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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Phosphor thermometry device for synchronized acquisition of luminescence lifetime decay and intensity on thermal barrier coatings

A phosphor thermometry device includes a laser that generates a laser pulse onto a thermal barrier coating (TBC) applied onto a substrate. A metallic bond coat layer is on the substrate. A ceramic top coat layer is on the bond coat layer and includes an undoped layer and a doped sensing layer having co-doped first and second rare-earth luminescent dopants that emit respective first and second different emission wavelengths upon excitation by the laser pulse. A detector receives reflected, convoluted luminescence signals from the TBC. First and second photomultiplier devices detect respective first and second different emission wavelengths of the convoluted luminescence signals. A controller receives and processes signals generated from respective first and second photomultiplier devices and determines luminescence lifetime decay and intensity variations for each of the respective first and second rare-earth luminescent dopants for temperature monitoring of the TBC.

Fouliard, Quentin↗
NASA NTRS2016

Thermochemistry of CaO-MgO-Al2O3-SiO2 (CMAS) and Advanced Thermal and Environmental Barrier Coating Systems

CaO-MgO-Al2O3-SiO2 (CMAS) oxides are constituents in a broad number of materials and minerals which have recently inferred to discussions in materials science, planetary science, geochemistry and cosmochemistry communities. In materials science, there is increasing interest in the degradation studies of thermal (TBC) and environmental (EBC) barrier coatings of gas turbines by molten CMAS. These coatings have been explored to be applied on silicon-based ceramics and composites which are lighter and more temperature capable hot-section materials of gas turbines than the current Ni-based superalloys. The degradation of the coatings occurs when CMAS minerals carried by the intake air into gas turbines, e.g. in aircraft engines, reacts at high temperatures (1000C) with the coating materials. This causes premature failure of the static and rotating components of the turbine engines. We discuss some preliminary results of the reactions between CMAS and Rare-Earth (RE Y, Yb and Gd) oxide stabilized ZrO2 systems, and stability of the resulting oxides and silicates.

CaO-MgO-Al2O3-SiO2 (CMAS)↗
NASA NTRS1988

Thermal barrier coating life prediction model development

A life prediction model for correlating the spallation life of ceramic thermal barrier coatings is developed which includes both cyclic and time-dependent damage. The cyclic damage is related to the calculated cyclic inelastic strain range, while the time-dependent damage is related to the oxidation kinetics at the bond-ceramic interface. The cyclic inelastic strain range is calculated using a modified form of the Walker viscoplastic material model; calculation of the oxidation kinetics is based on traditional oxidation algorithms using experimentally determined parameters. The correlation between the actual and predicted spallation lives is within a factor of 3.

Cruse, T. A.↗
NASA NTRS1988

Current status and future trends in turbine application of thermal barrier coatings

This paper provides an overview of the current status and future trends in application of thermal barrier coatings (TBC) to turbine components, and in particular to high turbine airfoils. Included are descriptions of the favorable results achieved to date with bill-of-material applications of plasma deposited TBC, and recent experience with developmental coatings applied by electron beam-physical vapor deposition.

Sheffler, Keith D.↗
NASA NTRS1989

Thermal modelling of various thermal barrier coatings in a high heat flux rocket engine

Traditional Air Plasma Sprayed (APS) ZrO2-Y2O3 Thermal Barrier Coatings (TBC's) and Low Pressure Plasma Sprayed (LPPS) ZrO2-Y2O3/Ni-Cr-Al-Y cermet coatings were tested in a H2/O2 rocked engine. The traditional ZrO2-Y2O3 (TBC's) showed considerable metal temperature reductions during testing in the hydrogen-rich environment. A thermal model was developed to predict the thermal response of the tubes with the various coatings. Good agreement was observed between predicted temperatures and measured temperatures at the inner wall of the tube and in the metal near the coating/metal interface. The thermal model was also used to examine the effect of the differences in the reported values of the thermal conductivity of plasma sprayed ZrO2-Y2O3 ceramic coatings, the effect of 100 micron (0.004 in.) thick metallic bond coat, the effect of tangential heat transfer around the tube, and the effect or radiation from the surface of the ceramic coating. It was shown that for the short duration testing in the rocket engine, the most important of these considerations was the effect of the uncertainty in the thermal conductivity of temperatures (greater than 100 C) predicted in the tube. The thermal model was also used to predict the thermal response of the coated rod in order to quantify the difference in the metal temperatures between the two substrate geometries and to explain the previously-observed increased life of coatings on rods over that on tubes. A thermal model was also developed to predict heat transfer to the leading edge of High Pressure Fuel Turbopump (HPFTP) blades during start-up of the space shuttle main engines. The ability of various TBC's to reduce metal temperatures during the two thermal excursions occurring on start-up was predicted. Temperature reductions of 150 to 470 C were predicted for 165 micron (0.0065 in.) coatings for the greater of the two thermal excursions.

Nesbitt, James A.↗
NASA NTRS1990

Thermal Conductivity and Temperature Limits of Electron-Beam Physical-Vapor-Deposited ZrO2-7wt%Y2O3 Thermal Barrier Coating

The electron-beam physical-vapor-deposited (EB-PVD) ZrO2-7wt%Y2O3 thermal barrier coating has been widely used to protect engine hot section components in modem aircraft engines. Thermal conductivity and the conductivity increases due to sintering and phase changes are important coating design parameters. There is a need to characterize the coating thermal conductivity behavior and temperature limits, in order to potentially take full advantage of the coating capability. In addition, since the ZrO2-7wt%Y2O3 coating is often used as a baseline coating for the development of advanced lower thermal conductivity and higher temperature capability coatings, a thorough evaluation of the coating conductivity behavior at future higher engine operating temperatures will be useful for more accurately assessing the benefit gained from the new coating systems. In this study, thermal conductivity behavior of EB-PVD ZrO2-7wt%Y2O3 coating has been systematically investigated as a function of temperature (up to 2600 F) and time under steady-state and cyclic test conditions using a laser heat-flux technique. Thermal conductivity change kinetics were determined under realistic engine high temperature thermal gradient conditions, and correlated to the coating microstructural and phase changes. The thermal conductivity prediction models have been established in terms of heat flux, time, and testing temperatures.

Zhu, Dongming↗
NASA NTRS1981

Burner Rig Evaluation of Thermal Barrier Coating Systems for Nickel-Base Alloys

Eight plasma sprayed bond coatings were evaluated for their potential use with ZrO2-Y2O3 thermal barrier coatings (TECs) which are being developed for coal derived fuel fired gas turbines. Longer TBC lives in cyclic burner rig oxidation to 1050 C were achieved with the more oxidation resistant bond coatings. These were Ni-14.1Cr-13.4A1-0.10Ar, Ni-14.1C4-14.4Al-0.16Y, and Ni-15.8Cr-12.8Al-0.36Y on Rene 41. The TBC systems performed best when 0.015-cm thick bond coatings were employed that were sprayed at 20 kW using argon 3.5v/o hydrogen. Cycling had a more life limiting influence on the TBC than accumulated time at 1050 C.

Gedwill, M. A.↗
NASA NTRS1990

Thermal barrier coating life and isothermal oxidation of low-pressure plasma-sprayed bond coat alloys

The paper investigates the isothermal oxidation kinetics of Ni-35Cr-6Al-0.95Y, Ni-18Cr-12Al-0.3Y, and Ni-16Cr-6Al-0.3Y low-pressure plasma-sprayed bond coat alloys and examines the effect of these alloys on the thermal barrier coating (TBC) cyclic life. TBC life was examined by cycling substrates coated with the different bond coats and a ZrO2-7 wt pct Y2O3 TBC in an air-rich burner rig flame between 1150 C and room temperature. The oxidation kinetics of the three bond coat alloys was examined by isothermal oxidation of monolithic NJiCrAlY coupons at 1083 C. The Ni-35Cr-6Al-0.95Y alloy exhibits comparatively high isothermal oxidation weight gains and provides the longest TBC life, whereas the Ni-16Cr-6Al-0.3Y alloy had the lowest weight gains and provided the shortest TBC life. The results show that, although bond coat oxidation is known to have a strong detrimental effect on TBC life, it is not the only bond coat factor that determines TBC life.

Brindley, W. J.↗
DOE OSTI2020

Impact damage of narrow silicon carbide (SiC) ceramics with and without environmental barrier coatings (EBCs) by various foreign object debris (FOD) simulants

The leading and trailing edges of turbine airfoils are highly susceptible to impact by foreign object debris (FOD) entrained in the gas stream of turbine engines. In this study, a narrow specimen geometry is implemented to study the FOD impact behavior of low curvature airfoil edges. Silicon carbide (SiC) ceramic specimens with and without an environmental barrier coating (EBC) are used as target materials. The EBC consists of an air plasma sprayed mullite topcoat (~ 166 µm) and silicon bond coat (~ 58 µm). Spherical (∅ 1.5 mm) FOD simulants of silicon nitride (Si3N4), partially stabilized zirconia (PSZ), and steel are used as impactors. Additionally, a modified gas gun is used to generate impact damage at normal incidence and velocities ranging between 300 to 400 m/s. In situ phase contrast X-ray radiographs, which render 2D representations of the internal transient damage, are captured during the impact experiments. Impactor hardness and toughness are found to primarily influence damage in the coating. Relative to wide specimens, the narrow specimens experience a greater level of cracking and this is postulated to result from reduced self-confinement. Irrespective of specimen geometry and impactor material type, limited cracking (i.e. enhanced shielding) is observed for the coated condition.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Understanding Environmental Barrier Coating Lifetimes and Performance for Industrial Gas Turbines

Hydrogen or hydrogen blend fuels are expected to replace natural gas in land-based industrial gas turbines (IGTs) to support a greener power economy. Silicon carbide (SiC) base ceramic matrix composites (CMCs) are considered for replacement of Ni-based superalloys to facilitate future efficiency improvements. SiC CMCs require environmental barrier coatings (EBCs) to mitigate volatilization from high-temperature steam, thus making the EBC lifetime critical information for identifying CMC component lifetimes. Here, the goal of this project is to determine the maximum bond coating temperature underneath the EBC for achieving an IGT component lifetime goal of 25,000 h, which is far greater than current CMC component lifetime requirements for aeroturbine applications. To provide data for the lifetime model, laboratory testing used atmospheric plasma-sprayed rare-earth silicate EBCs on monolithic SiC substrates with an intermediate Si bond coating. Specimens exposed to 1-h thermal cycles in flowing air–steam environments and reaction kinetics were assessed from 700 °C to 1350 °C by measuring the thickness of the thermally grown silica scales. The silica growth and phase transformation appear critical in predicting EBC lifetime and several strategies have been explored to reduce the oxide growth rate and improve EBC durability at elevated temperatures. Advanced characterization using Raman spectroscopy has helped clarify this system.

08 HYDROGEN↗
NASA NTRS1987

Thermal expansion mismatch and plasticity in thermal barrier coating

The basic objective of this investigation is the quantitative determination of stress states in a model thermal barrier coating (TBC) as it cools in the air to 600 C from an assumed stress-free state at 700 C. This model is intended to represent a thin plasma-sprayed zirconia-yttria ceramic layer with a nickel chromium-aluminum-yttrium bond coat on a cylindrical substrate made of nickel-based superalloys typically found in gas turbines.

Chang, George C.↗
NASA NTRS1987

Thermal barrier coating life-prediction model development

The primary objective of this program was to develop an operative thermal barrier coating (TBC) design model for life prediction. The objective was successfully accomplished with the development, calibration, and demonstration of a mechanistic thermochemical model which rapidly predicts TBC life as a function of engine, mission, and materials system parameters. This thermochemical design model accounts for the three operative TBC damage modes (bond coating oxidation, zirconia toughness reduction, and molten salt film damage), which all contribute to spalling of the insulating zirconia layer.

Strangman, T. E.↗
NASA NTRS2011

Monitoring Delamination of Thermal Barrier Coating During Interrupted High-Heat Flux Laser Testing Using Upconversion Luminescence Imaging

Upconversion luminescence imaging of thermal barrier coatings (TBCs) has been shown to successfully monitor TBC delamination progression during interrupted furnace cycling. However, furnace cycling does not adequately model engine conditions where TBC-coated components are subjected to significant heat fluxes that produce through-thickness temperature gradients that may alter both the rate and path of delamination progression. Therefore, new measurements are presented based on luminescence imaging of TBC-coated specimens subjected to interrupted high-heat-flux laser cycling exposures that much better simulate the thermal gradients present in engine conditions. The TBCs tested were deposited by electron-beam physical vapor deposition (EB-PVD) and were composed of 7wt% yttria-stabilized zirconia (7YSZ) with an integrated delamination sensing layer composed of 7YSZ co-doped with erbium and ytterbium (7YSZ:Er,Yb). The high-heat-flux exposures that produce the desired through-thickness thermal gradients were performed using a high power CO2 laser operating at a wavelength of 10.6 microns. Upconversion luminescence images revealed the debond progression produced by the cyclic high-heat-flux exposures and these results were compared to that observed for furnace cycling.

Eldridge, Jeffrey I.↗
NASA NTRS2013

Combined Experimental and Numerical Simulations of Thermal Barrier Coated Turbine Blades Erosion

A combined experimental and computational study was conducted to investigate the erosion of thermal barrier coated (TBC) blade surfaces by alumina particles ingestion in a single stage turbine. In the experimental investigation, tests of particle surface interactions were performed in specially designed tunnels to determine the erosion rates and particle restitution characteristics under different impact conditions. The experimental results show that the erosion rates increase with increased impingement angle, impact velocity and temperature. In the computational simulations, an Euler-Lagrangian two stage approach is used in obtaining numerical solutions to the three-dimensional compressible Reynolds Averaged Navier-Stokes equations and the particles equations of motion in each blade passage reference frame. User defined functions (UDF) were developed to represent experimentally-based correlations for particle surface interaction models which were employed in the three-dimensional particle trajectory simulations to determine the particle rebound characteristics after each surface impact. The experimentally based erosion UDF model was used to predict the TBC erosion rates on the turbine blade surfaces based on the computed statistical data of the particles impact locations, velocities and angles relative to the blade surface. Computational results are presented for the predicted TBC blade erosion in a single stage commercial APU turbine, for a NASA designed automotive turbine, and for the NASA turbine scaled for modern rotorcraft operating conditions. The erosion patterns in the turbines are discussed for uniform particle ingestion and for particle ingestion concentrated in the inner and outer 5 percent of the stator blade span representing the flow cooling the combustor liner.

Hamed, Awate↗
NASA NTRS2014

High Temperature Multilayer Environmental Barrier Coatings Deposited Via Plasma Spray-Physical Vapor Deposition

Si-based ceramic matrix composites (CMCs) require environmental barrier coatings (EBCs) in combustion environments to avoid rapid material loss. Candidate EBC materials have use temperatures only marginally above current technology, but the addition of a columnar oxide topcoat can substantially increase the durability. Plasma Spray-Physical Vapor Deposition (PS-PVD) allows application of these multilayer EBCs in a single process. The PS-PVD technique is a unique method that combines conventional thermal spray and vapor phase methods, allowing for tailoring of thin, dense layers or columnar microstructures by varying deposition conditions. Multilayer coatings were deposited on CMC specimens and assessed for durability under high heat flux and load. Coated samples with surface temperatures ranging from 2400-2700F and 10 ksi loads using the high heat flux laser rigs at NASA Glenn. Coating morphology was characterized in the as-sprayed condition and after thermomechanical loading using electron microscopy and the phase structure was tracked using X-ray diffraction.

Plasma↗