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NASA NTRS1999

Analyses of Contaminated Solar Array Handrail Samples Retrieved from Mir

In January 1998 during, the STS-89 mission, an eight section Russian solar array panel was retrieved after more than ten years exposure to the orbital space environment on the Russian space station Mir. Two darkened handrail samples from the Russian solar array have been evaluated for contamination: a section of a white paint covered rigid handrail and a section of woven fabric over-wrapped around a flexible handhold. The handrail samples were evaluated using optical microscopy (OM), field emission scanning electron microscopy (FESEM) and energy dispersive spectroscopy (EDS). Optical properties were also obtained. Microscopy has shown the discolored areas to have thick layers of contaminant that has crazed and spalled off in regions. Energy dispersive spectroscopy revealed that the brown contaminant is composed of oxidized silicon. No silicon was present on the unexposed fabric over-wrap, and very small amounts were present in the white paint. Therefore, the contaminant layer on both samples is attributed to silicone contamination from other spacecraft materials that have been oxidized by atomic oxygen while in orbit. A significant source of the silicone contamination appears to be from the solar array itself.

deGroh, Kim K.↗
NASA NTRS1999

Diagnostic Clast-Texture Criteria for Recognition of Impact Deposits

It is difficult to find definitive evidence for impact in the geological record because there are many endogenous geological processes that can produce diamictites similar to those generated by impact ejecta. The classic impact criteria of shock fabrics in certain minerals, and iridium layers, for example, may be either difficult to find, or long-since erased from the impact site (shock fabrics also anneal with time). It is important to be able to recognize impact-generated materials in order to understand earth's crustal development and biological evolution. In future exploration of Mars and other solar-system bodies, recognition of impact materials will be important for elucidating planetary evolution, planetary volatile inventories, and exobiological issues. The cobble depicted is typical of many that have been found in diamictite deposits in Belize generated by the Chicxulub K-T impact event. The pebbles are roughly-hewn in general shape with smoothed corners and edges. Surfaces are almost uniformly frosted (on both protuberances and hollows), but some asperities are glazed. Optical microscopy and thin-section petrographic microscopy reveal the frosting to be only a few microns thick, with a well-defined granular structure; grains are the same size as those composing the bulk of the limestone, but their clearer appearance may represent annealing. One or two adjacent pebble faces are often decorated with striated gouges and closely-spaced hemispherical depressions representing indentation hollows produced by well-rounded impacting clasts of up to 0.5 cm in diameter. Some of the impactors are still embedded in the cobble surface. Non-destructive x-ray diffraction techniques showed the impactors to be of the same mineralogy as the target cobble. We believe this unusual glazing and frosting to be related to the impact event, but this must be reconciled with its survival for over 60 my. since it is composed of one of the most alterable substances, CaCO3. We focus, however, on the non-fractured rounded pebbles that appear to have impacted the larger cobble as a swarm of clasts, probably encountered during ballistic flight. It cannot be defined whether the cobble swept through the pebble cloud, or the pebbles rained upon a slowermoving cobble. Two interesting questions arise: (1) Where did large numbers of such well rounded pebbles come from in the ejecta curtain?, and (2) How did they embed themselves in a nominally brittle rock without suffering damage? Are the well-rounded pebbles crystalline (devitrified) melt spherules? Further investigations are in progress. If the cobble was cold and brittle, impact of well-rounded pebbles would have produced Hertzian fracture patterns (a) in the virtually elastically isotropic cobble target. For penetration depths of about 0.5 of the impactor diameter, the pebbles would require a relative impact velocity sufficient to cause pebble fragmentation and crushing, and the development of a complex Hertzian-Boussinesq fracture field (b) involving deep fracturing and lateral surface spalling (impact velocities > 50 m/s). The existing relationship could only evolve by the impact of cold, hard pebbles into a soft, plastic cobble surface (c). For limestone to have been plastic, it must have been at elevated temperature, but to prevent calcification of the material, the ambient pressure must also have been elevated. This would be possible either in the impact's gas plume, or within the confines of a thin aerodynamically-produced shock bow generated by supersonic ballistic motion of the cobble. In the latter case, it is implied that the cobble swept through the pebbles rather than vice-versa. Although there are high T-P conditions associated with volcanism, such textures have not been reported on volcaniclastic materials, nor from other high T-P environments; e.g., metamorphic (as far as the authors are aware). We propose that this very easily recognizable embedding and indentation surface texture can be used as a diagnostic criterion for the recognition of impact ejecta. The term "peening texture" is suggested, because it is absolutely analogous to the plastic-deformation induced, metal-surface textures generated by ball-bearing bombardment used in engineering metallurgy to work-harden metal surfaces. Additional information is contained in the original (Figures).

Marshall, J. R.↗
NASA NTRS2000

Cyclic Oxidation Testing and Modelling: A NASA Lewis Perspective

The Materials Division of the NASA Lewis Research Center has been heavily involved in the cyclic oxidation of high temperature materials for 30 years. Cyclic furnace and burner rig apparati have been developed, refined, and replicated to provide a large scale facility capable of evaluating many materials by a standard technique. Material behavior is characterized by weight change data obtained throughout the test, which has been modelled in a step-wise process of scale growth and spallation. This model and a coupled diffusion model have successfully described cyclic behavior for a number of systems and have provided insights regarding life prediction and variations in the spalling process. Performance ranking and mechanistic studies are discussed primarily for superalloys and coating alloys. Similar cyclic oxidation studies have been performed on steels, intermetallic compounds, thermal barrier coatings, ceramics, and ceramic composites. The most common oxidation test was performed in air at temperatures ranging from 800 deg. to 1600 C, for times up to 10000 h, and for cycle durations of 0.1 to 1000 h. Less controlled, but important, test parameters are the cooling temperature and humidity level. Heating and cooling rates are not likely to affect scale spallation. Broad experience has usually allowed for considerable focus and simplification of these test parameters, while still revealing the principal aspects of material behavior and performance. Extensive testing has been performed to statistically model the compositional effects of experimental alloys and to construct a comprehensive database of complex commercial alloys.

Smialek, J. L.↗
NASA NTRS2000

The Effect of Hydrogen Annealing on the Impurity Content of Alumina-Forming Alloys

Previously, the effect of hydrogen annealing on increasing the adhesion of Al2O3 scales had been related to the effective desulfurization that occurred during this process. The simultaneous reduction of other impurities has now been re-examined for up to 20 impurity elements in the case of five different alloys (NiCrAl, FeCrAl, PWA 1480, Rene'142, and Rene'N5). Hydrogen annealing produced measurable reductions in elemental concentration for B, C, Na, Mg, P, K, Sr, or Sn in varying degrees for at least one and up to three of these alloys. No single element was reduced by hydrogen annealing for all the alloys except sulfur. In many cases spalling occurred at low levels of these other impurities, while in other cases the scales were adherent at high levels of the impurities. No impurity besides sulfur was strongly correlated with adhesion.

Smialek, James L.↗
NASA NTRS1960

Thermal Design of the Micrometeoroid Satellite S-55

The thermal design of the micrometeoroid satellite S-55 involves both experimental and analytical approaches in selecting materials and coatings. A cutaway drawing of the S-55 satellite is shown. The purpose of which is to obtain scientific and engineering design data on the frequency and penetration hazard of micrometeoroids at altitudes between about 250 nautical miles and 700 nautical miles. The passive method of thermal control used involves the selection of materials and coatings that give the desired ratio of absorptivity to emissivity alpha/epsilon for keeping the telemetry temperature within narrow limits and also to prevent overheating of the separate experiments. The selection of a material or coating for this purpose, however, is dictated not only by its absorptivity and emissivity values, but also by its reliability and the constancy of these values under long exposure to the space environment. Several test programs have been conducted in order to evaluate the materials and coatings being considered. Some of these are as follows: (1) Ultraviolet radiation in a vacuum to study discoloration and weight change. (2) Solar radiation in a vacuum to determine maximum equilibrium temperature, discoloration, and weight loss. (3) Thermal cycling and thermal shock to study material integrity (leaking, spalling, melting, etc.). (4) Proton radiation to observe effects on color, crystal structure, and strength. (5) Determination of effects of heat associated with coating application on the leak rate of pressurized parts. (6) Absorptivity and emissivity measurements. The experimental tests outlined and the maximum use of coating methods successfully employed on previous satellites should provide high reliability of the material used for the thermal design of this vehicle. A theoretical analysis was made to determine the values of alpha/epsilon required for different areas in order that the telemetry remain within the desired temperature limits.

Hastings, Earl C., Jr.↗
NASA NTRS2000

COSIM: A Finite-Difference Computer Model to Predict Ternary Concentration Profiles Associated with Oxidation and Interdiffusion of Overlay-Coated Substrates

A finite-difference computer program (COSIM) has been written which models the one-dimensional, diffusional transport associated with high-temperature oxidation and interdiffusion of overlay-coated substrates. The program predicts concentration profiles for up to three elements in the coating and substrate after various oxidation exposures. Surface recession due to solute loss is also predicted. Ternary cross terms and concentration-dependent diffusion coefficients are taken into account. The program also incorporates a previously-developed oxide growth and spalling model to simulate either isothermal or cyclic oxidation exposures. In addition to predicting concentration profiles after various oxidation exposures, the program can also be used to predict coating fife based on a concentration dependent failure criterion (e.g., surface solute content drops to two percent). The computer code, written in an extension of FORTRAN 77, employs numerous subroutines to make the program flexible and easily modifiable to other coating oxidation problems.

Nesbitt, James A.↗
NASA NTRS2000

Effect of Hf Additions to Pt Aluminide Bond Coats on EB-PVD TBC Life

Small Hf additions were incorporated into a Pt aluminide coating during chemical vapor deposition (CVD) on single crystal RENE N5 substrates. Standard yttria-stabilized zirconia top coats were subsequently deposited onto the coated substrates by electron beam-physical vapor deposition (EB-PVD). The coated substrates underwent accelerated thermal cycle testing in a furnace at a temperature in excess of 1121 C (2050 F) (45 minute hot exposure, 15 minute cool to approximately 121 C (250 F)) until the thermal barrier coating (TBC) failed by spallation. Incorporating Hf in the bond coat increased the TBC life by slightly more than three times that of a baseline coating without added Hf. Scanning electron microscopy of the spalled surfaces indicated that the presence of the Hf increased the adherence of the thermally grown alumina to the Pt aluminide bond coat. The presence of oxide pegs growing into the coating from the thermally grown alumina may also partially account for the improved TBC life by creating a near-surface layer with a graded coefficient of thermal expansion.

Nesbitt, James↗
NASA NTRS2001

Delayed Alumina Scale Spallation on Rene'n5+y: Moisture Effects and Acoustic Emission

The single crystal superalloy Rene'N5 (with or without Y-doping and hydrogen annealing) was cyclically oxidized at 1150 C for 1000 hours. After considerable scale growth (>= 500 hours), even the adherent alumina scales formed on Y-doped samples exhibited delayed interfacial spallation during subsequent water immersion tests, performed up to one year after oxidation. Spallation was characterized by weight loss, the amount of spalled area, and acoustic emission response. Hydrogen annealing (prior to oxidation) reduced spallation both before and after immersion, but without measurably reducing the bulk sulfur content of the Y-doped alloys. The duration and frequency of sequential, co-located acoustic emission events implied an interfacial crack growth rate at least 10(exp -3) m/s, but possibly higher than 10(exp 2) m/s. This is much greater than classic moisture-assisted slow crack growth rates in bulk alumina (10(exp -6) to 10(exp -3) m/s), which may still have occurred undetected by acoustic emission. An alternative failure sequence is proposed: an incubation process for preferential moisture ingress leads to a local decrease in interfacial toughness, thus allowing fast fracture driven by stored strain energy.

Smialek, James L.↗
NASA NTRS2001

Rock Abrasion and Ventifact Formation on Mars from Field Analog, Theoretical, and Experimental Studies

Rocks observed by the Viking Landers and Pathfinder Lander/Sojourner rover exhibit a suite of perplexing rock textures. Among these are pits, spongy textures, penetrative flutes, lineaments, crusts, and knobs Fluvial, impact, chemical alteration, and aeolian mechanisms have been proposed for many of these. In an effort to better understand the origin and characteristics of Martian rock textures, abraded rocks in the Mojave Desert and other regions have been studied. We find that most Martian rock textures, as opposed to just a few, bear close resemblance to terrestrial aeolian textures and can most easily be explained by wind, not other, processes. Flutes, grooves, and some pits on Mars are consistent with abrasion by saltating particles, as described previously. However, many other rock textures probably also have an aeolian origin. Sills at the base of rocks that generally lie at high elevations, such as Half Dome, are consistent with such features on Earth that are related to moats or soil ramps that shield the basal part of the rock from erosion. Crusts consisting of fluted fabrics, such as those on Stimpy and Chimp, are similar to fluted crusts on Earth that spall off over time. Knobby and lineated rocks are similar to terrestrial examples of heterogeneous rocks that differentially erode. The location of specific rock textures on Mars also gives insight into their origin. Many of the most diagnostic ventifacts found at the Pathfinder site are located on rocks that lie near the crests or the upper slopes of ridges. On Earth, the most active ventifact formation occurs on sloped or elevated topography, where windflow is accelerated and particle kinetic energy and flux are increased. Integrated 0 together, these observations point to significant aeolian 0 modification of rocks on Mars and cast doubt on whether many primary textures resulting from other processes are preserved. Experimental simulations of abrasion in the presence of abundant sand indicate that rocks on Mars should erode at a rate of 7.7 to 210 micrometers/yr. These rates cannot have operated over the entire history of the Pathfinder site or elsewhere on Mars, because craters, knobs, and other obstacles would be quickly worn away. More likely, rock abrasion occurs over short time periods when sand supplies are sufficient and saltation friction speeds are frequently reached. Depletion or exhaustion of sand and a decline in wind fluxes at speeds greater than that of saltation friction will then act to reduce the rate of further abrasion. We are currently engaged in a new set of wind tunnel experiments coupled with theoretical models and field studies that address rock abrasion and ventifact formation on Mars and Earth. These studies have implications for the Noachian, when sand supplies were probably more plentiful and the threshold friction speed was possibly lower because of a more dense atmosphere. Under these conditions, erosion rates from the wind could have been much greater than to day, contributing, along with probable fluvial erosion, to the Noachian landscape that is in limited preservation today.

Bridges, N. T.↗
NASA NTRS2001

COSIM: A Finite-Difference Computer Model to Predict Ternary Concentration Profiles Associated With Oxidation and Interdiffusion of Overlay-Coated Substrates

A finite-difference computer program (COSIM) has been written which models the one-dimensional, diffusional transport associated with high-temperature oxidation and interdiffusion of overlay-coated substrates. The program predicts concentration profiles for up to three elements in the coating and substrate after various oxidation exposures. Surface recession due to solute loss is also predicted. Ternary cross terms and concentration-dependent diffusion coefficients are taken into account. The program also incorporates a previously-developed oxide growth and spalling model to simulate either isothermal or cyclic oxidation exposures. In addition to predicting concentration profiles after various oxidation exposures, the program can also be used to predict coating life based on a concentration dependent failure criterion (e.g., surface solute content drops to 2%). The computer code is written in FORTRAN and employs numerous subroutines to make the program flexible and easily modifiable to other coating oxidation problems.

Nesbitt, James A.↗
NASA NTRS2001

Retention of Sputtered Molybdenum on Ion Engine Discharge Chamber Surfaces

Grit-blasted anode surfaces are commonly used in ion engines to ensure adherence of sputtered coatings. Next generation ion engines will require higher power levels, longer operating times, and thus there will likely be thicker sputtered coatings on their anode surfaces than observed to date on 2.3 kW-class xenon ion engines. The thickness of coatings on the anode of a 10 kW, 40-centimeter diameter thruster, for example, may be 22 micrometers or more after extended operation. Grit-blasted wire mesh, titanium, and aluminum coupons were coated with molybdenum at accelerated rates to establish coating stability after the deposition process and after thermal cycling tests. These accelerated deposition rates are roughly three orders of magnitude more rapid than the rates at which the screen grid is sputtered in a 2.3 kW-class, 30-centimeter diameter ion engine. Using both RF and DC sputtering processes, the molybdenum coating thicknesses ranged from 8 to 130 micrometers, and deposition rates from 1.8 micrometers per hour to 5.1 micrometers per hour. In all cases, the molybdenum coatings were stable after the deposition process, and there was no evidence of spalling of the coatings after 20 cycles from about -60 to +320 C. The stable, 130 micrometer molybdenum coating on wire mesh is 26 times thicker than the thickest coating found on the anode of a 2.3 kW, xenon ion engine that was tested for 8200 hr. Additionally, this coating on wire mesh coupon is estimated to be a factor of greater than 4 thicker than one would expect to obtain on the anode of the next generation ion engine which may have xenon throughputs as high as 550 kg.

Sovey, James S.↗
NASA NTRS2003

High Temperature Permeability of Carbon Cloth Phenolic Composite

The carbon fiber phenolic resin composite material used for the RSRM nozzle insulator occasionally experiences problems during operation from pocketing or spalling-like erosion and lifting of plies into the char layer. This phenomenon can be better understood if the permeability of the material at elevated temperatures is well defined. This paper describes an experimental approach to determining high temperature permeability of the carbon phenolic material used as the RSRM nozzle liner material. Two different approaches were conducted independently using disk and bar type specimens with the designed permeability apparatus. The principle of the apparatus was to subject a test specimen to a high pressure differential and a heat supply and to monitor both the pressure and temperature variations resulting from gas penetration through the permeable wall between the two chambers. The bar types, especially designed to eliminate sealing difficulties at a high temperature environment, were directly exposed to real time temperature elevation from 22 C to 260 C during the test period. The disk types were pre-heat treated up to 300 C for 8 hours and cooled to room temperature before testing. Nonlinear variation of downstream pressure at a certain temperature range implied moisture release and matrix pyrolysis. Permeability was calculated using a semi-numerical model of quasi-steady state. The test results and the numerical model are discussed in the paper.

Park, O. Y.↗
NASA NTRS2004

Impact Processes in the Solar System

Our laboratory has previously conducted impact fracture and dynamic failure tests. Polanskey and Ahrens [1990] mapped the fractures from a series of laboratory craters (Fig. 1) and Ahrens and Rubin [ 1993] inferred that the usually further extending radial cracks resulted from tensional failure during the compression of the shock propagation. The radial spreading induced by the particle velocity field caused the stresses perpendicular to the shock front to become sufficiently large and tensile. This induces "radial fractures." The concentric fractures are attributed to the tensional failure occurring after the initial compressive phase. Upon radial propagation of the stress wave the negative tension behind the stress-wave front caused failure along the quasi-spherical concentric fractures. The near-surface and spall fractures are attributed to the fractures described by Melosh [1984]. These are activated by impact and can launch relatively unshocked samples of planetary surfaces to speeds exceeding escape velocity. In the case of Mars, some of these surface samples presumably become the SNC (Mars) meteorites.

Ahrens, Thomas J.↗
NASA NTRS2004

Space Weathering of Apollo 16 Sample 62255: Lunar Rocks as Witness Plates for Deciphering Regolith Formation Processes

Space weathering, or alteration that occurs at the surfaces of materials exposed directly to space, has been one of the primary areas of focus of lunar studies for the past several years. It is caused by processes such as micrometeorite impacts and solar wind bombardment, and effects can include microcraters, spall zones, and vapor deposits. Much of the recent work on space weathering has been concentrated on nanoscale features, especially the amorphous rims commonly found on individual lunar soil grains. The rims typically contain nanophase Fe metal globules, which, along with Fe metal globules in agglutinates, have a profound effect on optical properties of lunar soils. The nanophase metallic iron globules cause the characteristic optical changes (reddening and darkening) found in mature lunar soils.

Wentworth, S. J.↗
NASA NTRS1999

10 000-hr Cyclic Oxidation Behavior of 68 High-Temperature Co-, Fe-, and Ni- Base Alloys Evaluated at 982 deg. C (1800 deg. F)

Power systems with operating temperatures in the range of 815 to 982 C (1500 to 1800 F) frequently require alloys that can operate for long times at these temperatures. A critical requirement is that these alloys have adequate oxidation resistance. The alloys used in these power systems require thousands of hours of operating life with intermittent shutdown to room temperature. Intermittent power plant shutdowns, however, offer the possibility that the protective scale will tend to spall (i.e., crack and flake off) upon cooling, increasing the rate of oxidative attack in subsequent heating cycles. Thus, it is critical that candidate alloys be evaluated for cyclic oxidation behavior. It was determined that exposing test alloys to ten 1000-hr cycles in static air at 982 10 000-hr Cyclic Oxidation Behavior of 68 High-Temperature Co-, Fe-, and Ni-Base Alloys Evaluated at 982 C (1800 F) could give a reasonable simulation of long-time power plant operation. Iron- (Fe-), nickel- (Ni-), and cobalt- (Co-) based high-temperature alloys with sufficient chromium (Cr) and/or aluminum (Al) content can exhibit excellent oxidation resistance. The protective oxides formed by these classes of alloys are typically Cr2O3 and/or Al2O3, and are usually influenced by their Cr, or Cr and Al, content. Sixty-eight Co-, Fe-, and Ni-base high-temperature alloys, typical of those used at this temperature or higher, were used in this study. At the NASA Lewis Research Center, the alloys were tested and compared on the basis of their weight change as a function of time, x-ray diffraction of the protective scale composition, and the physical appearance of the exposed samples. Although final appearance and x-ray diffraction of the final scale products were two factors used to evaluate the oxidation resistance of each alloy, the main criterion was the oxidation kinetics inferred from the specific weight change versus time data. These data indicated a range of oxidation behavior including parabolic (typical of isothermal oxidation), paralinear, linear, and mixed-linear kinetics.

Barrett, Charles A.↗
NASA NTRS2000

Erosion Coatings for High-Temperature Polymer Composites: A Collaborative Project With Allison Advanced Development Company

The advantages of replacing metals in aircraft turbine engines with high-temperature polymer matrix composites (PMC's) include weight savings accompanied by strength improvements, reduced part count, and lower manufacturing costs. Successfully integrating high-temperature PMC's into turbine engines requires several long-term characteristics. Resistance to surface erosion is one rarely reported property of PMC's in engine applications because PMC's are generally softer than metals and their erosion resistance suffers. Airflow rates in stationary turbine engine components typically exceed 2.3 kg/sec at elevated temperatures and pressures. In engine applications, as shown in the following photos, the survivability of PMC components is clearly a concern, especially when engine and component life-cycle requirements become longer. Although very few publications regarding the performance of erosion coatings on PMC's are available particularly in high-temperature applications the use of erosion-resistant coatings to significantly reduce wear on metallic substrates is well documented. In this study initiated by the NASA Glenn Research Center at Lewis Field, a low-cost (less than $140/kg) graphite-fiber-reinforced T650 35/PMR 15 sheet-molding compound was investigated with various coatings. This sheet-molding compound has been compression molded into many structurally complicated components, such as shrouds for gas turbine inlet housings and gearboxes. Erosion coatings developed for PMC s in this study consisted of a two-layered system: a bondcoat sprayed onto a cleaned PMC surface, followed by an erosion-resistant, hard topcoat sprayed onto the bondcoat as shown in following photomicrograph. Six erosion coating systems were evaluated for their ability to withstand harsh thermal cycles, erosion resistance (ASTM G76 83 "Standard Practice for Conducting Erosion Tests by Solid Particle Impingement Using Gas Jets") using Al2O3, and adhesion to the graphite fiber polyimide composite (ASTM D 4541 95 "Pull Off Strength of Coatings"). Glenn and Allison Advanced Development Company collaborated to optimize erosion coatings for gas turbine fan and compressor applications. All the coating systems survived aggressive thermal cycling without spalling. During erosion tests (see the final photo), the most promising coating systems tested had Cr3C2-NiCr and WC-Co as the hard topcoats. In all cases, these coating systems performed significantly better than that with a TiN hard topcoat. When material depth (thickness) loss is considered, the Cr3C2-NiCr and WC-Co coating systems provided, on average, an erosion resistance 8.5 times greater than that for the uncoated PMR 15/T650 35 composite. Similarly, Cr3C2-NiCr and WC-Co coating systems adhered to the PMC substrate during tensile tests significantly better than systems containing a TiN topcoat. Differences in topcoats of Cr3C2-NiCr and WC-Co were determined by considering issues such as cost and environmental impact. The preferred erosion-resistant coating system for PMR 15/T650 35 has WC-Co as the hard topcoat. This system provides the following benefits in comparison to the coating system with Cr3C2-NiCr topcoat: lower powder material cost (15 to 20 percent), environmentally friendly materials (Cr3C2-NiCr is hazardous), and higher deposition yield (10 to 15 percent), which results in less waste.

Sutter, James K.↗
NASA NTRS2004

Coating Development for GRCop-84 Liners for Reusable Launch Vehicles Aided by Modeling Studies

The design of the next generation of reusable launch vehicles calls for using GRCop-84 copper alloy liners based on a composition invented at the NASA Glenn Research Center. Despite its considerable advantage over other copper alloys, it is expected that GRCop-84 will suffer from environmental degradation depending on the type of rocket fuels used and on thermomechanical fatigue. Applying protective coatings on GRCop-84 substrates can minimize or eliminate many of these problems and extend the operational life of the combustion liner. This could increase component reliability, shorten depot maintenance turnaround times, and lower operating costs. Therefore, Glenn is actively pursuing the development of advanced coatings technology for GRCop-84 liners. Technology is being developed in four major areas: (1) new metallic coating compositions, (2) application techniques, (3) test methods, and (4) life prediction design methodology using finite element analysis. The role of finite element analysis in guiding the coating effort is discussed in this report. Thermal analyses were performed at Glenn for different combinations of top- and bondcoat compositions to determine the temperature variation across the coated cross section with the thickness of the top coat. These calculations were conducted for simulated LH2/LO2 booster engine conditions assuming that the bond coat had a constant thickness of 50 m. The preceding graphs show the predicted temperatures at the outer surface of the top coat (hot wall), at the top-coat/bond-coat interface, at the bond-coat/GRCop-84 interface, and at the GRCop-84 cold wall as a function of top-coat thickness for Cu- 26(wt%)Cr top coat (top graph), Ni-17(wt%)Cr-6%Al-0.5%Y top coat and Cu-26%Cr bond coat, and NiAl top coat and Ni bond coat. In all cases, the temperature of the top coat at the hot wall increased with increasing top-coat thickness and with corresponding decreases in the temperatures at the two interfaces and the cold wall. These temperatures are not acutely sensitive to the thermal conductivity of the top coat when it exceeds 25 and 50 W/m/K for low and high heat flux engines. This observation is significant for two reasons. First, several different top-coat compositions can be evaluated as potential protective coatings without loss in the heat-transfer efficiency of the coated system. Second, materials with thermal conductivities less than the critical values of 25 or 50 W/m/K are more likely to act as thermal barrier coatings. The deposition of overlay coatings on GRCop-84 substrates results in the development of residual stresses. The presence of these residual stresses influences the probability of coating spallation, the thermal cycling life, and the fatigue properties of the coated substrate during use. Since it is important to understand how these stresses develop during the vacuum-plasma-spraying coating deposition process, the nature and magnitudes of the cool-down residual stresses were calculated and compared with experimentally determined values across the coated cross section of a disk specimen. The calculations were conducted assuming that the specimen cools down to room temperature from vacuum plasma-spraying temperatures of either 250 or 650 C. The effects of coating the substrate with and without grit blasting were also theoretically examined. The final graph compares the predicted and the experimental results for a GRCop-84 disk coated with about a 50- m-thick Ni bond coat and a 75- to 100- m NiAl top coat, where the curves for NASA-2 assume the presence of a prior residual stress generated by grit blasting under conditions similar to the experimental situation. The predicted cool-down in-plane stresses were compressive in both the NiAl top coat and the Ni bond coat. They were also compressive in the substrate to a depth of about 0.25 mm from the Ni/GRCop-84 interface when the vacuum-plasma-spraying temperature was low. However, using a higher plasma spraying temperaturs likely to leave the substrate under a small tensile stress to counter the compressive stresses in the bond and top coats because of the relaxation of residual stresses generated in the substrate during the grit blasting of its surface prior to spraying. These results suggest that the NiAl and Ni coatings are unlikely to spall after spraying as confirmed by the microstructural observations shown in the following photomicrograph of an as-sprayed specimen. Finally, it is noted that the calculated and experimental results are not in complete agreement, which indicates that both the experimental and modeling techniques need further refinement.

Raj, Sai V.↗
NASA NTRS2003

Universal Responses of Cyclic-Oxidation Models Studied

Oxidation is an important degradation process for materials operating in the high-temperature air or oxygen environments typical of jet turbine or rocket engines. Reaction of the combustion gases with the component material forms surface layer scales during these oxidative exposures. Typically, the instantaneous rate of reaction is inversely proportional to the existing scale thickness, giving rise to parabolic kinetics. However, more realistic applications entail periodic startup and shutdown. Some scale spallation may occur upon cooling, resulting in loss of the protective diffusion barrier provided by a fully intact scale. Upon reheating, the component will experience accelerated oxidation due to this spallation. Cyclic-oxidation testing has, therefore, been a mainstay of characterization and performance ranking for high-temperature materials. Models simulate this process by calculating how a scale spalls upon cooling and regrows upon heating (refs. 1 to 3). Recently released NASA software (COSP for Windows) allows researchers to specify a uniform layer or discrete segments of spallation (ref. 4). Families of model curves exhibit consistent regularity and trends with input parameters, and characteristic features have been empirically described in terms of these parameters. Although much insight has been gained from experimental and model curves, no equation has been derived that can describe this behavior explicitly as functions of the key oxidation parameters.

Smialek, James L.↗