Advanced thermionic cathodes for Kaufman thrusters.
High endurance thermionic cathodes for Kaufman thrustors, discussing emissive coatings and emissive layer starvation
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A program continuation to develop processing procedures for advanced silicon solar cells
Shallow junctions, aluminum back surface fields and tantalum pentoxide (Ta205) antireflection coatings coupled with the development of a chromium-palladium-silver contact system, were used to produce a 2 x 4 cm wraparound contact silicon solar cell. One thousand cells were successfully fabricated using batch processing techniques. These cells were 0.020 mm thick, with the majority (800) made from nominal ten ohm-cm silicon and the remainder from nominal 30 ohm-cm material. Unfiltered, these cells delivered a minimum AMO efficiency at 25 C of 11.5 percent and successfully passed all the normal in-process and acceptance tests required for space flight cells.
Avery, J. E.↗
Cost/benefit analysis of advanced materials technologies for future aircraft turbine engines
The materials technologies studied included thermal barrier coatings for turbine airfoils, turbine disks, cases, turbine vanes and engine and nacelle composite materials. The cost/benefit of each technology was determined in terms of Relative Value defined as change in return on investment times probability of success divided by development cost. A recommended final ranking of technologies was based primarily on consideration of Relative Values with secondary consideration given to changes in other economic parameters. Technologies showing the most promising cost/benefits were thermal barrier coated temperature nacelle/engine system composites.
Stephens, G. E.↗
Recent advances in carbon-carbon materials systems
Carbon-carbon materials and new oxidation resistant coating developments are discussed. Potential areas of application are highlighted. A short bibliography of selected references is included that describe carbon-carbon materials and related technology in detail.
Donald R. Rummler↗
Development of thermomechanical life prediction models for thermal barrier coatings
Thermal barrier coatings (TBCs) for turbine airfoils in high-performance engines represent an advanced materials technology with both performance and durability benefits. The foremost TBC benefit is the reduction of heat transferred into air-cooled components. To achieve these benefits, however, the TBC system must be reliable. Mechanistic thermomechanical and thermochemical life models and statistically significant design data are therefore required for the reliable exploitation of TBC benefits on gas turbine airfoils. Garrett's NASA-HOST Program (NAS3-23945) is designed to fulfill these requirements. This program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant TBC systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma-spray (LPPS) applied oxidation resistant NiCrAlY bond coating, and an air-plasma-sprayed yttria partially stabilized zirconia insulated layer is applied by both Chromalloy and Klock. The second type of TBC is applied by the electron beam-physical vapor deposition process by Temescal. Thermomechanical life models are being tailored to predict TBC strain tolerance in terms of materials, engine, and mission parameters. Continuum and fracture mechanics approaches and statistical methods are being evaluated to develop tensile and compressive strain functions required to drive a mission analysis capable thermomechanical life model for TBCs. Results of initial testing to calibrate these life models will be presented.
Strangman, T. E.↗
Environmental Barrier Coatings for Ceramic Matrix Composites - An Overview
SiC/SiC Ceramic Matrix Composites (CMCs) are increasingly being considered as structural materials for advanced power generation equipment because of their light weight, higher temperature capability, and oxidation resistance. Limitations of SiC/SiC CMCs include surface recession and component cracking and associated chemical changes in the CMC. The solutions pursued to improve the life of SiC/SiC CMCs include the incorporation of coating systems that provide surface protection, which has become known as an Environmental Barrier Coating (EBC). The development of EBCs for the protection of gas turbine hot section CMC components was a continuation of coating development work for corrosion protection of silicon-based monolithics. Work on EBC development for SiC/SiC CMCs has been ongoing at several national laboratories and the original gas turbine equipment manufacturers. The work includes extensive laboratory, rig and engine testing, including testing of EBC coated SiC/SiC CMCs in actual field applications. Another EBC degradation issue which is especially critical for CMC components used in aircraft engines is the degradation from glassy deposits of calcium-magnesium-aluminosilicate (CMAS) with other minor oxides. This paper addresses the need for and properties of external coatings on SiC/SiC CMCs to extend their useful life in service and the retention of their properties.
EBC↗
Thermal Protective Coating for High Temperature Polymer Composites
The central theme of this research is the application of carboxylate-alumoxane nanoparticles as precursors to thermally protective coatings for high temperature polymer composites. In addition, we will investigate the application of carboxylate-alumoxane nanoparticle as a component to polymer composites. The objective of this research was the high temperature protection of polymer composites via novel chemistry. The significance of this research is the development of a low cost and highly flexible synthetic methodology, with a compatible processing technique, for the fabrication of high temperature polymer composites. We proposed to accomplish this broad goal through the use of a class of ceramic precursor material, alumoxanes. Alumoxanes are nano-particles with a boehmite-like structure and an organic periphery. The technical goals of this program are to prepare and evaluate water soluble carboxylate-alumoxane for the preparation of ceramic coatings on polymer substrates. Our proposed approach is attractive since proof of concept has been demonstrated under the NRA 96-LeRC-1 Technology for Advanced High Temperature Gas Turbine Engines, HITEMP Program. For example, carbon and Kevlar(tm) fibers and matting have been successfully coated with ceramic thermally protective layers.
Barron, Andrew R.↗
Space propulsion
Lewis Research Center is developing broad-based new technologies for space chemical engines to satisfy long-term needs of ETO launch vehicles and other vehicles operating in and beyond Earth orbit. Specific objectives are focused on high performance LO2/LH2 engines providing moderate thrusts of 7,5-200 klb. This effort encompasses research related to design analysis and manufacturing processes needed to apply advanced materials to subcomponents, components, and subsystems of space-based systems and related ground-support equipment. High-performance space-based chemical engines face a number of technical challenges. Liquid hydrogen turbopump impellers are often so large that they cannot be machined from a single piece, yet high stress at the vane/shroud interface makes bonding extremely difficult. Tolerances on fillets are critical on large impellers. Advanced materials and fabricating techniques are needed to address these and other issues of interest. Turbopump bearings are needed which can provide reliable, long life operation at high speed and high load with low friction losses. Hydrostatic bearings provide good performance, but transients during pump starts and stops may be an issue because no pressurized fluid is available unless a separate bearing pressurization system is included. Durable materials and/or coatings are needed that can demonstrate low wear in the harsh LO2/LH2 environment. Advanced materials are also needed to improve the lifetime, reliability and performance of other propulsion system elements such as seals and chambers.
Kazaroff, John M.↗
Environmental Stability and Oxidation Behavior of HfO2-Si and YbGd(O) Based Environmental Barrier Coating Systems for SiCSiC Ceramic Matrix Composites
Ceramic environmental barrier coatings (EBC) and SiCSiC ceramic matrix composites (CMCs) will play a crucial role in future aircraft propulsion systems because of their ability to significantly increase engine operating temperatures, improve component durability, reduce engine weight and cooling requirements. Advanced EBC systems for SiCSiC CMC turbine and combustor hot section components are currently being developed to meet future turbine engine emission and performance goals. One of the significant material development challenges for the high temperature CMC components is to develop prime-reliant, environmental durable environmental barrier coating systems. In this paper, the durability and performance of advanced Electron Beam-Physical Vapor Deposition (EB-PVD) NASA HfO2-Si and YbGdSi(O) EBC bond coat top coat systems for SiCSiC CMC have been summarized. The high temperature thermomechanical creep, fatigue and oxidation resistance have been investigated in the laboratory simulated high-heat-flux environmental test conditions. The advanced NASA EBC systems showed promise to achieve 1500C temperature capability, helping enable next generation turbine engines with significantly improved engine component temperature capability and durability.
Ceramic Matrix Composites↗
Plasma-Spraying Ceramics Onto Smooth Metallic Substrates
In fabrication process, plasma-sprayed ceramic coats bonded strongly to smooth metallic surfaces. Principal use of such coats in protecting metal parts in hot-gas paths of advanced gas turbine engines. Process consists of application of initial thin layer of ceramic on smooth surface by low-pressure-plasma spraying followed by application of layer of conventional, low-thermal-conductivity atmospheric-pressure plasma-sprayed ceramic.
Miller, Robert A.↗
Construction and testing of ceramic fabric heat pipe with water working fluid
A prototype ceramic fabric/titanium water heat pipe has been constructed and tested; it transported 25 to 80 W of power at 423 K. Component development and testing is continuing with the aim of providing an improved prototype, with a 38 micron stainless steel liner covered by a biaxially-braided Nextel (trademark) sleeve that is approximately 300 microns thick. This fabric has been tested to 800 K, and its emittance is about 0.5 at that temperature. Advanced versions of the water heat pipe will probably require a coating over the ceramic fabric in order to increase this emittance to the 0.8 to 0.9 range.
Antoniak, Zenen I.↗
Fatigue and flexural response of advanced carbon-carbon composites at room and elevated temperatures
The flexural response of SiC-coated carbon-carbon composites (ACC-4) at room and elevated temperatures is presented. Three-point bending tests were performed on virgin and mission-cycled specimens, and the variation in flexural strength is examined. The load-deflection behavior of the material at various temperatures is investigated, and the Weibull (1939) analysis of the strength data is performed. Micrographs of various cross sections in the damaged zone were taken, and the failure mechanisms are discussed. Fatigue tests were conducted under flexural loads, and the S-N diagram with the corresponding Weibull analysis are presented. Untested as well as fractured specimens under static and dynamic loading were C-scanned to identify the damaged zone and visualize the extent of the damage. Failure analyses are presented for both static and cyclic loading on the basis of NDE, the micrographs, and the experimental data.
Mahfuz, Hassan↗
NiAl Coatings Investigated for Use in Reusable Launch Vehicles
As part of its major investment in the area of advanced space transportation, NASA is developing new technologies for use in the second- and third-generation designs of reusable launch vehicles. Among the prototype rocket engines being considered for these launch vehicles are those designed to use liquid hydrogen as the fuel and liquid oxygen as the oxidizer. Advanced copper alloys, such as copper-chromium-niobium (Cu-8(at.%)Cr- 4(at.%)Nb, also referred to as GRCop-84), which was invented at the NASA Glenn Research Center, are being considered for use as liner materials in the combustion chambers and nozzle ramps of these engines. However, previous experience has shown that, in rocket engines using liquid hydrogen and liquid oxygen, copper alloys are subject to a process called blanching, where the material undergoes environmental attack under the action of the combustion gases. In addition, the copper alloy liners undergo thermomechanical fatigue, which often results in an initially square cooling channel deforming into a dog-house shape. Clearly, there is an urgent need to develop new coatings to protect copper liners from environmental attack inside rocket chambers and to lower the temperature of the liners to reduce the probability of deformation and failure by thermomechanical fatigue.
Raj, Sai V.↗
Continued Development of a Highly Reflective Solar Coating for Cryogenic Liquid Storage in Space
State-of-the-art solar reflectors absorb 6-8 % of the sun's irradiant power, which is adequate for spacecraft thermal control; but not for storage of cryogens in tanks exposed to the Sun. A solar reflector must absorb less than 0.4% of the Sun's power, while radiating effectively in the far IR, to allow LOX storage. Hibbard realized this in 1960's, at about the same time that nearly perfect optical reflectors were developed based on particle scattering. In 2015, under funding from the NASA Innovative Advanced Concepts Program (NIAC), these breakthroughs were rediscovered. Theoretical analysis showed that a tank coated with a thick (1 cm) layer of 150 nm particles, composed of a broadband material, could allow the tank to chill to cryogenic temperatures, even in the presence of 1 AU solar irradiance. Subsequent work lead to the demonstration and testing of BaF2 based rigid coupons. Placing one of these in a cryocooler-based simulated deep space environment and irradiating with simulated sunlight has shown about 1% absorption. This is better than the state-of-the-art but not yet sufficient for LOX storage.This paper will review the background material presented above but will concentrate on work performed over the last year, including the design and build-up of the testing apparatus. Since our last publication, we have changed materials from BaF2 to Y2O3. Y2O3 has slightly higher solar absorptance, but is hydrophobic and higher index.
Swanger, Adam↗
Advanced inorganic separators for alkaline batteries and method of making the same
A flexible, porous battery separator includes a coating applied to a porous, flexible substrate. The coating comprises: (1) a thermoplastic rubber-based resin which is insoluble and unreactive in the alkaline electrolyte, (2) a polar organic plasticizer which is reactive with the alkaline electrolyte to produce a reaction product which contains a hydroxyl group and/or a carboxylic acid group, and (3) a mixture of polar particulate filler materials which are unreactive with the electrode. The mixture comprises at least one first filler material having a surface area of greater than 25 sq meters/gram, at last one second filler material having a surface area of 10 to 25 sq meters/gram. The volume of the mixture of filler materials is less than 45% of the total volume of the fillers and the binder. The filler surface area per gram of binder is about 20 to 60 sq meters/gram, and the amount of plasticizer is sufficient to coat each filler particle.
Sheibley, D. W.↗
Fuel consumption improvement in current transport engines
A review is conducted of improvements which can be made with respect to the fuel consumption of current engines and new production versions of current engines. A description is presented of an engine diagnostics program which has the objective to identify and quantify the causes and sources of performance deterioration in the JT9D turbofan engine and to develop basic data which will be applied to minimize performance degradation of current and future engines. General areas where performance losses occur are examined, taking into account seals, blades and vanes, and cases. Potential performance improvement concepts are related to improved component aerodynamics, improved flowpath sealing, blade tip clearance control, improved turbine cooling effectiveness, improved turbine materials and coatings, duct and nozzle aerodynamic refinements, nacelle aerodynamic refinements, forced exhaust mixers, advanced nacelle materials, and advanced fuel control.
Hines, R. W.↗
Detecting Pores in SiC Coatings
Liquid-penetrant/fluorescence technique reveals cracks and pinholes in protective coatings. Developed for checking quality of overcoatings on silicon carbide layers on advanced carbon/carbon substrates. Technique similar to other liquid-penetrant/fluorescence techniques used to make pores visible. Porous areas absorb more suspension and therefore accumulate more fluorescent particles. They fluoresce more brightly than their surroundings.
Hamilton, A. B.↗
Versatile Vials
Advanced Fuel Research, Inc. (AFR) developed a new sol-gel material coating for sample vials to be used in surface-enhanced Raman (SER) spectroscopy. In the fields of biomedical and forensic science, the coated vials are used to identify physiological chemicals present in blood and urine. The vials are used in the pharmaceutical industry in the area of drug development and discovery. In the drug enforcement field, using the vials helps with detection of trace amounts of drugs on surfaces. The SER vials will also help to identify contaminants in water sources, such as various inorganics and pesticides. The new vials have advantages over other SER materials. Former products required that samples be pre-mixed or dissolved into specific solvents or reagents. The SER vials do not have these limitations, and measurements can be performed using any solvent. Furthermore, the signal appears in less than one second. The sol-gel material will stay active for at least one year and the vials are compatible with any Raman spectrometer. Most importantly, the SER activity can be duplicated from vial-to-vial, allowing for reproducible results.
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