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DOE OSTI2025

Phase Field Modeling of Chemical Reaction Related Damage Evolution in Environmental Barrier Coatings

The advent of next-generation engines necessitates materials capable of withstanding temperatures beyond the reach of current superalloys. SiC-based ceramic matrix composites, augmented with environmental barrier coatings (EBCs), present a promising materials solution. Given the active search for effective and durable EBCs, there is a pressing need for modeling tools to understand and predict damage evolution in these materials to help accelerate their development. This study introduces a phase-field model (PFM) designed to simulate the thermally grown oxides (TGO) and phase transformation in the degradation and failure of EBCs. The model accounts for the severe volume expansion due to oxidation, alongside phase transformations and porosity evolution during thermal cycling, offering a comprehensive view of the damage processes. Simulation results are validated against experimental findings reported in the literature, establishing the model's potential as a significant tool for understanding and improving the resilience of EBCs in cyclic oxidative environments.

fast-diffusion path↗

NASA NTRS1999

Development of Refractory Silicate-YSZ Dual Layer TBCs

Development of advanced thermal barrier coatings (TBCs) is the most promising approach for increasing the efficiency and performance of gas turbine engines by enhancing the temperature capability of hot section metallic components. Spallation of the yttria-stabilized zirconia (YSZ) top coat, induced by the oxidation of the bond coat coupled with the thermal expansion mismatch strain, is considered to be the ultimate failure mode for current state-of-the-art TBCS. Enhanced oxidation resistance of TBCs can be achieved by reducing the oxygen conductance of TBCs below that of thermally grown oxide (TGO) alumina scale. One approach is incorporating an oxygen barrier having an oxygen conductance lower than that of alumina scale. Mullite, rare earth silicates and glass ceramics have been selected as potential candidates for the oxygen barrier. This paper presents the results of cyclic oxidation studies of oxygen barrier/YSZ dual layer TBCs.

He, Yirong↗

NASA NTRS2005

Thermodynamic Effect of Platinum Addition to beta-NiAl: An Initial Investigation

An initial investigation was conducted to determine the effect of platinum addition on the activities of aluminum and nickel in beta-NiAl(Pt) over the temperature range 1354 to 1692 K. These measurements were made with a multiple effusion-cell configured mass spectrometer (multi-cell KEMS). The results of this study show that Pt additions act to decreased alpha(Al) and increased the alpha(Ni) in beta-NiAl(Pt) for constant X(sub Ni)/X(sub Al) approx. = 1.13, while at constant X(sub Al) the affect of Pt on Al is greatly reduced. The measured partial enthalpies of mixing indicate Al-atoms have a strong self interaction while Ni- and Pt-atoms in have similar interactions with Al-atoms. Conversely the binding of Ni-atoms in beta-NiAl decreases with Pt addition independent of Al concentration. These initial results prove the technique can be applied to the Ni-Al-Pt system but more activity measurements are required to fully understand the thermodynamics of this system and how Pt additions improved the scaling behavior of nickel-based superalloys. In addition, with the choice of a suitable oxide material for the effusion-cell, the "closed" isothermal nature of the effusion-cell allows the direct investigation of an alloy-oxide equilibrium which resembles the "local-equilibrium" description of the metal-scale interface observed during high temperature oxidation. It is proposed that with an Al(l) + Al2O3(s) experimental reference state together with the route measurement of the relative partial-pressures of Al(g) and Al2O(g) allows the activities of O and Al2O3 to be determined along with the activities of Ni and Al. These measurements provide a direct method of investigating the thermodynamics of the metal-scale interface of a TGO-scale.

Source record↗

NASA NTRS2018

Methane on Mars: New Insights into the Sensitivity of CH4 with the NOMAD/ExoMars Spectrometer Through Its First In-Flight Calibration

The Nadir and Occultation for MArs Discovery instrument (NOMAD), onboard the ExoMars Trace Gas Orbiter (TGO) spacecraft was conceived to observe Mars in solar occultation, nadir, and limb geometries, and will be able to produce an outstanding amount of diverse data, mostly focused on properties of the atmosphere. The infrared channels of the instrument operate by combining an echelle grating spectrometer with an Acousto- Optical Tunable Filter (AOTF). Using in-flight data, we characterized the instrument performance and parameterized its calibration. In particular: an accurate frequency calibration was achieved, together with its variability due to thermal effects on the grating. The AOTF properties and transfer function were also quantified, and we developed and tested a realistic method to compute the spectral continuum transmitted through the coupled grating and AOTF system. The calibration results enabled unprecedented insights into the important problem of the sensitivity of NOMAD to methane abundances in the atmosphere. We also deeply characterized its performance under realistic conditions of varying aerosol abundances, diverse albedos and changing illumination conditions as foreseen over the nominal mission. The results show that, in low aerosol conditions, NOMAD single spectrum, 1σ sensitivity to CH4 is around 0.33 ppbv at 20 km of altitude when performing solar occultation's, and better than 1 ppbv below 30 km. In dusty conditions, we show that the sensitivity drops to 0 below 10 km. In Nadir geometry, results demonstrate that NOMAD will be able to produce seasonal maps of CH4 with a sensitivity around 5 ppbv over most of planet's surface with spatial integration over 5×5° bins. Results show also that such numbers can be improved by a factor of ~10 to ~30 by data binning. Overall, our results quantify NOMAD's capability to address the variable aspects of Martian climate.

Liuzzi, Giuliano↗

NASA NTRS2018

Coupled Thermo-Mechanical Micromechanics Modeling of the Influence of Thermally Grown Oxide Layer in an Environmental Barrier Coating System

Environmental Barrier Coatings (EBCs) have emerged as a promising means of protecting silicon based ceramic matrix composite (CMC) components for high temperature applications (e.g., aircraft engines). EBCs are often used to protect an underlying material (substrate) such as silicon carbide from extreme thermal/chemical environments. In a typical CMC/EBC system, an EBC may or may not be adhered to an underlying substrate with a bond coat (e.g., silicon). Irrespective, systems that utilize EBCs are susceptible to a number of failure modes including oxidation/delamination, recession, chemical attack and dissolution, thermomechanical degradation, erosion, and foreign object damage. Current work at NASA Glenn Research Center is aimed at addressing these failure modes in EBC systems and developing robust analysis tools to aid in the design process. The Higher-Order Theory for Functionally Graded Materials (HOTFGM), a precursor to the High-Fidelity Generalized Method of Cells micromechanics approach, was developed to investigate the coupled thermo-mechanical behavior of functionally graded composites and will be used herein to assess the development and growth of a low-stiffness thermally grown oxide (TGO) layer in EBC/CMC systems without a silicon bond coat. To accomplish this a sensitivity study is conducted to examine the influence of uniformly and nonuniformly grown oxide layer on the associated driving forces leading to mechanical failure (spallation) of EBC layer when subjected to isothermal loading.

thermally grown oxide↗

NASA NTRS2019

Durability of YSZ Coated Ti2AlC in 1300°C Mach 0.3 Burner Rig Tests

A thermal barrier coating system survived burner rig testing at 1300°C for 500 h. A 160 µm thick YSZ coating was applied to a Ti2AlC MAX phase sample by PS-PVD and tested face-on in an atmospheric Mach 0.3 jet fuel burner, using 5-h thermal cycles. No TBC spallation or recession was observed, only a 2.4 mg/sq. cm mass gain. The modest weight gain precluded severe volatility losses under high velocity burner conditions. The coating surface exhibited colonies of (111) flourite fiber-textured columns separated by craze patterns, with no visible moisture attack. The metastable tetragonal t' YSZ phase was obtained initially, transitioning to teq and cubic YSZ, but with little detrimental monoclinic. The thickness of the alumina TGO was ~21-23 m under the heated YSZ face and ~13-15 m on the uncoated, cooler backside. The backside exhibited removal of initial transient TiO2 nodules and etching of the underlying Al2O3 scale by volatile hydroxides in high temperature, high velocity water vapor. Aerodynamic forces produced some bending of the cantilevered sample due to creep. The test indicated exceptional stability of YSZ coatings on Ti2AlC under turbine conditions.

Smialek, J.↗

NASA NTRS2018

Practical Orbit Determination for Aerobraking with Accumulated Accelerometer Data

Navigation during aerobraking missions has historically relied solely on radiometric Doppler data. Accelerometer data, available on all modern spacecraft, has the potential to supplement Doppler data, increasing operational tempos, filling tracking data gaps, and improving the accuracy of orbit determination solutions. However, integration of Doppler and accelerometer data into the batch filter solutions used for operational navigation has proven to be practically challenging, due to the narrow region of adequate linear approximation for acceleration incurred by drag. This work proposes to use the accumulated velocity changes derived from these values as a more compatible data type. Demonstrations of results focus on NASA’s Maven and ESA’s TGO mission, and how this technique can be used to improve operations for the upcoming Maven aerobraking phase with reduced tracking data and lighter staffing requirements.

Young, Brian↗

NASA NTRS2019

Leveraging Mars aerobraking experience for the Venus environment

Aerobraking was first demonstrated at Venus during the Magellan extended mission in 1993 and on every Mars orbiter since, from the Mars Global Surveyor (MGS) in 1997 to ESA’s Trace Gas Orbiter (TGO) in 2017. This paper illustrates the differences between aerobraking at Venus and at Mars from both the astrodynamics and thermal perspectives. It shows how the periapsis velocity hammers the drag versus aerothermal heating relationship with comparable aerothermal heating limits and initial conditions at Mars and at Venus. Even though there are noticeable differences in the aerobraking environment between these two planets, the Mars heritage operations, processes, tactics, and strategy remain the same while addressing these differences in mission design and environment. Additionally, the spacecraft design requirements, capabilities, and thermal guards are retained across projects and planets. The operations processes and procedures developed over the 20 years of Mars experience can be equally applied back to the birthplace of aerobraking: Venus.

Wallace, Mark S.↗

NASA NTRS2020

Communications with Curiosity during solar conjunction

This study examines the methodology for operating and communicating with NASA's Curiosity Rover (MSL) during the 2019 solar conjunction. For MSL, solar conjunction occurs when the viewing angle between the Sun and Mars from Earth's perspective falls below 3 degrees, which occurs roughly every two Earth years and lasts for about two weeks. This presents a challenge for engineers operating a vehicle on Mars because the degraded signal to noise ratio disrupts data flow between Earth and the spacecraft. As a result, operators designate a command moratorium in which no commands are sent to the rover and instead design long-term plans that are uplinked weeks in advance (rather than the nominal case of daily uplinks). Coordinating communications with the rover leading up to and following conjunction requires negotiations with several orbiters, another lander, and the Deep Space Network (DSN) each with their own set of constraints. It is the Strategic Comm Planning T coordination, which acts as a baseline for the conjunction Comm team faced additional complications such as the arrival of two new spacecraft at Mars - Roscosmos ExoMars Trace Gas Orbiter (TGO).

Laubach, Sharon↗

NASA NTRSDate not supplied

Foreign Object Damage in Yb 2 Si 2 O 7 Environmental Barrier Coatings

Environmental Barrier Coatings (EBCs) have been developed as an enabling technology for silicon carbide based ceramic matrix composites in gas turbine engines. Two of the key failure mechanisms identified in EBC systems are foreign object damage (FOD) and the oxidative growth of a SiO 2 thermally grown oxide (TGO) layer that can lead to premature coating spallation. Previously the effects of FOD on NASA’s second generation Ytterbium Disilicate EBC were studied and recently it was shown that the addition of oxide modifiers resulted in improved oxidation resistance in the EBC. This work will compare FOD of the baseline Ytterbium Disilicate EBC to the that of the modified EBC. FOD was performed at room temperature using a 1.59 mm hardened steel ball with projectile velocities of 50-300 m/s. Additionally, the effects of oxidation via cyclic steam exposure prior to impact were investigated.

environmental barrier coatings (EBCs)↗

NASA NTRS2024

Differential Absorption Lidar for Searching Water Sources on Mars

Water vapor has been detected in the Martian atmosphere by multiple orbiting instruments. The Atmospheric Chemistry Suite (ACS) on the ExoMars Trace Gas Orbiter (TGO) observed H2O mixing ratios reaching up to 50 ppmv at altitudes of 100-120 km during global dust storms, while levels remained low (<2 ppmv) during other seasons. The Neutral Gas and Ion Mass Spectrometer (NGIMS) on the Mars Atmosphere and Volatile EvolutioN (MAVEN) spacecraft revealed that water transported to the upper atmosphere is dissociated by ions, producing atomic hydrogen that escapes into space, contributing to Mars’ water loss. This transport is seasonal, peaking in southern summer and intensifying during dust storms. Additionally, the Mars Reconnaissance Orbiter’s (MRO) imaging spectrometer detected hydrated minerals on slopes, suggesting that liquid water may intermittently flow on present-day Mars. However, an observational gap exists between high-altitude water vapor and surface water due to limitations in spatial resolution and a lack of measurements in the lower atmosphere. To address this gap, we propose using an airborne differential absorption lidar (DIAL) to search for water sources. DIAL provides high-resolution measurements both day and night, bridging the observational gap between high-altitude water vapor and surface water, thus enhancing our understanding of water transport and loss on Mars. Absorption lines of water vapor in the 2.7 μm and 1.8 μm bands have been selected in this study. Simulations show that both lines are capable of detecting water vapor sources with reasonable system parameters.

lidar↗

NASA NTRSDate not supplied

SiO2 Activity Measurements in the Gd2O3-SiO2 System Via Knudsen Effusion Mass Spectrometry (KEMS)

Environmental barrier coatings (EBCs) are required for the use of silicon carbide (SiC)-based ceramic matrix composites (CMCs) in gas turbine engines, as they protect the SiO 2 thermally grown oxide (TGO) formed at the CMC/coating interface from volatilization in a combustion environment. Current-generation EBCs consist of a silicon bond coat and a rare earth (RE) silicate topcoat. The RE silicate topcoat is exposed to high-velocity steam during engine operation, and SiO 2 within the coating can preferentially volatilize to form Si(OH) 4 gas species, albeit at a lesser degree than SiO 2 alone. Therefore, it is of interest to investigate the stability of these materials in steam as a function of their RE. In this study, SiO 2 activity, which can be related to the partial pressure of Si(OH) 4 , was measured across the Gd 2 O 3 -SiO 2 phase diagram, which includes Gd 2 SiO 5 , Gd 9.33 (SiO 4 ) 6 O 2 , and Gd 2 Si 2 O 7 as line compounds, via Knudsen Effusion Mass Spectrometry (KEMS). Values obtained for the Gd 2 O 3 -SiO 2 system were compared to those of other RE2O3-SiO2 systems and contextualized in terms of EBC viability.

EBCs↗

DOE OSTI2024

Phase-Field Model Incorporating Large Inelastic Strain with Application to the Oxidation of High-Temperature Coating Systems

Structural metallic and ceramic materials at high temperatures often suffer from creep, fatigue and oxidation, which typically involves local large inelastic strain. The large strain is usually approached by Lagrangian-description-based finite deformation theory. Here we develop an efficient, Eulerian-description-based, Incremental Realization of Inelastic Deformation (IRID) algorithm to deal with large inelastic strain with small elastic strain. We apply this algorithm to simulate high temperature oxidation with severe volume expansion using a phase-field approach. The oxidation and deformation of bond coat can lead to spallation and failure of the thermal barrier coatings (TBC) and environmental barrier coatings (EBC), which is a critical concern in design of these coatings. We simulate the growth of thermally grown oxide (TGO) in these coating systems, with phase transformations and microstructure evolution incorporated. The simulation results are compared with relevant experimental reports in the literature.

Cheng, Tianle↗