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At least 343 records · Page 19

Improved performance thermal barrier coatings

Thermal barrier coatings offer an attractive approach to improving the durability and efficiency of the hot section of heat engines. The coatings typically consist of an inner alloy bond coating about 0.01 cm thick resistant to oxidation and hot corrosion and an outer ceramic layer, usually a stabilized zirconia, 0.01-0.05 cm thick. Here, the materials, thermomechanical stress, and hot corrosion problems associated with thermal barrier coatings are reviewed along with the capabilities and limitations of current technology. The coatings discussed include ZrO2-Y2O3/NiCrAlY, ZrO2-Y2O3/NiCoCrAlY, ZrO2-MgO/NiCoCrAlY, CaO-SiO2/Co-Cr-Al-Y, and CaO-SiO2/NiCrAlY systems. It is emphasized that the performance of thermal barrier coatings is governed by many complex and interrelated factors, so that optimization of these coatings always involves certain tradeoffs.

Levine, S. R.↗

Microlaminate composites: An alternate approach to thermal barrier coatings

Ceramic thermal barrier coatings suffer from a major drawback, i.e., brittle behavior. An alternate approach is microlaminate composite coatings consisting of alternate layers of metal and oxide. As the thickness of the individual laminae decrease while keeping the total thickness of the coating constant, the thermal conductivity drops markedly. Data on the Fe-Cu system will be presented. A model is proposed for an MCrAlY-Al2O3 microlaminate coating for thermal barriers. The methods of fabrication will also be discussed.

Bunshah, R. F.↗

Shock Generation and Control Using DBD Plasma Actuators

This report is the final report of a NASA Phase I SBIR contract, with some revisions to remove company proprietary data. The Shock Boundary Layer Interaction (SBLI) phenomena in a supersonic inlet involve mutual interaction of oblique shocks with boundary layers, forcing the boundary layer to separate from the inlet wall. To improve the inlet efficiency, it is desired to prevent or delay shock-induced boundary layer separation. In this effort, Innovative Technology Applications Company (ITAC), LLC and the University of Notre Dame (UND) jointly investigated the use of dielectric-barrier-discharge (DBD) plasma actuators for control of SBLI in a supersonic inlet. The research investigated the potential for DBD plasma actuators to suppress flow separation caused by a shock in a turbulent boundary layer. The research involved both numerical and experimental investigations of plasma flow control for a few different SBLI configurations: (a) a 12 wedge flow test case at Mach 1.5 (numerical and experimental), (b) an impinging shock test case at Mach 1.5 using an airfoil as a shock generator (numerical and experimental), and (c) a Mach 2.0 nozzle flow case in a simulated 15 X 15 cm wind tunnel with a shock generator (numerical). Numerical studies were performed for all three test cases to examine the feasibility of plasma flow control concepts. These results were used to guide the wind tunnel experiments conducted on the Mach 1.5 12 degree wedge flow (case a) and the Mach 1.5 impinging shock test case (case b) which were at similar flow conditions as the corresponding numerical studies to obtain experimental evidence of plasma control effects for SBLI control. The experiments also generated data that were used in validating the numerical studies for the baseline cases (without plasma actuators). The experiments were conducted in a Mach 1.5 test section in the University of Notre Dame Hessert Laboratory. The simulation results from cases a and b indicated that multiple spanwise actuators in series and at a voltage of 75 kVp-p could fully suppress the flow separation downstream of the shock. The simulation results from case c showed that the streamwise plasma actuators are highly effective in creating pairs of counter-rotating vortices, much like the mechanical vortex generators, and could also potentially have beneficial effects for SBLI control. However, to achieve these effects, the positioning and the quantity of the DBD actuators used must be optimized. The wind tunnel experiments mapped the baseline flow with good agreement to the numerical simulations. The experimental results were conducted with spanwise actuators for cases a and b, but were limited by the inability to generate a sufficiently high voltage due to arcing in the wind-tunnel test-section. The static pressure in the tunnel was lower than the static pressure in an inlet at flight conditions, promoting arching and degrading the actuator performance.

Patel, Mehul P.↗

Thermal barrier coatings for heat engine components

A comprehensive NASA-Lewis program of coating development for aircraft gas turbine blades and vanes is presented. Improved ceramic layer compositions are investigated, along the MCrAlY bond films and the methods of uniform deposition of the coatings; the thermomechanical and fuel impurity tolerance limits of the coatings are being studied. Materials include the ZrO2-Y2O3/NiCrAlY system; the effects of the bond coat and zirconia composition on coating life and Mach 1 burner rig test results are discussed. It is concluded that Diesel engines can also utilize thermal barrier coatings; they have been used successfully on piston crowns and exhaust valves of shipboard engines to combat lower grade fuel combustion corrosion.

Levine, S. R.↗

Thermal Radiation Effects Analyzed in Translucent Composite and Thermal Barrier Coating

Ceramic parts and coatings are needed to withstand high temperatures in advanced aircraft engines. In hot environments, such as in the combustion chambers of these engines, infrared and visible radiation can penetrate into some ceramics and heat them internally. The internal temperatures depend on radiative effects combined with heat conduction, and on convection and radiation at the material boundaries. Since engine temperatures are high, radiant emission can be large from within translucent parts and coatings, and this must be included in the analysis. Transient and steady-state behavior are both important. During a transient, radiant penetration provides more rapid internal heating than conduction alone, and the temperature distributions are usually considerably different than for steady-state conditions; this can produce transient thermal stresses. Analytical and numerical methods are being used at the NASA Lewis Research Center to predict transient temperatures and heat flows in translucent materials. A transient analysis was done for a composite of two translucent layers. The layer refractive indices were larger than 1, producing internal reflections at the boundaries and at the internal interface. In addition, steady-state results were computed for a two-layer composite with one layer opaque. The results were used to assess the importance of internal radiation in a zirconia thermal barrier coating on a cooled metal wall. Since the radiative transfer equations are rather complex, especially when internal scattering is included, approximate methods are being investigated that might be convenient for computer design programs. An approximate two-flux method was used and verified by comparisons with solutions that used exact radiative transfer relations. The two-flux equations include scattering without increasing solution difficulty.

Siegel, Robert↗

The Effect of Oxidation in Environmental Barrier Coatings Subject to Foreign Object Damage

Oxidation and foreign object damage (FOD) are two key failure modes for environmental barrier coatings (EBCs). For EBCs with a silicon (Si) bond coat, a thermally grown oxide (TGO) layer forms at the EBC –bond coat interface. The TGO layer is considered the weak interface, and directly influences the life of the EBC. Moreover, FOD has been shown to cause significant subsurface damage resulting in delamination or spallation of the EBC which can occur at the EBC -bond coat interface or the bond coat -substrate interface. The purpose of this work is to investigate the synergistic effects of oxidation and FOD in a ytterbium disilicate (𝑌𝑏2𝑆𝑖2𝑂7) EBC. FOD testing is conducted on as-deposited and steam oxidized samples at room temperature using a 1.59-mm hardened steel ball projectile. The resulting damage is characterized by optical profilometry and scanning electron microscopy (SEM). Additionally, a quasi-static, mechanical assessment of the EBC bond strength in the presence of a growing TGO is presented.

environmental barrier coatings (EBCs)↗

Forward- and reverse-bias tunneling effects in n/+/p silicon solar cells

Excess currents due to field-assisted tunneling in both forward and reverse bias directions have been observed in n(+)-p silicon solar cells. These currents arise from the effect of conducting paths produced in the depletion layer by n(+) diffusion and cell processing. Forward-bias data indicate a small potential barrier with height of 0.04 eV at the n(+) end of conducting paths. Under reverse bias, excess tunneling currents involve a potential barrier at the p end of the conducting paths, the longer paths being associated with smaller barrier heights and dominating at the lower temperatures. Low-reverse-bias data give energy levels of 0.11 eV for lower temperatures (253-293 K) and 0.35 eV for higher temperatures (293-380 K). A model is suggested to explain the results.

Garlick, G. F. J.↗

Ballistic Performance of Porous-Ceramic, Thermal Protection Systems

Porous-ceramic, thermal protection systems are used heavily in current reentry vehicles like the Orbiter, and they are currently being proposed for the next generation of US manned spacecraft, Orion. These systems insulate reentry critical components of a spacecraft against the intense thermal environments of atmospheric reentry. Additionally, these materials are highly exposed to space environment hazards like solid particle impacts. This paper discusses impact studies up to 10 km/s on 8 lb/cu ft alumina-fiber-enhanced-thermal-barrier (AETB8) tiles coated with a toughened-unipiece-fibrous-insulation/ reaction-cured-glass layer (TUFI/RCG). A semi-empirical, first principals impact model that describes projectile dispersion is described that provides excellent agreement with observations over a broad range of impact velocities, obliquities and projectile materials. Model extensions to look at the implications of greater than 10 GPa equation of state is also discussed. Predicted penetration probabilities for a vehicle visiting the International Space Station is 60% lower for orbital debris and 95% lower for meteoroids with this model compared to an energy scaled approach.

Miller, J. E.↗

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↗

Heat dissipation in controlled environment enclosures through the application of water screens

The use of plate glass-water thermal barriers in controlled environment facilities effectively reduces the thermal load within the plant growth chamber. This allows high PPFs to be provided for plant growth and development studies, adequate simulation of daily light integrals, and simulation of peak PPF's. Further, substantial amounts of incandescent lamp supplementation can be used to achieve simulation of daylight R:FR ratios which are needed to ensure adequate stem development in some species. While the focus in this paper is on the use of entire thermal barriers which separate the lighting enclosure from the plant growth chamber, the same principles apply to the use of water jackets for cooling individual lamps (such as can occur with xenon-arc lamps). In this instance, the barrier separating the lamps from the plant chamber can be much simpler (e.g., plexiglass) as the main function of the barrier is to separate the air ventilation of the lamp enclosure from the air system within the plant growth chamber. The main advantage of water as a thermal barrier is the negligible absorption of radiation in the photosynthetically-active and near infrared wavebands. Consequently, plate glass-water barriers typically allow transmission of approximately 90% of radiation in these regions. While ventilated double and triple glazing systems appear to be attractive alternative to water barriers from an operating standpoint, their significant absorption in the biologically-important wavebands (7 - 12%) with each glass layer and longer-wave cut-offs (typically 2500 - 4000 nm) makes them a much less attractive alternative. The data presented here demonstrate clearly that measurement of PPF alone is not an adequate representation of the radiation environment being used in a controlled environment study. The amounts and proportions of long-wave and short-wave radiation in a plant growth chamber are dependent on lamp type, lamp combination, presence of a thermal barrier, the type of thermal barrier between the lamps and the plant growing area and the overall construction and design of the chamber. It is important, therefore, in reporting results of controlled environment studies, to adequately describe both the details of the lighting system used and the characteristics of the radiation produced by that system, so results of different studies can be adequately evaluated and compared.

Warrington, I. J.↗

Multilayer Thermal Barrier Coating (TBC) Architectures Utilizing Rare Earth Doped YSZ and Rare Earth Pyrochlores

To allow for increased gas turbine efficiencies, new insulating thermal barrier coatings (TBCs) must be developed to protect the underlying metallic components from higher operating temperatures. This work focused on using rare earth doped (Yb and Gd) yttria stabilized zirconia (t' Low-k) and Gd2Zr2O7 pyrochlores (GZO) combined with novel nanolayered and thick layered microstructures to enable operation beyond the 1200 C stability limit of current 7 wt% yttria stabilized zirconia (7YSZ) coatings. It was observed that the layered system can reduce the thermal conductivity by approximately 45 percent with respect to YSZ after 20 hr of testing at 1316 C. The erosion rate of GZO is shown to be an order to magnitude higher than YSZ and t' Low-k, but this can be reduced by almost 57 percent when utilizing a nanolayered structure. Lastly, the thermal instability of the layered system is investigated and thought is given to optimization of layer thickness.

Thermal Barrier Coating↗

Cryogenic foam insulation for LH2 fueled subsonic transports

Shortages of petroleum-based aircraft fuels are foreseen before the end of the century. To cope with such shortages, NASA is developing a commercial aircraft which can operate on liquid hydrogen. Various foam insulators for LH2 storage are considered in terms of thermal performance and service life. Of the cryogenic foams considered (plain foam, foam with flame retardants and fiberglass reinforcement, and foam with vapor barriers), polyurethane foams were found to be the best. Tests consisted of heating a 5 cm layer of insulation around an aluminum tank containing LH2 to 316 K, and then cooling it to 266 K, while the inner surface was maintained at LH2 temperature (20 K).

Sharpe, E. L.↗

A widely adaptable habitat construction system utilizing space resources

This study suggests that the cost of providing accommodations for various manned activities in space may be reduced by the extensive use of resources that are commonly found throughout the solar system. Several concepts are proposed for converting these resources into simple products with many uses. Concrete is already being considered as a possible moonbase material. Manufacturing equipment should be as small and simple as possible, which leads to the idea of molding it into miniature modules that can be produced and assembled in large numbers to create any conceivable shape. Automated equipment could build up complex structures by laying down layer after layer in a process resembling stereolithography. These tiny concrete blocks handle compression loads and provide a barrier to harmful radiation. They are joined by a web of tension members that could be made of wire or fiber-reinforced plastic. The finished structure becomes air-tight with the addition of a flexible liner. Wire can be made from the iron modules found in lunar soil. In addition to its structural role, a relatively simple apparatus can bend and weld it into countless products like chairs and shelving that would otherwise need to be supplied from Earth. Wire woven into a loose blanket could be an effective micrometeoroid shield, tiny wire compression beams could be assembled into larger beams which in turn form larger beams to create very large space-frame structures. A technology developed with lunar materials could be applied to the moons of Mars or the asteroids. To illustrate its usefulness several designs for free-flying habitats are presented. They begin with a minimal self-contained living unit called the Cubicle. It may be multiplied into clusters called Condos. These are shown in a rotating tether configuration that provides a substitute for gravity. The miniature block proposal is compared with an alternate design based on larger triangular components and a tetrahedral geometry. The overall concept may be expanded to envision city-sized self-sufficient environments where humans could confortably live their entire lives. One such proposal is the Hive. It is configured around a unique sunlight collection system that could provide all its energy needs and that could be scaled up to compensate for the reduced solar intensity at greater distances from the sun. Its outer perimeter consists of a cylindrical section mated to two conical end walls that taper inwards toward a small aperture at the center of rotation. Light collected by two huge mirrors of unusual design enters the aperture and is redirected to the inside of the cylinder. The conical end walls are shielded from direct sunlight and are designed to radiate heat into space. They are lined with air ducts that passively recirculate the atmosphere while extracting moisture by condensation. Although there is no immediate demand for spacecraft on this scale, their consideration can influence even the earliest stages of the development process.

Wykes, Harry B.↗

Ballistic Performance of Porous Ceramic Thermal Protection Systems at 9 km/s

Porous-ceramic, thermal-protection-systems are used heavily in current reentry vehicles like the Orbiter, and they are currently being proposed for the next generation of manned spacecraft, Orion. These materials insulate the structural components and sensitive electronic components of a spacecraft against the intense thermal environments of atmospheric reentry. Furthermore, these materials are also highly exposed to space environmental hazards like meteoroid and orbital debris impacts. This paper discusses recent impact testing up to 9 km/s on ceramic tiles similar to those used on the Orbiter. These tiles have a porous-batting of nominally 8 lb/cubic ft alumina-fiber-enhanced-thermal-barrier (AETB8) insulating material coated with a damage-resistant, toughened-unipiece-fibrous-insulation (TUFI) layer.

Miller, Joshua E.↗

Inductively Coupled Plasma Etching for Delineation of InAs/GaSb Pixels

We developed 320x256 Complimentary Barrier Infrared (CBIRD) focal plane array (FPA) for long wave infrared (LWIR) imaging application. The FPA layers grown by molecular beam epitaxy (MBE) had 300 periods 1.9 micro m thick absorber. The CBIRD arrays showed the mean dark current density of 2.2 x 10(exp -4) A/cm2, when 128 mV bias voltage was applied. The long wave cut off was observed at 8.8 micrometers at the 50% peak and the maximum quantum efficiency was 54% at 5.6 micrometers. The arrays had 81% fill factor with 97% operability with noise equivalent difference temperature (NE(delta)T) of 18.6 mK and a mean detectivity of D*=1.3 x 10(exp 11) Hz(exp 1/2)/W.

InAs/GaSb↗

Possibilities for LWIR detectors using MBE-grown Si(/Si(1-x)Ge(x) structures

Traditionally, long wavelength infrared (LWIR) detection in Si-based structures has involved either extrinsic Si or Si/metal Schottky barrier devices. Molecular beam epitaxially (MBE) grown Si and Si/Si(1-x)Ge(x) heterostructures offer new possibilities for LWIR detection, including sensors based on intersubband transitions as well as improved conventional devices. The improvement in doping profile control of MBE in comparison with conventional chemical vapor deposited (CVD) Si films has resulted in the successful growth of extrinsic Si:Ga, blocked impurity-band conduction detectors. These structures exhibit a highly abrupt step change in dopant profile between detecting and blocking layers which is extremely difficult or impossible to achieve through conventional epitaxial growth techniques. Through alloying Si with Ge, Schottky barrier infrared detectors are possible, with barrier height values between those involving pure Si or Ge semiconducting materials alone. For both n-type and p-type structures, strain effects can split the band edges, thereby splitting the Schottky threshold and altering the spectral response. Measurements of photoresponse of n-type Au/Si(1-x)Ge(x) Schottky barriers demonstrate this effect. For intersubband multiquntum well (MQW) LWIR detection, Si(1-x)Ge(x)/Si detectors grown on Si substrates promise comparable absorption coefficients to that of the Ga(Al)As system while in addition offering the fundamental advantage of response to normally incident light as well as the practical advantage of Si-compatibility. Researchers grew Si(1-x)Ge(x)/Si MQW structures aimed at sensitivity to IR in the 8 to 12 micron region and longer, guided by recent theoretical work. Preliminary measurements of n- and p-type Si(1-x)Ge(x)/Si MQW structures are given.

Hauenstein, Robert J.↗

Ceramic thermal barrier coatings for electric utility gas turbine engines

Research and development into thermal barrier coatings for electric utility gas turbine engines is reviewed critically. The type of coating systems developed for aircraft applications are found to be preferred for clear fuel electric utility applications. These coating systems consists of a layer of plasma sprayed zirconia-yttria ceramic over a layer of MCrAly bond coat. They are not recommended for use when molten salts are presented. Efforts to understand coating degradation in dirty environments and to develop corrosion resistant thermal barrier coatings are discussed.

Miller, R. A.↗

Ballistic-electron-emission microscopy of subsurface defects at the Au-GaAs(100) interface

The application of ballistic-electron-emission microscopy (BEEM) to a study of the influence of GaAs(100) substrate conditions on the formation of a multidefect structure at the Au-GaAs(100) Schottky barrier interface is described. Interfaces prepared on both melt-grown GaAs(100) wafer substrates and MBF-deposited GaAs(100) buffer layers are considered. As a comparison to the study of Au-GaAs(100) interfaces, BEEM imaging is performed on Au-Si(100) interfaces. It is noted that Au-GaAs(100) interface formation is relatively insensitive to the effects of substrate surface condition and substrate bulk defect density, and that the combination of BEEM imaging and BEEM spectroscopy indicates that the heterogeneous interface defects are the result of diffusion between the Schottky barrier electrodes.

Hecht, M. H.↗