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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
NASA NTRS1985

High time service evaluation of thermal barrier coatings on the Rolls-Royce RB211 engine

One of the main concerns of airline operators for the use of thermal barrier coatings (TBC) in the turbine is that the coating will spall and cause a premature engine removal. Even though much cyclic data is available on TBCs, high time data is much harder and expensive to come by. The typical 150 h type test used to qualify hardware, or modifications, falls far short of the 5 to 10,000 hour experience desired. One way to obtain data demonstrating the longevity of TBCs is through a service evaluation program on a commercial engine. For a meaningful evaluation of the TBC system it must be applied to a component which operates in a typical hot end environment. In addition the component performance should not suffer if the coating is lost. For these reasons Rolls-Royce chose to coat the IP turbine nozzle guide vanes, and run these in an RB211 engine. Two ceramic top coats and several different bond coats were tested in a rainbow fashion on several engines. Three layer magnesium zirconate was used as a base line. Various yttria stabilized zirconia ceramics were used. Top MCrAlY bond coats were applied by various techniques. Some of the coated vanes have now accumulated ofer 5000 hours. The results are presented from the first sets with 2500 and 4200 hours of service respectively.

Toriz, F. Chris↗
DOE OSTI2026

Polymer coatings on zirconia microspheres via rotating flow fluid dynamics

Conventional tristructural isotropic (TRISO) coatings for nuclear fuels require multi-step and expensive formation processes; any breakage of the coatings may lead to fission species release. Polymer derived ceramic (PDC) coatings can be a suitable alternative to address these issues. In this study, allylhydridopolycarbosilane (SMP-10) coatings were created on yttria stabilized zirconia (YSZ) microspheres using a Rotating Flow Fluid Dynamics (RFFD) coating method. The effects of curing temperature, rotation speed, and coating cycle/time on the coating were analyzed. Surface functionalization of YSZ microspheres with NaOH resulted in good adhesion between the polymer precursor and the YSZ kernel particles. Spectroscopy analysis revealed complete curing of SMP-10 coated YSZ at 160 °C. Rotation speed and coating time significantly affect the coating characteristics. After 3 cycles at lower rotation speed (50 rpm) for 10 min each, the coating obtained was uniform and homogeneous. In comparison, the coating showed almost 10 times less eccentricity at a high rotation speed of 300 rpm. Compared with the coatings prepared at 300 rpm condition, the coatings have higher sphericity and lower eccentricity at 50 rpm. Overall, this study provides a novel and effective route for fabricating and curing SMP-10 precursor coatings on YSZ microspheres.

Ravi, Nivetha [University of Alabama, Birmingham]↗
NASA NTRS1997

Materials Testing on the DC-X and DC-XA

Flight testing of thermal protection materials has been carried out over a two year period on the base heat shield of the Delta Clipper (DC-X and DC-XA), as well on a body flap. The purpose was to use the vehicle as a test bed for materials and more efficient repair or maintenance processes which would be potentially useful for application on new entry vehicles (i.e., X-33, RLV, planetary probes), as well as on the existing space shuttle orbiters. Panels containing Thermal Protection Systems (TPS) and/or structural materials were constructed either at NASA Ames Research Center or at McDonnell Douglas Aerospace (MDA) and attached between two of the four thrusters in the base heat shield of the DC-X or DC-XA. Three different panels were flown on DC-X flights 6, 7, and 8. A total of 7 panels were flown on DC-XA flights 1, 2, and 3. The panels constructed at Ames contained a variety of ceramic TPS including flexible blankets, tiles with high emissivity coatings, lightweight ceramic ablators and other ceramic composites. The MDS test panels consisted primarily of a variety of metallic composites. This report focuses on the ceramic TPS test results.

Smith, Dane↗
NASA NTRS1989

Instrumented adhesion tests on plasma sprayed thermal barrier coatings

The failure mechanisms of plasma-sprayed two-layer coatings consisting of an NiCrAlY or NiCrAlZr bond coat with an yttria-stabilized zirconia overlay are presently examined by tensile adhesion tests. It has been found that adhesive failure within the bond coat exhibits greater failure strain than the cohesive failure of the ceramic overlay, supporting the view of the intermediate coatings being highly compliant. The absolute extension exhibited by failures occurring only through the ceramic coating is greater than that of adhesive failure, since the ceramic coating is much thicker than the bond coat.

Berndt, Christopher C.↗
NASA NTRS2004

A Coating That Cools and Cuts Costs

To enable low-cost space access for advanced exploration vehicles, researchers from NASA's Ames Research Center invented and patented a protective coating for ceramic materials (PCCM) in 1994. The technology, originally intended to coat the heat shields of the X-33 and X-34 next-generation vehicles for optimum protection during atmospheric reentry, greatly reduces surface temperature of a thermal control structure while it reradiates absorbed energy to a cooler surface or body, thus preventing degradation of the underlying ceramic material.

Source record↗
NASA NTRS2000

Current status of environmental barrier coatings for Si-Based ceramics

Silicon-based ceramics are the leading candidates for high temperature structural components in next generation gas turbine engines. One key drawback of silicon-based ceramics for such an application is volatilization of the protective silica scale in water vapor and the resulting rapid ceramic recession. Therefore, the realization of Si-based ceramics components in advanced gas turbine engines depends on the development of protection schemes from water vapor attack. Currently, plasma-sprayed external environmental barrier coatings (EBCs) arc the most promising approach. In the late 1980s and early 1990s a wide range of refractory oxide materials were tested as coatings on Si-based ceramics to provide protection from hot corrosion. After the discovery of silica volatilization in water vapor in the early 1990s, the focus of EBC development research has been shifted towards the protection from water vapor attack. Experience learned form the earlier coating developmental effort provided the foundation upon which more complex and advanced EBC coatings have been developed. This paper will discuss the brief history and the current status of EBC development for Si-based ceramics with the main focus on water vapor protection.

Lee, K. N.↗
NASA NTRS1987

Some adhesion/cohesion characteristics of plasma-sprayed ZrO2-Y2O3 under tensile loading

A set of 12.7 mm diameter stainless steel tubes were coated with ceramic and expanded. The bond cast was 0.08 to 0.13 mm NiCrAlY with 0.38 mm of ZrO2-8Y2O3 ceramic. Upon pressurization, the tube substrate yielded and overstressed the coatings in tension. The coatings cracked (i.e., they failed) but did not come off the tube. These results demonstrate that tensile failure of plasma-sprayed coatings is not catastrophic as is compressive failure, which leads to spallation.

Mullen, Robert L.↗
NASA NTRS1995

Screen-Cage Ion Plating Of Silver On Polycrystalline Alumina

Screen-cage ion plating (SCIP) cost-effective technique offering high throwing power for deposition of adherent metal films on ceramic substrates. Applies silver films to complexly shaped substrates of polycrystalline alumina. Silver adheres tenaciously and reduces friction. SCIP holds promise for applying lubricating soft metallic films to high-temperature ceramic components of advanced combustion engines. Other potential uses include coating substrates with metal for protection against corrosion, depositing electrical conductors on dielectric substrates, making optically reflective or electrically or thermally conductive surface layers, and applying decorative metal coats to ceramic trophies or sculptures.

Spalvins, Talivaldis↗
NASA NTRS2016

Advanced Environmental Barrier Coating Development for SiC-SiC Ceramic Matrix Composite Components

This presentation reviews the NASA advanced environmental barrier coating (EBC) system development for SiCSiC Ceramic Matrix Composite (CMC) components for next generation turbine engines. The emphasis has been placed on the current design challenges of the 2700F environmental barrier coatings; coating processing and integration with SiCSiC CMCs and component systems; and performance evaluation and demonstration of EBC-CMC systems. This presentation also highlights the EBC-CMC system temperature capability and durability improvements through advanced compositions and architecture designs, as shown in recent simulated engine high heat flux, combustion environment, in conjunction with mechanical creep and fatigue loading testing conditions.

Simulated Engine Test↗
DOE OSTI2021

Airfoil having internally cooled wall with liner and shell

An airfoil includes an airfoil section that has an airfoil wall that surrounds a cavity. The airfoil wall includes a first wall section comprised of a monolithic ceramic shell, a second wall section comprised of a CMC liner that is bonded along an interface to an interior side of the monolithic ceramic shell, and a ceramic barrier coating that is bonded to an exterior side of the monolithic ceramic shell. The airfoil wall includes at least one of: inter-section cooling channels that extend along the interface and are bounded by the monolithic ceramic shell and the CMC liner, or intra-section cooling channels that extend within the CMC liner.

Croteau, Paul F.↗
NASA NTRS1997

Plasma-Sprayed Refractory Oxide Coatings on Silicon-Base Ceramics

Silicon-base ceramics are promising candidate materials for high temperature structural applications such as heat exchangers, gas turbines and advanced internal combustion engines. Composites based on these materials are leading candidates for combustor materials for HSCT gas turbine engines. These materials possess a combination of excellent physical and mechanical properties at high temperatures, for example, high strength, high toughness, high thermal shock resistance, high thermal conductivity, light weight and excellent oxidation resistance. However, environmental durability can be significantly reduced in certain conditions such as when molten salts, H2 or water vapor are present. The oxidation resistance of silicon-base materials is provided by SiO2 protective layer. Molten salt reacts with SiO2 and forms a mixture of SiO2 and liquid silicate at temperatures above 800C. Oxygen diffuses more easily through the chemically altered layer, resulting in a catastrophic degradation of the substrate. SiC and Si3N4 are not stable in pure H2 and decompose to silicon and gaseous species such as CH4, SiH, SiH4, N2, and NH3. Water vapor is known to slightly increase the oxidation rate of SiC and Si3N4. Refractory oxides such as alumina, yttria-stabilized zirconia, yttria and mullite (3Al2O3.2SiO2) possess excellent environmental durability in harsh conditions mentioned above. Therefore, refractory oxide coatings on silicon-base ceramics can substantially improve the environmental durability of these materials by acting as a chemical reaction barrier. These oxide coatings can also serve as a thermal barrier. The purpose of this research program has been to develop refractory oxide chemical/thermal barrier coatings on silicon-base ceramics to provide extended temperature range and lifetime to these materials in harsh environments.

Tewari, Surendra↗
NASA NTRS1982

Ion Beam Sputtered Coatings of Bioglass

The ion beam sputtering technique available at the NASA-Lewis was used to apply coatings of bioglass to ceramic, metallic, and polymeric substrates. Experiments in vivo and in vitro described investigate these coatings. Some degree of substrate masking was obtained in all samples although stability and reactivity equivalent to bulk bioglass was not observed in all coated samples. Some degree of stability was seen in all coated samples that were reacted in vitro. Both metallic and ceramic substrates coated in this manner failed to show significantly improved coatings over those obtained with existing techniques. Implantation of the coated ceramic substrate samples in bone gave no definite bonding as seen with bulk glass; however, partial and patchy bonding was seen. Polymeric substrates in these studies showed promise of success. The coatings applied were sufficient to mask the underlying reactive test surface and tissue adhesion of collagen to bioglass was seen. Hydrophilic, hydrophobic, charged, and uncharged polymeric surfaces were successfully coated.

Hench, Larry L.↗
NASA NTRS1982

Spray coating apparatus having a rotatable workpiece holder

A spray coating apparatus is provided for rotating a workpiece relative to a spray station to obtain a uniform coating of the workpiece. In a typical example, the workpiece comprises a ceramic tile which is to be coated with a ceramic coating and the tile is to be used as a reusable component of the thermal protection system for a space shuttle. The apparatus for rotating the workpiece includes a base support having a first rotatable stage for rotation in the horizontal plane and a second rotatable stage for rotation in a second plane inclined at an angle, such as 45 degrees, to the horizontal plane and the workpiece is supported on this second stage. Thus the workpiece is rotatable in both of two planes of rotation.

Smith, M.↗
NASA NTRS1983

Thermal and mechanical analysis of major components for the advanced adiabatic diesel engine

The proposed design for the light duty diesel is an in-line four cylinder spark assisted diesel engine mounted transversely in the front of the vehicle. The engine has a one piece cylinder head, with one intake valve and one exhaust valve per cylinder. A flat topped piston is used with a cylindrical combustion chamber recessed into the cylinder head directly under the exhaust valve. A single ceramic insert is cast into the cylinder head to insulate both the combustion chamber and the exhaust port. A similar ceramic insert is cast into the head to insulate the intake port. A ceramic faceplate is pressed into the combustion face of the head to insulate the face of the head from hot combustion gas. The valve seats are machined directly into the ceramic faceplate for the intake valve and into the ceramic exhaust pot insert for the exhaust valve. Additional ceramic applications in the head are the use of ceramic valve guides and ceramic insulated valves. The ceramic valve guides are press fit into the head and are used for increased wear resistance. The ceramic insulated valves are conventional valves with the valve faces plasma spray coated with ceramic for insulation.

Source record↗
NASA NTRS1973

Characterization of RSI coating

X-ray diffraction analyses on mullite, silica, and ceramic mullite fiber coating materials to investigate the effects of thermal cycling, show that ceramic mullite fiber coating porosity is little affected by cycling to 1250 C and that material pores are mostly smaller than 15 nm. Some mullite coatings experience a slight increase in crystobalite with somewhat increased porosity. Silica coatings show a marked tendency to precipitate cristobalite with increased porosity and dimensional instability.

Miller, A. D.↗
NASA NTRS1983

Studies of the Inverted Meniscus Deposition of Silicon on Ceramic

Controlled temperature profiles essential to production of solar cells. Studies of inverted meniscus process for depositing silicon coatings on ceramic substrates described in new report. When fully developed, processed used to manufacture low-cost solar photovoltaic cells.

Zook, J. D.↗
NASA NTRS2005

Thermal and Environmental Barrier Coatings for Advanced Turbine Engine Applications

Ceramic thermal and environmental barrier coatings (T/EBCs) will play a crucial role in advanced gas turbine engine systems because of their ability to significantly increase engine operating temperatures and reduce cooling requirements, thus help achieve engine low emission and high efficiency goals. Advanced T/EBCs are being developed for the low emission SiC/SiC ceramic matrix composite (CMC) combustor applications by extending the CMC liner and vane temperature capability to 1650 C (3000 F) in oxidizing and water vapor containing combustion environments. Low conductivity thermal barrier coatings (TBCs) are also being developed for metallic turbine airfoil and combustor applications, providing the component temperature capability up to 1650 C (3000 F). In this paper, ceramic coating development considerations and requirements for both the ceramic and metallic components will be described for engine high temperature and high-heat-flux applications. The underlying coating failure mechanisms and life prediction approaches will be discussed based on the simulated engine tests and fracture mechanics modeling results.

Zhu, Dong-Ming↗