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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 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Deposition of an ultrathin palladium (Pd) coating on SAPO-34 membranes for enhanced H 2 /N 2 separation

Hydrogen energy has attracted great attention due to its properties of high energy transferring efficiency and zero pollution emission. Zeolite membranes are promising candidates for H 2 separation because of their uniform, molecular-sized pores and high thermal and mechanical stabilities. However, thicker membranes or modification treatments are often necessary to eliminate the defects formed during synthesis and post calcination, leading to low gas permeance. In this paper, we reported the deposition of an ultrathin palladium (Pd) coating on SAPO-34 membranes to improve H 2 separation performance. H 2 /N 2 selectivity was greatly increased by deposition of an ultrathin Pd coating on SAPO-34 membranes, while maintaining similar H 2 permeance. This might be attributed to the dissociative adsorption and associative desorption of H 2 on Pd, as well as fast diffusion of H 2 through ultrathin Pd coating. We also noticed that excessive Pd deposition would lead to the formation of cracks on SAPO-34 membranes, leading to deteriorated membrane performance.

08 HYDROGEN↗
DOE OSTI2018

Interfacial Characteristics Investigation for One-Step EDM Drilling of Cooling Holes in TBCs

In this study, the one-step electrical discharge machining of inclined cooling holes is performed in thermal-barrier-coated nickel-based superalloys via the assisting electrode method. The effects of the process parameters, including the inclination angle, peak current, pulse duration, and duty cycle, on interfacial characteristics of cooling holes were investigated. The research results are as follows: After machining, the hardness of TBCs increases slightly and the adhesion strength of ceramic coating has a slight reduction. Delamination prevailingly appears at the ceramic coating/bonding coating interface, and its length at the trailing edge is greater than that at the leading edge. Increasing either the discharge energy or the duty cycle also aggravates the severity of the delamination. Under an excessive peak current of 22.5 A, the complete spalling of the ceramic coating occurs in the vicinity of the holes. Additionally, a reduction in the inclination angle results in a significant increase in delamination cracking and poorer interface integrity. The interfacial microstructure features of the holes vary with the inclination angle. The large-scale spalling of ceramic coating is prone to occur at the trailing edge when using an inclination angle of 30°. The spattering is susceptible to appear at the entrance of the holes under inclination angles of 60° and 75°, and its composition is primarily Ni, C, Zr, Cr, Nb, Fe, and Cu.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Mechanical measurements on lithium phosphorous oxynitride coated silicon thin film electrodes for lithium-ion batteries during lithiation and delithiation

The development of large stresses during lithiation and delithiation drives mechanical and chemical degradation processes (cracking and electrolyte decomposition) in thin film silicon anodes that complicate the study of normal electrochemical and mechanical processes. To reduce these effects, lithium phosphorous oxynitride (LiPON) coatings were applied to silicon thin film electrodes. Applying a LiPON coating has two purposes. First, the coating acts as a stable artificial solid electrolyte interphase. Second, it limits mechanical degradation by retaining the electrode's planar morphology during cycling. The development of stress in LiPON-coated electrodes was monitored using substrate curvature measurements. LiPON-coated electrodes displayed highly reproducible cycle-to-cycle behavior, unlike uncoated electrodes which had poorer coulombic efficiency and exhibited a continual loss in stress magnitude with continued cycling due to film fracture. The improved mechanical stability of the coated silicon electrodes allowed for a better investigation of rate effects and variations of mechanical properties during electrochemical cycling.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Phase-field modeling of thermally-grown oxide and damage evolution in environmental barrier coatings

Silicon carbide-based ceramic matrix composites protected by environmental barrier coatings (EBCs) present a promising materials solution for next-generation gas turbines. Developing more robust and efficient EBCs is therefore of significant technological importance. During the service in high-temperature oxidative environments, there is a thermally grown oxide (TGO) layer, spontaneously formed in the EBC system. TGO is recognized as a critical factor for the degradation and failure of EBCs, yet the detailed mechanisms of TGO growth and its effect on EBC failure remain unclear. In this study we develop a comprehensive chemo-mechano-phase-field model to simulate growth of the TGO in EBCs, factoring in creep and deformation, and especially the cracking behaviors. The volume expansion due to TGO growth and the resulting large inelastic deformation are addressed by using our recently developed, so-called incremental realization of inelastic deformation (IRID) algorithm, in combination with an adapted Hu-Chen spectral solver for elasticity. Simulations of TGO growth are performed considering different growth modes of TGOs determined mainly by the ratio of oxidant permeability in the topcoat to that in the TGO itself. Large-scale three-dimensional (3D) simulations are performed to model the formation of interconnecting vertical/channel cracks (often called ‘mud cracks’). The simulated crack morphology are in excellent agreement with the experimental observations from the literature. The simulations also provide insights into the cracking of EBCs and its dependence on the structure and constituent properties of the coating system. Furthermore, these results demonstrate the developed damage model can be a useful tool for design of more durable EBCs.

Cracking↗
DOE OSTI2023

Hermeticity of SiC/SiC composite and monolithic SiC tubes irradiated under radial high-heat flux

Demonstration of hermetic SiC fiber–reinforced SiC matrix composite cladding under normal operating environments has been identified as one of the most critical feasibility issues for accident-tolerant fuel cladding in light-water reactors. This study provides critical experimental data needed for understanding the effects of irradiation on hermeticity. SiC composite and monolithic tubes were neutron-irradiated to 2 displacements per atom with and without a nominal radial heat flux of 0.6 MW/m2 to produce a simulated in-pile stress state for the normal operation of a light-water reactor. The through-thickness temperature gradient under irradiation results in a gradient in swelling, which causes a significant stress buildup. Such irradiation-induced stress was modeled using a commercial finite element analysis code. The radial heat flux–irradiation synergism was experimentally investigated by constructing a special irradiation capsule and evaluating the helium hermeticity of the specimens. The simulated stress state exhibited a near equi-biaxial tensile axial and hoop stress of ~150 MPa at the inner surface of the SiC composite tube. This stress level is potentially beyond the matrix cracking stress. Degradation of hermeticity of the SiC composite tubes was observed after irradiation, indicating irradiation-induced cracking, whereas the irradiated monolithic SiC tubes remained hermetic. In conclusion, the results indicate that loss of hermeticity caused by radiation-induced microcracking is a potential issue for SiC composite cladding, depending on the magnitude of the temperature gradients. Coating the outer surface of the cladding was identified as a mitigation strategy that might overcome the cracking issue.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Evaluating the Chemical Resistance of Salt-stone Disposal Unit (SDU) Concrete and Polymeric Coatings - 18494

Salt-stone Disposal Units (SDUs) are multi-million liter concrete structures that are used at the Savannah River Site (SRS) for the permanent disposal of low-activity salt solution incorporated in a cementitious grout matrix, termed salt-stone. The major chemical constituents of the salt solution include sodium, aluminum, nitrate, nitrite, hydroxide, carbonate, and sulfate. The potential exists for the SDU interior to be chronically exposed to these corrosive constituents resulting in deleterious reactions and physical damage. Sulfate attack is an example of such an interaction whereby aqueous sulfates may penetrate the concrete, and react with hydration products in the cured concrete to form expansive phases that can cause excessive strains and cracking. Recently constructed SDUs have utilized sulfate-resistant Type V cement and polymeric coatings to minimize the potential impacts of SDU concrete exposure to the highly caustic (pH > 13) salt solution. Not only must the concrete and coatings exhibit high resistance to the caustic salt solution but they are also subjected to above ambient temperatures due to the exothermic nature of the grout hydration reaction. As such, both the SDU concrete and the coatings need to be tested with respect to stability in the aforementioned chemical and thermal environments. Two primary investigations were considered in this work. The first was to evaluate the resistance of two previously used epoxy coatings (Hempel Versiline TL-45 S Novolac and EC-66 elastomeric epoxies) to chemical attack from a simulated salt solution. In addition, a third coating was included in the study, a poly-urea coating (Sherwin Williams Envirolastic AR425) that may be considered as an alternative to the epoxy coatings on future SDUs. Each coating was applied to concrete cylinders (actual SDU 6 test cores) and subsequently exposed to salt-stone, or full and half strength caustic salt solution; 50% dilution was considered since salt-stone processing involves addition of flush water to the SDUs, which is expected to dilute any residual salt solution or bleed water in the SDU. Exposure testing was conducted at 68 deg. C for 1,000 hours followed by ambient exposure to provide a full exposure time of approximately 90 days. It is important to note that evaluation criteria for the coated materials were only visual in nature. Other than coating discoloration, which was limited to the surfaces, no other visual indications of reactivity between the three coatings and any of the exposure mediums were observed. Cross-sectioned samples indicated no through-thickness coating penetration or reaction, and showed no signs of delamination. The second investigation was also performed to determine if SDU concrete without a polymeric barrier would resist ingress and reaction with salt solution at the elevated temperature. Again, only slight discoloration of the concrete surfaces was observed after the 90-day exposure test irrespective of the salt solution concentration. A requirement of structural concrete in the SDUs is that it possesses a minimum compressive strength of 42 MPa (6,000 psi). The average compressive strength of samples exposed to the full-strength salt solution was recorded at 68 MPa compared to 66 MPa for the unexposed samples thus indicating that the exposure conditions considered in this study were not detrimental to the concrete strength. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1999

Analysis of an Interface Crack for a Functionally Graded Strip Sandwiched between Two Homogeneous Layers of Finite Thickness

The interface crack problem for a composite layer that consists of a homogeneous substrate, coating and a non-homogeneous interface was formulated for singular integral equations with Cauchy kernels and integrated using the Lobatto-Chebyshev collocation technique. Mixed-mode Stress Intensity Factors and Strain Energy Release Rates were calculated. The Stress Intensity Factors were compared for accuracy with relevant results previously published. The parametric studies were conducted for the various thickness of each layer and for various non-homogeneity ratios. Particular application to the Zirconia thermal barrier on steel substrate is demonstrated.

Shbeeh, N. I.↗
DOE OSTI2014

TRISO-Coated Fuel Durability Under Extreme Conditions

The PIs propose to examine TRISO-coated particles (SiC and ZrC coatings) in an integrated two-part study. In the first part, experiments will be performed to assess the reaction kinetics of the carbides under CO-CO2 environments at temperatures up to 1800 degree C. Kinetic model will be applied to describe the degradation. Scanning and transmission electron microscopy will be employed to establish the chemical and microstructure evolution under the imposed environmental conditions. The second part of the proposed work focuses on establishing the role of the high temperature, environmental exposure described above on the mechanical behavior of TRISO-coated particles. Electron microscopy and other advanced techniques will be subsequently performed to evaluate failure mechanisms. The work is expected to reveal relationships between corrosion reactions, starting material characteristics (polytype of SiC, impurity concentration, flaw distribution), flaw healing behavior, and crack growth.

36 MATERIALS SCIENCE↗
DOE OSTI2021

SNF Canister Coatings for Corrosion Prevention and Mitigation (FY21 Status Report)

This report summarizes the current actives in FY21 related to the effort by Sandia National Laboratories to identify and test coating materials for the prevention, mitigation, and repair of spent nuclear fuel dry storage canisters against potential chloride-induced stress corrosion cracking. This work follows up on the details provided in Sandia National Laboratories FY20 report on the same topic, which provided a detailed description of the specific coating properties desired for application and implementation on spent nuclear fuel canisters, as well as provided detail into several different coatings and their applicability to coat spent nuclear fuel canisters. In FY21, Sandia National Laboratories has engaged with private industry to create a Memorandum of Understanding and established a collaborative R&D program building off the analytical and laboratory capabilities at Sandia National Laboratories and the material design and synthesis capabilities of private industry. The resulting Memorandum of Understanding included four companies to date (Oxford Performance Materials, White Horse R&D, Luna Innovations, and Flora Coating) proposing six different coating technologies (polyetherketoneketone, modified polyimide/polyurea, modified phenolic resin, silane-based polyurethane hybrid with and without a Znrich primer, and a quasi-ceramic sol-gel polyurethane hybrid) to be tested, evaluated, and optimized for their potential use for this application. This report provides a detailed description of each of the coating systems proposed by the participating industry partners. It also provides a description of the planned experimental actives to be performed by Sandia National Laboratories including physical tests, electrochemical tests, and characterization methods. These analyses will be used to identify specific ways to further improve coating technologies toward their application and implementation on spent nuclear fuel canisters. In FY21, Sandia National Laboratories began baseline testing of the base metal material in according with activities of the Memorandum of Understanding. In FY22, Sandia National Laboratories will receive coated coupons from each of the participating industry partners and begin characterization, physical, and electrochemical testing following the test plan described herein.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Field Testing of Self-Healing Metallic Coatings for Internal Corrosion Protection of Natural Gas Pipelines

Internal corrosion occurs in natural gas pipelines primarily due to the presence of water, carbon dioxide, and hydrogen sulfide. Internal corrosion can eventually result in leakage, cracks, and rupture of the pipeline. The objective of this work is to mitigate internal corrosion in steel pipelines transporting natural gas using cold spray coatings. The corrosion behavior of carbon steel coated with self-healing zinc chromium (ZnCr) and zinc niobium (ZnNb) cold spray coatings was investigated in a natural gas environment. For comparison purposes, hot-dip galvanized steel (HDGS) was tested under the same conditions as cold spray coatings. The field test was performed at the NW Natural gas storage facility in Mist, Oregon. The field test was conducted in a 6-inch diameter pipe transporting wet natural gas out of an underground storage well at 500 psi and 4.4 °C. The coupons were tested for 15 and 32 days under stagnant and flow conditions, respectively. Weight loss method was used to measure the corrosion rate of metallic coatings. Post-corrosion surface characterization was performed on the specimen using a scanning electron microscopy (SEM) equipped with energy dispersive X-ray spectroscopy (EDS). Crystalline phases were determined by X-ray diffraction (XRD). The field-test results confirmed that the metallic coatings provided corrosion protection of carbon steel exposed to wet natural gas under stagnant and flow conditions. The formation of the ZnCO 3 layer on top of ZnNb and ZnCr coatings led to passivation of the coatings which helps to reduce the self-corrosion. These layers form a barrier for diffusion of corrosive species to the surface.

03 NATURAL GAS↗
DOE OSTI2019

An Integrated Numerical Method to Predict the Strain Sensing Behavior of Flexible Conductive Fibers under Electric–Thermal Conditions

Flexible conductive textiles have attracted an increasing amount of attention due to being flexible and stretchable with multi-functions, in addition to the strain sensing function. In this paper, an integrated numerical method is established to predict the strain sensing behavior of PPy-coated flexible conductive fibers. Based on our previous investigation on the strain sensing behavior of the PPy-coated elastic conductive fibers, it has been known that the main strain sensing mechanisms of the conductive fibers are micro-cracks opening under stretching and closing under unloading. Therefore, in the numerical approach, extended finite element method is used to simulate the multi-crack initiation and propagation. Then, by establishing a representative element model including a single crack, the resistance variation with the increase in crack width/depth can be obtained using the electric–thermal package in ABAQUS software. Combining the relationship between crack width and strain, the relationship between fractional increment in resistance (ΔR/R{sub 0}) and the strain can be obtained. The prediction of the fractional increment in resistance (ΔR/R{sub 0}) versus strain is consistent with the experimental results of PPy-coated Lycra fibers. The new integrated method is further verified by experimental results of PPy-coated XLA fibers, showing that the integrated numerical approach can capture the complicated strain sensing mechanisms of PPy-coated elastic fibers and predict the strain sensing behavior of flexible conductive fibers. This approach will make it possible to shorten the period, and reduce the cost in R&D of the PPy-coated electrically conductive fibers, comparing with the corresponding experimental work.

36 MATERIALS SCIENCE↗
DOE OSTI2022

FY2022 Status Report: Cold Spray for Canister SCC Mitigation and Repair

This progress report describes work performed during FY22 at Sandia National Laboratories (SNL) to assess the corrosion performance of cold spray coatings to enable optimization of cold spray for the purposes of mitigation and/or repair of potentially susceptible regions, corrosion, or stress corrosion cracking (SCC) in austenitic stainless steel for spent nuclear fuel (SNF) storage. Of particular concern is SCC, by which a through-wall crack could potentially form in a canister outer wall over time intervals that may be shorter than possible dry storage times. In FY21, initial corrosion explorations of cold spray coating were evaluated and in FY22, an expanded set of cold spray coatings with in-depth analysis of post-exposure accelerated testing was explored. Additionally, relevant atmospheric exposure testing was carried out and initial results are presented herein. The corrosion attack from the accelerated testing and more realistic atmospheric exposures environments were compared to identify potentially deleterious factors for corrosion as well as help to understand the applicability of accelerated testing for cold spray optimization. This initial analysis will help to enable optimization of the corrosion resistance cold spray, one of the more promising coating and repair techniques, for potential application in an SNF environment. Learnings from both are summarized, and implications and future work are presented in this report.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Mechanical Characteristics of SiC Coating Layer in TRISO Fuel Particles

Tristructural isotropic (TRISO) particles are considered as advanced fuel forms for a variety of fission platforms. While these fuel structures have been tested and deployed in reactors, the mechanical properties of these structures as a function of production parameters need to be investigated in order to ensure their reliability during service. Nanoindentation techniques, indentation crack testing, and half sphere crush testing were utilized in order to evaluate the integrity of the SiC coating layer that is meant to prevent fission product release in the coated particle fuel form. The results are complimented by scanning electron microscopy (SEM) of the grain structure that is subject to change as a function of processing parameters and can alter the mechanical properties such as hardness, elastic modulus, fracture toughness and fracture strength. Through utilization of these advanced techniques, subtle differences in mechanical properties that can be important for in-pile fuel performance can be distinguished and optimized in iteration with processing science of coated fuel particle production.

99 GENERAL AND MISCELLANEOUS↗
NASA NTRS1988

Cracking of a layered medium on an elastic foundation under thermal shock

The cladded pressure vessel under thermal shock conditions which is simulated by using two simpler models was studied. The first model (Model 1) assumes that, if the crack size is very small compared to the vessel thickness, the problem can be treated as a semi-infinite elastic medium bonded to a very thin layer of different material. However, if the crack size is of the same order as the vessel thickness, the curvature effects may not be negligible. In this case it is assumed that the relatively thin walled hollow cylinder with cladding can be treated as a composite beam on an elastic foundation (Model 2). In both models, the effect of surface cooling rate is studied by assuming the temperature boundary condition to be a ramp function. The calculated results include the transient temperature, thermal stresses in the uncracked medium and stress intensity factors which are presented as a function of time, and the duration of cooling ramp. The stress intensity factors are also presented as a function of the size and the location of the crack. The problem is solved for two bonded materials of different thermal and mechanical properties. The mathematical formulation results in two singular integral equations which are solved numerically. The results are given for two material pairs, namely an austenitic steel layer welded on a ferritic steel substrate, and a ceramic coating on ferritic steel. In the case of the yielded clad, the stress intensity factors for a crack under the clad are determined by using a plastic strip model and are compared with elastic clad results.

Rizk, Abd El-Fattah A.↗
NASA NTRS2020

Durability of YSZ coated Ti2AlC in 1300°C high velocity burner rig tests

A thermal barrier coating system survived 500 h in cyclic burner rig tests at 1300°C, exceeding the life of all previous systems. An yttria stabilized zirconia (7YSZ) thermal barrier coating (TBC) was plasma sprayed on the oxidation resistant Ti2AlC MAX phase and tested in a jet fuel burner. No coating spallation or recession was observed, only a 2.4 mg/sq.cm mass gain due to typical cubic Al2O3 oxidation kinetics. The modest weight gain contrasted with large TBC spallation or oxide volatility losses that might occur under cyclic, high velocity (~100 m/s) burner conditions. The coating surface exhibited colonies of [111]flourite fiber-textured columns separated by craze crack patterns, but with no visible moisture attack. The thickness of the alumina scale under the YSZ face was >20 μm, more than twice that formed on TBC/superalloy systems at failure. TiO2 nodules, initially formed on the uncoated backside, were then removed as volatile hydroxides formed in high temperature, high velocity water vapor (~10%). Overall, the test indicated the exceptional stability of the YSZ/Ti2AlC system under turbine conditions, due in large part to good thermal expansion matching.

alumina, MAX phases, thermal barrier coatings (TBC↗
NASA NTRS2017

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↗
DOE OSTI2014

Lu{sub 2}O{sub 3}:Eu{sup 3+} glass ceramic films: Synthesis, structural and spectroscopic studies

Graphical abstract: - Highlights: • Lu{sub 2}O{sub 3}:Eu{sup 3+}@SiO{sub 2} films were synthesized by sol–gel and by dip-coating technique. • Effects of incorporating PVP on structural properties were studied. • Effects of incorporating silica (SiO{sub 2}) luminescence characteristics were analyzed. • X-ray diffraction results showed that Lu{sub 2}O{sub 3}:Eu{sup 3+}@SiO{sub 2} crystallizes at 700 °C. • The 611 nm emission for the Lu:Si = 8:1 system presented an improvement. - Abstract: For the first time, transparent and crack free europium-doped lutetia silica sol–gel films were synthesized using the dip-coating technique on silica quartz substrates. In this study, we examined the effects of incorporating polyvinylpyrrolidone (PVP) and silica (SiO{sub 2}) into different precursor solutions for different Lu–Si molar ratios: 4:1, 6:1, 8:1 and 10:1. Different systems, such as Lu{sub 2}O{sub 3}:Eu{sup 3+}@SiO{sub 2} (using the above Lu:Si molar ratios), were synthesized by sol–gel and by dip-coating technique, employing acetylacetonate lutetium and tetraethylorthosilicate as Lu and Si precursors, in order to produce Lu{sub 2}O{sub 3}:Eu{sup 3+} (5 mol%)@SiO{sub 2} glass–ceramic films. The film microstructure was studied by microRaman spectroscopy (MRS) and X-ray diffraction (XRD) for different Lu:Si molar ratios on films annealed at 700 °C. X-ray diffraction results showed that the lutetium oxide cubic phase crystallizes in the silica matrix at 700 °C, and the crystallite size of Lu{sub 2}O{sub 3}:Eu{sup 3+}@SiO{sub 2} films varies from 5 nm to 17 nm according to the respective Lu:Si molar ratios. Opto-geometrical parameters determined by m-lines spectroscopy using a 632.5 nm He–Ne laser showed that the Eu{sup 3+} doped films heat-treated at 700 °C presented a thickness and density of 1.7 μm (8.8 g cm{sup −3}), 970 nm (9.2 g cm{sup −3}), 1 μm (9.3 g cm{sup −3}) and 1.3 μm (9.25 g cm{sup −3}) for the Lu:Si = 4:1, 6:1, 8:1 and 10:1 molar ratio systems, respectively. The Lu:Si = 8:1 system 611 nm emission presented an improvement. These results were provided by photoluminescent spectroscopy.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Ultra-High Temperature Thermal Barrier Coating Development and Validation

The most effective method to improve industrial gas turbine power is to increase firing temperature. To maintain component durability at these higher temperatures, thermal barrier coatings (TBC’s) are playing an increasing role in protecting turbine hardware. TBC’s have been successfully used on Solar Turbines’ combustor liners and turbine airfoils, but there is a need for TBC’s that can operate at higher temperatures. Based on recent, favorable rig testing experience, Solar recognized that yttrium aluminum garnet (YAG) TBC’s made by the Solution Precursor Plasma Spray Process (SPPS) has great potential for higher turbine temperatures. This testing verified the thermal cycle durability of the SPPS YAG TBC’s, as well as demonstrated that the temperature drop through the SPPS YAG TBC was twice that measured across a companion APS YSZ TBC. The SPPS YAG TBC with the potential for a 200°C improvement in temperature capability represents a materials breakthrough. The SPPS process also produces a number of unique microstructural features that confer superior properties. SPPC TBC’s have ultra-fine splats that increase toughness and erosion resistance, and the process can be tailored to produce through-thickness cracks for strain-tolerance and control porosity for lower thermal conductivity and increase coating abradability. This proposal would include further development of SPPS YAG density-graded coatings, optimization of the application process, and validation of higher temperature capability and durability through rig and engine testing of coated combustion liners and turbine outer air seals. The technology would be advanced from a TRL 3 to a proposed TRL 6 by overcoming processing concerns on efficiency, application distance and optimization of a graded coating without impacting coating durability by demonstrating the coating performance on components in rig and development gas turbine engine testing.

36 MATERIALS SCIENCE↗