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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 NTRS1980

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.↗
NASA NTRS2002

Health Monitoring of Thermal Barrier Coatings by Mid-Infrared Reflectance

Mid-infrared (MIR) reflectance is shown to be a powerful tool for monitoring the integrity of 8wt% yttria-stabilized zirconia (8YSZ) thermal barrier coatings (TBCs). Because of the translucent nature of plasma-sprayed 8YSZ TBCs, particularly at MIR wavelengths (3 to 5 microns), measured reflectance does not only originate from the TBC surface, but contains strong contributions from internal scattering within the coating as well as reflectance from the underlying TBC/substrate interface. Therefore, changes in MIR reflectance measurements can be used to monitor the progression of TBC delamination. In particular, MIR reflectance is shown to reproducibly track the progression of TBC delamination produced by repeated thermal cycling (to 1163 C) of plasma-sprayed 8YSZ TBCs on Rene N5 superalloy substrates. To understand the changes in MIR reflectance with the progression of a delamination crack network, a four-flux scattering model is used to predict the increase in MIR reflectance produced by the introduction of these cracks.

Eldridge, J. I.↗
NASA NTRS2002

Health Monitoring of Thermal Barrier Coatings by Mid-Infrared Reflectance

Mid-infrared (MIR) reflectance is shown to be a powerful tool for monitoring the integrity of 8wt% yttria-stabilized zirconia (8YSZ) thermal barrier coatings (TBCs). Because of the translucent nature of plasma-sprayed 8YSZ TBCs at MIR wavelengths (3 to 5 pm), measured reflectance does not only originate from the TBC surface, but contains strong contributions from internal scattering within the coating as well as reflectance from the underlying TBC/substrate interface. Therefore, changes in MIR reflectance measurements can be used to monitor the progression of TBC delamination. In particular, MIR reflectance is shown to reproducibly track the progression of TBC delamination produced by repeated thermal cycling (to 1163 C) of plasma-sprayed 8YSZ TBCs on Rene N5 superalloy substrates. To understand the changes in MIR reflectance with the progression of a delamination crack network, a four-flux scattering model is used to predict the increase in MIR reflectance produced by the introduction of these cracks.

Eldridge, J. I.↗
NASA NTRS1991

Thermal barrier coating life prediction model development, phase 2

The objective of this program was to generate a life prediction model for electron-beam-physical vapor deposited (EB-PVD) zirconia thermal barrier coating (TBC) on gas turbine engine components. Specific activities involved in development of the EB-PVD life prediction model included measurement of EB-PVD ceramic physical and mechanical properties and adherence strength, measurement of the thermally grown oxide (TGO) growth kinetics, generation of quantitative cyclic thermal spallation life data, and development of a spallation life prediction model. Life data useful for model development was obtained by exposing instrumented, EB-PVD ceramic coated cylindrical specimens in a jet fueled burner rig. Monotonic compression and tensile mechanical tests and physical property tests were conducted to obtain the EB-PVD ceramic behavior required for burner rig specimen analysis. As part of that effort, a nonlinear constitutive model was developed for the EB-PVD ceramic. Spallation failure of the EB-PVD TBC system consistently occurred at the TGO-metal interface. Calculated out-of-plane stresses were a small fraction of that required to statically fail the TGO. Thus, EB-PVD spallation was attributed to the interfacial cracking caused by in-plane TGO strains. Since TGO mechanical properties were not measured in this program, calculation of the burner rig specimen TGO in-plane strains was performed by using alumina properties. A life model based on maximum in-plane TGO tensile mechanical strain and TGO thickness correlated the burner rig specimen EB-PVD ceramic spallation lives within a factor of about plus or minus 2X.

Meier, Susan Manning↗
NASA NTRS2015

A CFD-Based Study of the Feasibility of Adapting an Erosion Burner Rig for Examining the Effect of CMAS Deposition Corrosion on Environmental Barrier Coatings

Thermodynamic and computational fluid dynamics modeling has been conducted to examine the feasibility of adapting the NASA-Glenn erosion burner rigs for use in studies of corrosion of environmental barrier coatings by the deposition of molten CMAS. The effect of burner temperature, Mach number, particle preheat, duct heating, particle size, and particle phase (crystalline vs. glass) were analyzed. Detailed strategies for achieving complete melting of CMAS particles were developed, thereby greatly improving the probability of future successful experimental outcomes.

Deposition Studies↗
NASA NTRS1985

Thermal barrier coating life prediction model

This is the first report of the first phase of a 3-year program. Its objectives are to determine the predominant modes of degradation of a plasma sprayed thermal barrier coating system, then to develop and verify life prediction models accounting for these degradation modes. The first task (Task I) is to determine the major failure mechanisms. Presently, bond coat oxidation and bond coat creep are being evaluated as potential TBC failure mechanisms. The baseline TBC system consists of an air plasma sprayed ZrO2-Y2O3 top coat, a low pressure plasma sprayed NiCrAlY bond coat, and a Rene'80 substrate. Pre-exposures in air and argon combined with thermal cycle tests in air and argon are being utilized to evaluate bond coat oxidation as a failure mechanism. Unexpectedly, the specimens pre-exposed in argon failed before the specimens pre-exposed in air in subsequent thermal cycles testing in air. Four bond coats with different creep strengths are being utilized to evaluate the effect of bond coat creep on TBC degradation. These bond coats received an aluminide overcoat prior to application of the top coat to reduce the differences in bond coat oxidation behavior. Thermal cycle testing has been initiated. Methods have been selected for measuring tensile strength, Poisson's ratio, dynamic modulus and coefficient of thermal expansion both of the bond coat and top coat layers.

Hillery, R. V.↗
NASA NTRS2001

Upper Temperature Limit of Environmental Barrier Coatings for Enabling Propulsion Materials Established

Silicon-based ceramics, such as SiC/SiC composites and Si3N4, are the prime candidates for hot section structural components of next-generation gas turbines. A key barrier to such an application is the rapid recession of silicon-based ceramics in combustion environments because of the volatilization of silica scale by water vapor (refs. 1 and 2). Environmental barrier coatings (EBC's) were developed to prevent recession in the High Speed Research--Enabling Propulsion Materials (HSR-EPM) Program (refs. 3 and 4). An investigation under the Ultra-Efficient Engine Technology Program was undertaken at the NASA Glenn Research Center to establish the upper temperature limit of the EPM EBC.

Lee, Kang N.↗
NASA NTRS1988

Durability of thermal barrier coatings in a high heat flux environment

Thermal shock is a significant factor in the limited service life of Space Shuttle Main Engine (SSME) high pressure, fuel turbopump (HPFTP) turbine blades. Addition of advanced thermal barrier coatings (TBCs) to the blades could serve to dampen the thermal shock, thereby increasing the life of the blades. However, testing and use of TBCs to date is performed primarily under moderate heat flux conditions which are typical of aircraft turbines. Only limited testing was conducted that addresses high heat flux and severe thermal shock conditions. Therefore, it is not clear if TBCs can survive severe thermal shocks or provide adequate thermal shock protection to the HPFTP turbine blades. The purpose is to experimentally evaluate the potential durability and protective capability of a variety of advanced TBCs in a cyclic thermal shock environment. A secondary goal is to identify significant parameters affecting TBC life during high heat flux testing. Parameters investigated include top coat thickness, bond coat thickness, substrate type, and substrate geometry.

Brindley, William J.↗
NASA NTRS1986

Evaluation of moisture barrier coatings on carbon-phenolic SRM nozzle materials

The carbon-phenolic composite ablative material used on the Solid Rocket Motor (SRM) nozzle is known to absorb moisture from the atmosphere. This could cause problems such as pocketing during firing. Several moisture barrier coatings were tested on the SRM nozzle material. Data are presented for six of the 12 coatings to be tested. The data were obtained from immersion of coated samples in an environmental chamber at 100 F and 100% relative humidity and by using a modified TGA (thermal gravimetric analysis) technique. The TGA technique involved allowing wet nitrogen (25 C, 80% relative humidity) to flow across a small sample at about 65 cu cm per minute while continually monitoring the weight increase. These preliminary results show Kel-F-800, a material supplied by 3M Corporation to be the better moisture barrier. A second task was to collect data on the relative absorption of water and kerosene into the carbon-phenolic SRM nozzle material. These data indicate that water absorbs into the nozzle material to a much greater extent than kerosene. Thus kerosene is the more likely solvent in which to make specific gravity measurements on the SRM nozzle material.

Mcnutt, Ronald C.↗
NASA NTRS2000

Thermal Conductivity Change Kinetics of Ceramic Thermal Barrier Coatings Determined by the Steady-State Laser Heat Flux Technique

A steady-state laser heat flux technique has been developed at the NASA Glenn Research Center at Lewis Field to obtain critical thermal conductivity data of ceramic thermal barrier coatings under the temperature and thermal gradients that are realistically expected to be encountered in advanced engine systems. In this study, thermal conductivity change kinetics of a plasma-sprayed, 254-mm-thick ZrO2-8 wt % Y2O3 ceramic coating were obtained at high temperatures. During the testing, the temperature gradients across the coating system were carefully measured by the surface and back pyrometers and an embedded miniature thermocouple in the substrate. The actual heat flux passing through the coating system was determined from the metal substrate temperature drop (measured by the embedded miniature thermocouple and the back pyrometer) combined with one-dimensional heat transfer models.

Zhu, Dongming↗
NASA NTRS2016

Temperature Mapping of Air Film-Cooled Thermal Barrier Coated Surfaces Using Cr-Doped GdAlO3 Phosphor Thermography

It has been recently shown that the high luminescence intensity from a Cr-doped GdAlO3 (Cr:GdAlO3) thermographic phosphor enables non-rastered full-field temperature mapping of thermal barrier coating (TBC) surfaces to temperatures above 1000C. In this presentation, temperature mapping by Cr:GdAlO3 based phosphor thermometry of air film-cooled TBC-coated surfaces is demonstrated for both scaled-up cooling hole geometries as well as for actual components in a burner rig test environment. The effects of thermal background radiation and flame chemiluminescence on the measurements are investigated, and advantages of this method over infrared thermography as well as the limitations of this method for studying air film cooling are discussed.

thermographic phoshor↗
NASA NTRS1986

Thermal barrier coating life prediction model

This is the second annual report of the first 3-year phase of a 2-phase, 5-year program. The objectives of the first phase are to determine the predominant modes of degradation of a plasma sprayed thermal barrier coating system and to develop and verify life prediction models accounting for these degradation modes. The primary TBC system consists of an air plasma sprayed ZrO-Y2O3 top coat, a low pressure plasma sprayed NiCrAlY bond coat, and a Rene' 80 substrate. Task I was to evaluate TBC failure mechanisms. Both bond coat oxidation and bond coat creep have been identified as contributors to TBC failure. Key property determinations have also been made for the bond coat and the top coat, including tensile strength, Poisson's ratio, dynamic modulus, and coefficient of thermal expansion. Task II is to develop TBC life prediction models for the predominant failure modes. These models will be developed based on the results of thermmechanical experiments and finite element analysis. The thermomechanical experiments have been defined and testing initiated. Finite element models have also been developed to handle TBCs and are being utilized to evaluate different TBC failure regimes.

Hillery, R. V.↗
NASA NTRS1978

A computer program for full-coverage film-cooled blading analysis including the effects of a thermal barrier coating

The program input, coolant flow and heat transfer model, and the program output are discussed. As an example, sections of the suction and pressure sides of a high temperature, high pressure turbine vane are analyzed to show the effects of a thermal barrier coating. Compared to the uncoated design, the coating halves the required coolant flow, while simultaneously reducing metal outer temperatures by over 111 K.

Source record↗
NASA NTRS2003

Delamination Mechanisms of Thermal and Environmental Barrier Coatings on SiC/SiC Ceramic Matrix Composites

Advanced ceramic thermal harrier coatings will play an increasingly important role In future gas turbine engines because of their ability to effectively protect the engine components and further raise engine temperatures. However, the coating durability issue remains a major concern with the ever-increasing temperature requirements. In this paper, thermal cyclic response and delamination failure modes of a ZrO2-8wt%Y2O3 and mullite/BSAS thermaVenvironmenta1 barrier coating system on SiC/SiC ceramic matrix composites were investigated using a laser high-heat-flux technique. The coating degradation and delamination processes were monitored in real time by measuring coating apparent conductivity changes during the cyclic tests under realistic engine temperature and stress gradients, utilizing the fact that delamination cracking causes an apparent decrease in the measured thermal conductivity. The ceramic coating crack initiation and propagation driving forces under the cyclic thermal loads, in conjunction with the mechanical testing results, will be discussed.

Zhu, Dongming↗
NASA NTRS2020

Stochastic Simulation of Mudcrack Damage Formation in an Environmental Barrier Coating

The FEAMAC/CARES program, which integrates finite element analysis (FEA) with the MAC/GMC (Micromechanics Analysis Code with Generalized Method of Cells) and the CARES/Life (Ceramics Analysis and Reliability Evaluation of Structures / Life Prediction) programs, was used to simulate the formation of mudcracks during the cooling of a multilayered environmental barrier coating (EBC) deposited on a silicon carbide substrate. FEAMAC/CARES combines the MAC/GMC multiscale micromechanics analysis capability (primarily developed for composite materials) with the CARES/Life probabilistic multiaxial failure criteria (developed for brittle ceramic materials) and Abaqus (Dassault Systèmes) FEA. In this report, elastic modulus reduction of randomly damaged finite elements was used to represent discrete cracking events. The use of many small-sized low-aspect-ratio elements enabled the formation of crack boundaries, leading to development of mudcrack-patterned damage. Finite element models of a disk-shaped three-dimensional specimen and a twodimensional model of a through-the-thickness cross section subjected to progressive cooling from 1,300 °C to an ambient temperature of 23 °C were made. Mudcrack damage in the coating resulted from the buildup of residual tensile stresses between the individual material constituents because of thermal expansion mismatches between coating layers and the substrate. A two-parameter Weibull distribution characterized the coating layer stochastic strength response and allowed the effect of the Weibull modulus on the formation of damage and crack segmentation lengths to be studied. The spontaneous initiation of cracking and crack coalescence resulted in progressively smaller mudcrack cells as cooling progressed, consistent with a fractal-behaved fracture pattern. Other failure modes such as delamination, and possibly spallation, could also be reproduced. The physical basis assumed and the heuristic approach employed, which involves a simple stochastic cellular automaton methodology to approximate the crack growth process, are described. The results ultimately show that a selforganizing mudcrack formation can derive from a Weibull distribution that is used to describe the stochastic strength response of the bulk brittle ceramic material layers of an EBC.

Nemeth, Noel N.↗
NASA NTRS1996

Temperature measurement involving nanostructured thermal barrier coating using a multiwavelength pyrometer

It has been reported that erroneous results were obtained when a conventional pyrometer was used to measure the surface temperature of turbine engine components. Temperatures discrepancies were observed in components which were identical, except that one had its measured surface covered by a nanostructured thermal barrier coating (TBC) whereas the other component's surface was not so coated. These components were placed in an identical environment, receiving identical heat fluxes. A pyrometer measured the TBC covered surface hundreds degrees lower. These coatings were about 25 (mu)m thick, consisting of hundreds of layers of finer structures. The TBC's had very low thermal conductivity, heat flux calculations indicated that the temperatures of the coated surface should exhibit much higher temperature than the uncoated surface. Because these coatings were transparent to radiation from the visible to the infrared region, the temperatures measured by the pyrometer should be the temperature of the covered surface. Turbo components' performance and service life depend critically on the temperatures that it would experience; it is therefore important to know accurately and confidently the real surface temperature. Out of these concerns, an investigation into the measurement of nanostructured material surface temperature was carried out.

Ng, Daniel↗
NASA NTRS2006

Effects of Doping on Thermal Conductivity of Pyrochlore Oxides for Advanced Thermal Barrier Coatings

Pyrochlore oxides of general composition, A2B2O7, where A is a 3(+) cation (La to Lu) and B is a 4(+) cation (Zr, Hf, Ti, etc.) have high melting point, relatively high coefficient of thermal expansion, and low thermal conductivity which make them suitable for applications as high-temperature thermal barrier coatings. The effect of doping at the A site on the thermal conductivity of a pyrochlore oxide La2Zr2O7, has been investigated. Oxide powders of various compositions La2Zr2O7, La(1.7)Gd(0.3)Zr2O7, La(1.7)Yb(0.3)Zr2O7 and La(1.7)Gd(0.15)Yb(0.15)Zr2O7 were synthesized by the citric acid sol-gel method. These powders were hot pressed into discs and used for thermal conductivity measurements using a steady-state laser heat flux test technique. The rare earth oxide doped pyrochlores La(1.7)Gd(0.3)Zr2O7, La(1.7)Yb(0.3)Zr2O7 and La(1.7)Gd(0.15)Yb(0.15)Zr2O7 had lower thermal conductivity than the un-doped La2Zr2O7. The Gd2O3 and Yb2O3 co-doped composition showed the lowest thermal conductivity.

Bansal, Narottam P.↗
NASA NTRS2017

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. CMAS minerals usually are carried by the intake air into gas turbines, e.g. in aircraft engines, and their deposits react at high temperatures (1000C) with the coating materials. This causes degradation and accelerated 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, Dy, Gd, Nd and Sm) oxide stabilized ZrO2 or HfO2 systems, and the stability of the resulting oxides and silicates. Plasma sprayed hollow tube samples ( 2.2 mm and 26 mm height) were half filled with CMAS powder, wrapped and sealed with platinum foil, and heat treated at 1310 C for 5h. Samples were characterized by differential scanning calorimetry, X-ray diffraction and cross section electron microscopy analysis.

degradation↗