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NASA NTRS2002

Thermal Gradient Cyclic Behavior of a Thermal/Environmental Barrier Coating System on SiC/SiC Ceramic Matrix Composites

Thermal barrier and environmental barrier coatings (TBCs and EBCs) will play a crucial role in future advanced gas turbine engines because of their ability to significantly extend the temperature capability of the ceramic matrix composite (CMC) engine components in harsh combustion environments. In order to develop high performance, robust coating systems for effective thermal and environmental protection of the engine components, appropriate test approaches for evaluating the critical coating properties must be established. In this paper, a laser high-heat-flux, thermal gradient approach for testing the coatings will be described. Thermal cyclic behavior of plasma-sprayed coating systems, consisting of ZrO2-8wt%Y2O3 thermal barrier and NASA Enabling Propulsion Materials (EPM) Program developed mullite+BSAS/Si type environmental barrier coatings on SiC/SiC ceramic matrix composites, was investigated under thermal gradients using the laser heat-flux rig in conjunction with the furnace thermal cyclic tests in water-vapor environments. The coating sintering and interface damage were assessed by monitoring the real-time thermal conductivity changes during the laser heat-flux tests and by examining the microstructural changes after the tests. The coating failure mechanisms are discussed based on the cyclic test results and are correlated to the sintering, creep, and thermal stress behavior under simulated engine temperature and heat flux conditions.

Zhu, Dongming↗

NASA NTRS1999

Impact of Thermal Gradients on Wind Tunnel Force Measurements

In a wind tunnel facility, the direct measurement of forces and moments induced on the model are performed by a force measurement balance. The measurement balance is a precision-machined device that has strain gages at strategic locations to measure the strain (i.e., deformations) due to applied forces and moments. The strain gages convert the strain (and hence the applied force) to an electrical voltage that is measured by external meters. Thermal gradients can complicate the process, however. Thermal gradients on the balance cause differential expansion (or contraction) of various parts of the balance that induce a strain that is detected by the strain gages and is indistinguishable from an external applied force. The thermal gradients can result when testing is done at elevated temperatures or at cryogenic temperatures such as at the National Transonic Facility (NTF) at NASA Langley Research Center (LaRC).

Hereford, James↗

NASA NTRS2006

Minimum mass design of large-scale space trusses subjected to thermal gradients

Lightweight, deployable trusses are commonly used to support space-borne instruments including RF reflectors, radar panels, and telescope optics. While in orbit, these support structures are subjected to thermal gradients that vary with altitude, location in orbit, and self-shadowing. Since these instruments have tight dimensional-stability requirements, their truss members are often covered with multi-layer insulation (MLI) blankets to minimize thermal distortions. This paper develops a radiation heat transfer model to predict the thermal gradient experienced by a triangular truss supporting a long, linear radar panel in Medium Earth Orbit (MEO). The influence of self-shadowing effects of the radar panel are included in the analysis, and the influence of both MLI thickness and outer covers/coatings on the magnitude of the thermal gradient are formed into a simple, two-dimensional analysis. This thermal model is then used to size and estimate the structural mass of a triangular truss that meets a given set of structural requirements.

thermal truss analysis↗

NASA NTRS1996

Fossilization processes in siliceous thermal springs: trends in preservation along thermal gradients

To enhance our ability to extract palaeobiological and palaeoenvironmental information from ancient thermal spring deposits, we have studied the processes responsible for the development and preservation of stromatolites in modern subaerial thermal spring systems in Yellowstone National Park (USA). We investigated specimens collected from silica-depositing thermal springs along the thermal gradient using petrographic techniques and scanning electron microscopy. Although it is known that thermophilic cyanobacteria control the morphogenesis of thermal spring stromatolites below 73 degrees C, we have found that biofilms which contain filamentous thermophiles contribute to the microstructural development of subaerial geyserites that occur along the inner rims of thermal spring pools and geyser effluents. Biofilms intermittently colonize the surfaces of subaerial geyserites and provide a favoured substrate for opaline silica precipitation. We have also found that the preservation of biotically produced microfabrics of thermal spring sinters reflects dynamic balances between rates of population growth, decomposition of organic matter, silica deposition and early diagenesis. Major trends in preservation of thermophilic organisms along the thermal gradient are defined by differences in the mode of fossilization, including replacement, encrustation and permineralization.

NASA Discipline Exobiology↗

NASA NTRS2002

Cyclic Failure Mechanisms of Thermal and Environmental Barrier Coating Systems Under Thermal Gradient Test Conditions

Plasma-sprayed ZrO2-8wt%Y2O3 and mullite+BSAS/Si multilayer thermal and environmental barrier coating (TBC-EBC) systems on SiC/SiC ceramic matrix composite (CMC) substrates were thermally cyclic tested under high thermal gradients using a laser high-heat-flux rig in conjunction with furnace exposure in water-vapor environments. Coating sintering and interface damage were assessed by monitoring the real-time thermal conductivity changes during the laser heat-flux tests and by examining the microstructural changes after exposure. Sintering kinetics of the coating systems were also independently characterized using a dilatometer. It was found that the coating failure involved both the time-temperature dependent sintering and the cycle frequency dependent cyclic fatigue processes. The water vapor environments not only facilitated the initial coating conductivity increases due to enhanced sintering and interface reaction, but also promoted later conductivity reductions due to the accelerated coating cracking and delamination. The failure mechanisms of the coating systems are also discussed based on the cyclic test results and are correlated to the sintering and thermal stress behavior under the thermal gradient test conditions.

Zhu, Dongming↗

NASA NTRS1984

The thermocapillary motion of two bubbles oriented arbitrarily relative to a thermal gradient

The interaction problem of two bubbles oriented at an arbitrary angle to a thermal gradient in the absence of gravity is studied. The problem is considered in the quasi-static limit, wherein unsteady and convective transport terms are completely neglected in the momentum and energy equations. Instead of bipolar coordinates, an approximation used in a previous analysis of the interaction effects of two bubbles moving along their line of centers in a thermal gradient is applied here to predict the interaction parameter.

Meyyappan, M.↗

NASA NTRS2018

Through Thickness Thermal Gradients in Thick Laminates During Cure, Influence on Tg and Modulus

Carbon fiber composites are materials of great interest to the aerospace industry because of their light weight and high strength properties. Composite use in high load bearing applications such as roto-craft gearing requires manufacturing parts that are 1.5 inches thick and beyond. Very thick composite parts (laminates) produce thermal gradients and temperature spikes due to the heat released by resin polymerization and cross-linking during composite cure. It is believed that these thermal gradients will cause internal stresses to build-up inside these ultra-thick laminates during the cure-cycle, yielding parts with non-uniform mechanical properties throughout the thickness of the laminate. The goal of this study is to identify these thermal gradients and determine the magnitude of difference in mechanical properties generated by them.

Mechanical Properties↗

NASA NTRSDate not supplied

Compostional Variation of Venusian Melts as A Function of Thermal Gradient and Protolith

Average surface pressure and temperature conditions of 92 bars and 460 °C and thermal gradients in the range of 5-25 °C/km and up to 50 °C/km for specific cases on Venus suggest that the lower crust and upper mantle are exposed to conditions suitable for partial melting. Further, constraints from terrestrial crystallization experiments are indicative of magmatic diversity on Venus due to variations in melting depths and volatile content. Here, we use phase equilibria modeling to determine the melt compositions resulting from partial melting of a mantle protolith and two mafic crustal compositions for sever-al Venusian thermal gradients. The modeled melt compositions are then compared to experimental eclogite and peridotite melt compositions and analyses from the Venusian surface to further constrain melting processes.

J Semprich↗

NASA NTRS2004

TIGER: Development of Thermal Gradient Compensation Algorithms and Techniques

In a wind tunnel facility, the direct measurement of forces and moments induced on the model are performed by a force measurement balance. The measurement balance is a precision-machined device that has strain gages at strategic locations to measure the strain (i.e., deformations) due to applied forces and moments. The strain gages convert the strain (and hence the applied force) to an electrical voltage that is measured by external instruments. To address the problem of thermal gradients on the force measurement balance NASA-LaRC has initiated a research program called TIGER - Thermally-Induced Gradients Effects Research. The ultimate goals of the TIGER program are to: (a) understand the physics of the thermally-induced strain and its subsequent impact on load measurements and (b) develop a robust thermal gradient compensation technique. This paper will discuss the impact of thermal gradients on force measurement balances, specific aspects of the TIGER program (the design of a special-purpose balance, data acquisition and data analysis challenges), and give an overall summary.

Hereford, James↗

NASA NTRS1992

The effects of thermal gradients on the Mars Observer Camera primary mirror

The paper discusses the effect of thermal gradients on the optical performance of the primary mirror of Mars Observer Camera (MOC), which will be launched on the Mars Observer spacecraft in September 1992. It was found that mild temperature gradients can have a large effect on the mirror surface figure, even for relatively low coefficient-of-thermal-expansion materials. However, in the case of the MOC primary mirror, it was found that the radius of curvature (ROC) of the reflective surface of the mirror changed in a nearly linear fashion with the radial temperature gradient, with little additional aberration. A solid-state ROC controller using the thermal gradient effect was implemented and verified.

Applewhite, Roger W.↗

NASA NTRS1993

Study of bubble behavior in weightlessness (effects of thermal gradient and acoustic stationary wave) (M-16)

The aim of this experiment is to understand how bubbles behave in a thermal gradient and acoustic stationary wave under microgravity. In microgravity, bubble or bubbles in a liquid will not rise upward as they do on Earth but will rest where they are formed because there exists no gravity-induced buoyancy. We are interested in how bubbles move and in the mechanisms which support the movement. We will try two ways to make bubbles migrate. The first experiment concerns behavior of bubbles in a thermal gradient. It is well known than an effect of surface tension which is masked by gravity on the ground becomes dominant in microgravity. The surface tension on the side of the bubble at a lower temperature is stronger than at a higher temperature. The bubble migrates toward the higher temperature side due to the surface tension difference. The migration speed depends on the so-called Marangoni number, which is a function of the temperature difference, the bubble diameter, liquid viscosity, and thermal diffusivity. At present, some experimental data about migration speeds in liquids with very small Marangoni numbers were obtained in space experiments, but cases of large Marangoni number are rarely obtained. In our experiment a couple of bubbles are to be injected into a cell filled with silicon oil, and the temperature gradient is to be made gradually in the cell by a heater and a cooler. We will be able to determine migration speeds in a very wide range of Marangoni numbers, as well as study interactions between the bubbles. We will observe bubble movements affected by hydrodynamical and thermal interactions, the two kinds of interactions which occur simultaneously. These observation data will be useful for analyzing the interactions as well as understanding the behavior of particles or drops in materials processing. The second experiment concerns bubble movement in an acoustic stationary wave. It is known that a bubble in a stationary wave moves toward the node or the loop according to whether its diameter is larger or smaller than that of the main resonant radius. In our experiment fine bubbles will be observed to move according to an acoustic field formed in a cylindrical cell. The existence of bubbles varies the acoustic speed, and the interactive force between bubbles will make the bubble behavior collective and complicated. This experiment will be very useful to development of bubble removable technology as well as to the understanding of bubble behavior.

Azuma, H.↗

NASA NTRS2001

Thermal Conductivity and Thermal Gradient Cyclic Behavior of Refractory Silicate Coatings on SiC/SiC Ceramic Matrix Composites

Plasma-sprayed mullite and BSAS coatings have been developed to protect SiC/SiC ceramic matrix composites from high temperature environmental attack. In this study, thermal conductivity and thermal barrier functions of these coating systems are evaluated using a laser high-heat-flux test rig. The effects of water vapor on coating thermal conductivity and durability are studied by using alternating furnace and laser thermal gradient cyclic tests. The influence of laser high thermal-gradient cycling on coating failure modes is also investigated.

Zhu, Dongming↗

NASA NTRS1994

Design of a High Thermal Gradient Bridgman Furnace

The Advanced Automated Directional Solidification Furnace (AADSF) is a Bridgman-Stockbarger microgravity processing facility, designed and manifested to first fly aboard the second United States Microgravity Payload (USMP-2) Space Shuttle mission. The AADSF was principally designed to produce high axial thermal gradients, and is particularly suitable for metals solidification experiments, including non-dilute alloys. To accommodate a wider range of experimental conditions, the AADSF is equipped with a reconfigurable gradient zone. The overall design of the AADSF and the relationship between gradient zone design and furnace performance are described. Parametric thermal analysis was performed and used to select gradient zone design features that fulfill the high thermal gradient requirements of the USMP-2 experiment. The thermal model and analytical procedure, and parametric results leading to the first flight gradient zone configuration, are presented. Performance for the USMP-2 flight experiment is also predicted, and analysis results are compared to test data.

LeCroy, J. E.↗

NASA NTRS1984

Holographic interferometry - Errors caused by thermal gradients in holographic plates

Thermal effects as sources of errors in holographic interferometry are illustrated on an example of reflection holography patterns obtained on graphite-epoxy specimens exposed before and after compressive loading. The numerical interpretation of the obtained holograms indicated some peculiar unexpected thickness changes in the specimen. In addition, some patterns showed random occurrence of zones of low and zero contrast. These discrepancies occurred usually in the first of the two exposures and were traced to thermal warping and thermal relaxation patterns caused by small temperature gradients that resulted from heat transfer to the photographic plates during their installation. Suggested precautions to minimize thermal effects include using thick holographic plates (photographic plates attached to glass plates) and insulated gloves during handling and allowing time to establish thermal equilibrium before the exposure.

Post, D.↗

NASA NTRS2013

The NTF Inlet Guide Vanes Thermal Gradient Problem and Its Mitigation

The National Transonic Facility (NTF) utilizes Inlet Guide Vanes (IGV) to provide precise, quick response Mach number control for the tunnel. During cryogenic operations, the massive IGV structure can experience large thermal gradients, measured as "Delta T or (Delta)T", between the IGV ring and its support structure called the transfer case. If these temperature gradients are too large, the IGV structure can be stressed beyond its safety limit and cease operation. In recent years, (Delta)T readings exceeding the prescribed safety limits were observed frequently during cryogenic operations, particularly during model access. The tactical operation methods of the tunnel to minimize (Delta)T did not always succeed. One obvious option to remedy this condition is to warm up the IGV structure by disabling the main drive operation, but this "natural" warm up method can takes days in some cases, resulting in productivity loss. This paper documents the thermal gradient problem associated with the IGV structure during cryogenic operation and how the facility has recently achieved an acceptable mitigation which has resulted in improved efficiency of operations.

Venkat, Venki S.↗

NASA NTRS1985

High-thermal-gradient Superalloy Crystal Growth

Single, (001)-oriented crystals of PWA 1480 were processed in alumina/silica shell molds in a laboratory high gradient furnace. The furnace employs a graphite resistance heated element, a radiation baffle, and a water cooled radiation trap below the baffle. All crystals were grown in vacuum (10 torr) and all heat transfer was radiative. The element is constructed with a variable cross section that is tapered just above the baffle to maximize heat input and therefore thermal gradient. A maximum alloy temperature of 1600 C was used. A thermal gradient of 130 deg C/cm was recorded at 1370 C just above the solidus of the PWA 1480 alloys. Crystal bars with 14.4 and 17.5 mm diameters were grown in alumina/silica shell molds. Each crystal was started from a 1.6 mm pencil seed at a rate of 76 mm/hr and slowly accelerated to a rate of 200 mm/hr under computer control. Volume percent porosity and average pore size were measured as functions of distance in representative bars. Low cycle fatigue behavior and stress rupture properties were determined.

Pearson, D. D.↗

NASA NTRS1983

Controlling Thermal Gradients During Silicon Web Growth

Strategically placed slot helps to control critical thermal gradients in crucible for silicon web growth. Slot thermally isolates feed region of crucible from growth region; region where pellets are added stays hot. Heat absorbed by pellets during melting causes thermal unbalance than upsets growth conditions.

Duncan, C. S.↗

NASA NTRS2014

Calcium-Magnesium-Aluminosilicate (CMAS) Infiltration and Cyclic Degradations of Thermal and Environmental Barrier Coatings in Thermal Gradients

In a continuing effort to develop higher temperature capable turbine thermal barrier and environmental barrier coating systems, Calcium-Magnesium-Aluminosilicate (CMAS) resistance of the advanced coating systems needs to be evaluated and improved. This paper highlights some of NASA past high heat flux testing approaches for turbine thermal and environmental barrier coatings assessments in CMAS environments. One of our current emphases has been focused on the thermal barrier - environmental barrier coating composition and testing developments. The effort has included the CMAS infiltrations in high temperature and high heat flux turbine engine like conditions using advanced laser high heat flux rigs, and subsequently degradation studies in laser heat flux thermal gradient cyclic and isothermal furnace cyclic testing conditions. These heat flux CMAS infiltration and related coating durability testing are essential where appropriate CMAS melting, infiltration and coating-substrate temperature exposure temperature controls can be achieved, thus helping quantify the CMAS-coating interaction and degradation mechanisms. The CMAS work is also playing a critical role in advanced coating developments, by developing laboratory coating durability assessment methodologies in simulated turbine engine conditions and helping establish CMAS test standards in laboratory environments.

Thermal Barrier Coatings↗