they deteriorate rapidly when subjected to demanding conditions of the lunar environment, such as extreme thermal cycles, solar particle radiation, and abrasive regolith. Cryo-milled powders were employed to deposit hBN-reinforced protective titanium coatings through plasma spray (atmospheric APS and vacuum-VPS) with 2 and 10 vol% of hBN on Ti6Al4V and Al6061 substrates. These coatings were evaluated for durability under extreme lunar-like conditions, including thermal cycling, electron radiation, and synergistic (electron radiation-thermal cycle) exposure. The coatings exhibited radiation-induced hardening, resulting in a substantial increase in their microhardness ~20–40% compared to virgin condition. Bright-field transmission electron microscopy (TEM) analysis reveals the presence of high dislocation densities, black dot defects, and dislocation clusters, providing evidence of the severe impact of synergistic environmental stresses. Ball-on-disk tribological tests were conducted in the presence of JSC-1 A lunar regolith simulant to evaluate the wear performance of coatings. Compared to conventional Ti6Al4V substrate, 50%, 90%, and 70% reductions in wear volume were observed in the Ti/2 vol% hBN coatings in thermal-only, radiation-only, and synergistic environments. Neutron shielding tests indicate that the synergistic coatings offer higher neutron shielding performance by up to 28% compared to virgin coatings, attributed to improved neutron capture by 10B isotopes. Upon a comprehensive assessment and ranking of multiple coatings under varying conditions, the VPS Ti/2 vol% hBN coating emerges as the top choice for protection against extreme radiation and thermal cycles for future lunar explorations.

Boron nitride↗
DOE OSTI2026

Using Artificial Soiling to Rank Anti-Soiling Coatings for Arid Climates

A simple method to evaluate (e.g., screen and rank) the performance of coatings that are fully or partially anti-soiling (AS) is lacking within the PV industry. Artificial soiling may be used as a rapid and economical assessment approach, offering an efficient alternative to time-intensive, site-specific field testing. In this study, we present an artificial soiling method to replicate the anti-soiling performance rankings of two groups of coated glass samples supplied by two manufacturers (group C with CA, CP, and CS coatings; group A with AC coating). These are compared to field aging in two climates: semi-arid Lemoore, California over 4 months, and the hot desert in Mesa, Arizona over 7 months. Both field and indoor performance ranking utilize the transmittance ratio, defined as the optical transmittance between a coated sample and an uncoated reference in each group, as an evaluation metric to assess the effectiveness of the artificial soiling approach in replicating field soiling. It is critical to mimic the dominant field meteorological conditions associated with soiling-prone days and vulnerable times of day during the soiling season. Our results reveal that the use of artificial soiling for field performance ranking among coatings strongly depends on the soil type (composition and particle distribution), dust surface density, and prevalent environmental factors (wetting saturation by humidity, dew condensation extent, and prior weathering history of the coating). The similar rank order relative to the field suggests that the artificial soiling approach presented may be used for down-selecting anti-soiling coatings prior to prolonged field validation.

14 SOLAR ENERGY↗
DOE OSTI2025

The impact of chromium coatings on Zircaloy cladding deformation behavior under reactivity-initiated accident-like mechanical loading conditions

A reactivity-initiated accident (RIA) occurs when a control rod ejection or control blade drop causes an increase in the fission rate. The injection of energy results in an increase in fuel temperature which in turn causes rapid thermal expansion of the fuel pellet. This thermal expansion may result in pellet-cladding mechanical interaction (PCMI) in which the fuel imparts a mechanical strain to the cladding. PCMI may cause the cladding to fail, and thus, the mechanical response of cladding due to PCMI must be investigated when characterizing new cladding materials. Chromium-coated Zircaloy-4 is a near-term accident-tolerant fuel cladding that exhibits improved high-temperature oxidation resistance. Modified burst testing was utilized to experimentally simulate the effects of PCMI on both uncoated and chromium-coated Zircaloy cladding samples at hot zero power conditions. Samples were coated using either cold spraying or physical vapor deposition to understand the differences in behavior that the coating application method may cause. Digital image correlation was used to analyze images of the deforming specimens to extract the in-situ strain behavior of the cladding. The uncoated specimens burst at hoop strains ranging from 8.8 % to 17.2 %. The cold-spray chromium-coated Zircaloy specimens burst at hoop strains of 7.0 % to 11.0 %. The physical vapor deposition coated tubes burst at hoop strains of 9.1 % to 11.5 %. These results indicate that the chromium coating causes a loss in the ductility of the cladding. Furthermore, the higher burst hoop strains of the physical vapor deposition-coated samples relative to the cold-spray samples indicate that the cold-spraying technique causes more of a loss in ductility than physical vapor deposition. All samples burst at higher hoop strains than those expected to occur in an RIA for fresh cladding.

Accident-tolerant fuel↗
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 NTRS2013

Absolute Thickness Measurements on Coatings Without Prior Knowledge of Material Properties Using Terahertz Energy

This study investigates the applicability of a novel noncontact single-sided terahertz electromagnetic measurement method for measuring thickness in dielectric coating systems having either dielectric or conductive substrate materials. The method does not require knowledge of the velocity of terahertz waves in the coating material. The dielectric coatings ranged from approximately 300 to 1400 m in thickness. First, the terahertz method was validated on a bulk dielectric sample to determine its ability to precisely measure thickness and density variation. Then, the method was studied on simulated coating systems. One simulated coating consisted of layered thin paper samples of varying thicknesses on a ceramic substrate. Another simulated coating system consisted of adhesive-backed Teflon adhered to conducting and dielectric substrates. Alumina samples that were coated with a ceramic adhesive layer were also investigated. Finally, the method was studied for thickness measurement of actual thermal barrier coatings (TBC) on ceramic substrates. The unique aspects and limitations of this method for thickness measurements are discussed.

Nondestructive evaluation↗
NASA NTRS2016

Environmental Barrier Coating Development for SiC/SiC Ceramic Matrix Composites: Recent Advances and Future Directions

This presentation briefly reviews the SiC/SiC major environmental and environment-fatigue degradations encountered in simulated turbine combustion environments, and thus NASA environmental barrier coating system evolution for protecting the SiC/SiC Ceramic Matrix Composites for meeting the engine performance requirements. The presentation will review several generations of NASA EBC materials systems, EBC-CMC component system technologies for SiC/SiC ceramic matrix composite combustors and turbine airfoils, highlighting the temperature capability and durability improvements in simulated engine high heat flux, high pressure, high velocity, and with mechanical creep and fatigue loading conditions. This paper will also focus on the performance requirements and design considerations of environmental barrier coatings for next generation turbine engine applications. The current development emphasis is placed on advanced NASA candidate environmental barrier coating systems for SiC/SiC 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, erosion-impact resistance, and long-term fatigue-environment system durability 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 briefly discussed.

Environmental Barrier Coatings↗
NASA NTRS2017

Kinetic Monte Carlo Simulations of Diffusion in Environmental Barrier Coating Materials

Ceramic Matrix Components (CMC) components for use in turbine engines offer a number of advantages compared with current practice. However, such components are subject to degradation through a variety of mechanisms. In particular, in the hot environment inside a turbine in operation a considerable amount of water vapor is present, and this can lead to corrosion and recession. Environmental Barrier Coating (EBC) systems that limit the amount of oxygen and water reaching the component are required to reduce this degradation and extend component life. A number of silicate-based materials are under consideration for use in such coating systems, including Yttterbium and Yttrium di- and monosilicates. In this work, we present results of kinetic Monte Carlo computer simulations of oxygen diffusion in Yttrium disilicate, and compare with previous work on Yttterbium disilicate. Coatings may also exhibit cracking, and the cracks can provide a direct path for oxygen to reach the component. There is typically a bond coat between the coating and component surface, but the bond coat material is generally chosen for properties other than low oxygen diffusivity. Nevertheless, the degree to which the bond coat can inhibit oxygen diffusion is of interest, as it may form the final defense against oxygen impingement on the component. We have therefore performed similar simulations of oxygen diffusion through HfSiO4, a proposed bond coat material.

Computer Simulation↗
NASA NTRS2017

Environmental Barrier Coating Fracture, Fatigue and High-Heat-Flux Durability Modeling and Stochastic Progressive Damage Simulation

Advanced environmental barrier coatings will play an increasingly important role in future gas turbine engines because of their ability to protect emerging light-weight SiC/SiC ceramic matrix composite (CMC) engine components, further raising engine operating temperatures and performance. Because the environmental barrier coating systems are critical to the performance, reliability and durability of these hot-section ceramic engine components, a prime-reliant coating system along with established life design methodology are required for the hot-section ceramic component insertion into engine service. In this paper, we have first summarized some observations of high temperature, high-heat-flux environmental degradation and failure mechanisms of environmental barrier coating systems in laboratory simulated engine environment tests. In particular, the coating surface cracking morphologies and associated subsequent delamination mechanisms under the engine level high-heat-flux, combustion steam, and mechanical creep and fatigue loading conditions will be discussed. The EBC compostion and archtechture improvements based on advanced high heat flux environmental testing, and the modeling advances based on the integrated Finite Element Analysis Micromechanics Analysis Code/Ceramics Analysis and Reliability Evaluation of Structures (FEAMAC/CARES) program will also be highlighted. The stochastic progressive damage simulation successfully predicts mud flat damage pattern in EBCs on coated 3-D specimens, and a 2-D model of through-the-thickness cross-section. A 2-parameter Weibull distribution was assumed in characterizing the coating layer stochastic strength response and the formation of damage was therefore modeled. The damage initiation and coalescence into progressively smaller mudflat crack cells was demonstrated. A coating life prediction framework may be realized by examining the surface crack initiation and delamination propagation in conjunction with environmental degradation under high-heat-flux and environment load test conditions.

Mechanical creep and fatigue loading condition↗
NASA NTRS2019

Sublimation Protection Coatings for Thermoelectric Materials for Space Power Applications

The compounds such as Yb14MnSb11 are relatively new p-type thermoelectric materials, respectively. NASA's interest in these material are to replace the state-of-the-art Si-Ge legs of the current radioisotope thermoelectric generators (RTGs). Ideally, the hot end of this leg would operate at 1000 degrees C in the vacuum of space. These materials, however, suffer from a high sublimation rate at elevated temperatures and would require a coating in order to survive the required RTG lifetime of 14 years. The purpose of present work is to develop sublimation protection coatings for Yb14MnSb11 at temperatures up to 1000 degrees C. Coatings for Yb14MnSb11 present many challenges. The coating must not significantly react or interdiffuse with the substrate thereby degrading the substrate or consuming the coating, must remain intact and not crack or spall during thermal cycling prior to launch, and must be a good insulator both electrically and thermally so as not to provide a short circuit for either electron flow or heat through the coating rather than through the leg. Based on these requirements, several oxides have been selected as possible coating candidates. This paper discusses the development of slurry processes to deposit these oxides coatings on thermoelectric materials.

Sublimation↗
NASA NTRSDate not supplied

Metallic Environmentally Resistant Coating Rapid Innovation Initiative

Lightweight alloys such as aluminum (Al) and titanium (Ti) are often specified for space systems to minimize mass while maintaining structural integrity [1,2]. Such alloys however, have poor tribological response (high friction and wear), especially in extreme space environments, which becomes worse with the additional presence of lunar regolith. This leads to short lifetimes and premature failures that will ultimately limit long term operations on the lunar surface [2]. This project is addressing this technology gap by developing advanced wear- and radiation-resistant coatings for lightweight parts to extend the life-time and sustainability of both lunar and Martian assets. Ceramics were considered for their high wear resistance, but were rejected because of their low fracture toughness, which would be especially problematic for structural components. The novel and existing coating technologies and deposition methods are being tested in this project. The coating materials are Boron Nitride-Aluminum (BN-Al), Nickle Titanium (NiTi), Aluminum Oxide (AlO3), Ti64 with hBN at 2 and 10 vol percent (Ti-2vol%hBN and Ti-10vol%hBN), and the deposition techniques are high pressure cold-spray (CS) and ambient and vacuum plasma-spray (APS and VPS) [3,4,5]. BN-Al, NiTi, Ti-2vol%hBN, and Ti-10vol%hBN were applied with all three deposition techniques, and AlO3 was applied only using the APS deposition technique. A tungstenite (WS2) film was applied to the NiTi VPS coating. The coating and deposition technique configurations are being tested against several key end-use performance parameters. The parameters include the capabilities of the coatings under wear environments such as regolith simulant, thermal cycling from high (120°C) to cryogenic (-173°C), high vacuum (~10-7 torr), and pre- and post-exposure to ionizing particle radiation. Wear tests include pin on disk, three-body abrasion, and surface erosion by high velocity regolith impacts. The initial down selection is being performed using on virgin and environmental exposure samples using pin on disk and three body abrasion wear tests. From preliminary assessment of this testing, a few configurations were eliminated. Ti-10vol%hBN could not be applied using CS application and NiTi could not be applied using APS or CS application so these configurations did not get tested. Early pin on disk wear tests showed poor wear performance of BN-Al so this coating was eliminated early in the testing process. AlO3 on Al substrate did not survive thermal cycling, but wear testing is continuing for AlO3 on Ti substrate. A more detailed analysis is being con-ducted to further reduce the number of configuration for phase II and III. Phase II testing will include conventionally and additively manufactured substrates with surface erosion testing. In phase III, the coatings will be applied to three mechanism types: channel and slot, ball and socket, and a hinge joint. Each will demonstrate a different type of wear incidence. The mechanisms and their base materials are of direct interest to the end users and infusion points: the Human Landing System (HLS) and the Lunar Surface Innovation Initiative (sustained lunar surface operations). The technology development project is based out of Marshall Space Flight Center, has partnered with Florida International University (Miami, FL) and Plasma Processes (Huntsville, Al), and is supported by a group of NASA mentors from different centers.

dust mitigation↗
NASA NTRSDate not supplied

Material Compatibility Study of Coated Metals to Maintain Biocidal Silver in a Spacecraft Potable Water System

Ionic silver-based biocide remains an option of choice for microbial control in spacecraft potable water systems. However, depletion of silver ions by wetted materials readily reduces ionic silver to nonbiocidal levels. This phenomenon occurs via various transport mechanisms at the liquid-solid interfaces between the silver-containing water and adjacent surfaces. Consequently, challenges remain in the design and/or selection of materials that can be used for the wetted system components that will help ensure silver is maintained at biocidal levels. Since silver has been baselined, and/or remains, as a potable water biocide option for several future spacecraft potable water systems, a multitiered approach is being investigated, looking at heritage materials, new processes, and/or alterative materials. This study conducted the application of eleven chemically-resistant coatings onto coupons that were cut out from three types of spacecraft-grade metals (Titanium Grade 2, Inconel 718, and 316L Stainless Steel) to investigate the performance of this material strategy as a barrier against silver depletion. In this investigation, the coated metals were immersed in a static 400 parts per billion silver biocide solution at a surface-area-to-volume ratio of 2.0 cm^(-1) and left to soak for predefined time periods. The concentration of the solution in contact with the coated samples was analyzed at various points via inductively coupled plasma mass spectrometry, and the measurements were interpreted as silver retention percentages over time. This paper summarizes the coating selection process, the configuration of the test, and the performance of each coating-metal combination at diminishing silver depletion. The preliminary results demonstrate that some of the selected coatings succeeded at maintaining biocidal silver concentrations far beyond the corresponding base metal in a similar test. The knowledge acquired through this investigation supports the deploying of coatings on plumbing lines for the integration of biocidal silver in the water system architecture of a spacecraft. Nevertheless, further testing must be continued to assess the performance of these coatings on other wetted geometries and any implications of unifying this material strategy with traditional and developmental engineering design processes for spacecraft potable water systems.

water↗
NASA NTRS2026

Radiation-Conditioned Ti–hBN Coatings for Space Mechanisms: Bridging Tribology and Irradiation Effects from Laboratory to Low-Earth Orbit

The longevity of tribological components in extraterrestrial environments is challenged by abrasive regolith, extreme temperatures, and ionizing radiation. This study evaluates the performance of vacuum plasma sprayed (VPS) Ti-2vol.% hexagonal boron nitride (hBN) coatings applied to joint mechanisms such as rod and slot, ball and socket, and hinge assemblies, fabricated from Al6061 and Ti6Al4V for planetary structures. Coated and uncoated samples were tested under vacuum with lunar regolith simulant (JSC-1A), followed by environmental exposures including electron radiation and thermal cycling. Results show that coated samples consistently outperformed uncoated counterparts across all configurations. Wear depth in coated components was reduced by over 80%, as confirmed by 3D profilometry and surface imaging. SEM analysis revealed severe abrasion and localized plastic deformation in uncoated surfaces, while coated samples retained structural integrity due to synergy of hard protective phases formed during deposition and retained hBN providing solid lubrication in the sliding surface. Coated and exposed samples exhibited smoother actuation profiles and reduced friction, indicating a beneficial "conditioning" effect from environmental exposure. The coatings-maintained performance even on complex geometries with minimal delamination. These findings demonstrate the potential of VPS Ti-hBN coatings to extend the operational life of lunar mechanisms, bridging laboratory-scale tribology with flight-relevant mechanical applications.

tribology↗
DOE OSTI2025

Hygroscopic Metal-Complex Coated Metal Foam for Moisture Management

Moisture management for improving indoor air quality is critical for health and thermal comfort. Recently, the use of desiccant-coated heat exchangers (HXs) has emerged as a promising dehumidification approach to reduce energy consumption as compared with conventional vapor compression-based air dehumidification. The desiccant material is a key component of dehumidification performance. However, currently used desiccant materials have a low moisture uptake capability and require a high temperature for regeneration. The current study investigated the dehumidification performance of a metal-complex-based hygroscopic desiccant-coated metal foam HX. Furthermore, the results revealed that the desiccant-coated foams display increased hydrophilicity compared with the uncoated metal surfaces. Additionally, the desiccant coating had superior moisture absorption capability of more than 2 g/g desiccant , which is much higher than commonly used zeolite and silica gels. Wind tunnel experiments showed that the coating absorbs moisture from humid air and can be effectively regenerated at low temperatures. Additionally, the coating did not increase the pressure drop of the HX. Overall, the results of this study suggest that this desiccant-coated metal form can potentially be used for moisture management in the building sector.

Atmospheric chemistry↗
DOE OSTI2025

Crack mitigation and wear performance of high-strength steel coatings deposited by high-speed laser cladding

This article investigates the fabrication of defect-free Rockit® 606, a high‑carbon, vanadium- and chromium-enriched precipitation-hardening martensitic steel coating, using high-speed laser cladding (HSLC). Compared to conventional laser cladding, HSLC offers higher deposition efficiency, improved coating quality, minimal thermal distortion, and a reduced heat-affected zone. Various HSLC parameters—including laser power, travel speed, powder feed rate, and overlap distance—were optimized to achieve superior coating properties. Microstructural analysis revealed solidification cracks in coatings deposited on carburized steel, regardless of processing parameters. However, preheating the substrate to 250 °C effectively eliminated cracking by reducing thermal gradients. The coatings exhibited a columnar dendritic microstructure, with coarser dendrites near the substrate and finer dendrites towards the surface. Hardness measurements confirmed that all coatings significantly exceeded the industry-specified threshold of 60 HRC, with preheating having minimal effect on overall hardness distribution. Reciprocating sliding wear tests demonstrated a substantial improvement in wear resistance for the defect-free HSLC coatings compared to baseline carburized steel. These findings underscore the potential of HSLC for producing high-performance, wear-resistant coatings suitable for industrial applications.

36 MATERIALS SCIENCE↗