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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
NASA NTRS1973

An Exploratory Study of the Microstructure of Mullite Fibers

The microstructures of mullite composition fibers were examined by transmission electron microscopic techniques and by X-ray diffraction analyses. Both spun and monofilament fiber structures contained little porosity, nor did the degree of porosity change after heating the monofilament to 1205 C for one half hour. Thermal exposure produced crystallite growth and nucleation from the amorphous phase in all three of the spun fibers. After 116 hours at 1426 C, the crystallites of the standard spun fibers became contiguous. In addition, the surface crystallites of these fibers were found to be more than twice as large as the interior crystallites.

Santoro, G.↗
NASA NTRS1973

Entry environmental simulation testing of REI-Mullite TPS

Glassy fibrous mullite coatings exhibit noncatalytic surface characteristics which limit surface temperature rise under certain convective heat flux conditions. Thermal conductivity design curves provide good agreement with test results. The inclusion of shine-in effects results in improved accuracy of transient temperature gradient predictions for the materials.

Florence, D. E.↗
NASA NTRS1973

Optimum TPS Design with Rei-mullite

It has been shown that a ceramic mullite fiber/mullite insulation has adequate margins-of-safety based on minimum strengths for the critical thermostructural conditions of the shuttle mission. Introduction into the design of the new lower density foam bond material provides cold soak and cold entry capability at 116 K (-250 F). Finally, design solutions to the coating cracking tendencies have been identified and the solution analytically verified with three dimensional thermostructural analysis.

Hess, T. E.↗
NASA NTRS1974

Thermal conductivity measurements on Mullite and Silica REI for the Space Shuttle - Complementary guarded hot plate and radical outflow measurements

The materials studied are described along with the apparatus and the experimental techniques employed. The results of the measurements involving two REI Silica materials and a Mod 1 B REI Mullite are listed in a table. Measurements were conducted at unusually high temperature differences to detect 'shine-through' radiation transparency. Photographs are presented of the high-temperature guarded hot plate assembly.

Brazel, J. P.↗
NASA NTRS1982

Development of low-thermal expansion mullite bodies

A series of ceramic compositions based on variations in the crystal-glass ratio of a mullite body were developed. The thermal expansion of these compositions varies from 3.7 to 5.0 x 10 to the -6th/deg C to 800 C. The materials are particularly useful for applications involving silicon, in that an identical thermal expansion is available. The high-temperature creep data for the lower-expansion compositions are inferior as a result of their higher glass contents. Raw material sources and fabrication procedures for specific compositions are given.

Leipold, M. H.↗
NASA NTRS1990

Production of continuous mullite fiber via sol-gel processing

The development of a continuous ceramic fiber which could be used in rocket engine and rocket boosters applications was investigated at the Marshall Space Flight Center. Methods of ceramic fiber production such as melt spinning, chemical vapor deposition, and precursor polymeric fiber decomposition are discussed and compared with sol-gel processing. The production of ceramics via the sol-gel method consists of two steps, hydrolysis and polycondensation, to form the preceramic, followed by consolidation into the glass or ceramic structure. The advantages of the sol-gel method include better homogeneity and purity, lower preparation temperature, and the ability to form unique compositions. The disadvantages are the high cost of raw materials, large shrinkage during drying and firing which can lead to cracks, and long processing times. Preparation procedures for aluminosilicate sol-gel and for continuous mullite fibers are described.

Tucker, Dennis S.↗
NASA NTRS1991

Mechanical properties of a porous mullite material

Modulus of rupture specimens were used to determine crack growth parameters of a porous mullite material. Strength testing was performed in ambient and moist environments. The power law crack growth rate parameters n and 1n B in 50 percent relative humidity were found to be 44.98 and 0.94, respectively. The inert strength, fracture toughness, and elastic modulus were also determined and found to be 19 MPa, 055 MPa(m) exp 1/2, and 11.6 GPa, respectively.

Viens, Michael J.↗
NASA NTRS1976

Coatings for mullite insulation

Series of coatings provides hard, impermeable, waterproof layer. Inclusion of color oxides imparts high emittance to surface. Refractory fillers investigated include TiO2, BaO.ZrO2, SrO.TiO2 ziron, spodumene, petalite, and kryptonite. Colorants include Cr2O3, NiO, and CoO.

Bolinger, P. N.↗
NASA NTRS1996

Mullite fiber reinforced reaction bonded Si3N4 composites

Fracture toughnesses of brittle ceramic materials have been improved by introducing reinforcements and carefully tailored interface layers. Silicon carbide and Si3N4 have been emphasized as matrices of structural composites intended for high temperature service because they combine excellent mechanical, chemical, thermal and physical properties. Both matrices have been successfully toughened with SiC fibers, whiskers and particles for ceramic matrix composite (CMC) parts made by sintering, hot pressing or reaction forming processes. These SiC reinforced CMCs have exhibited significantly improved toughnesses at low and intermediate temperature levels, as well as retention of properties at high temperatures for selected exposures; however, they are vulnerable to attack from elevated temperature dry and wet oxidizing atmospheres after the matrix has cracked. Property degradation results from oxidation of interface layers and/or reinforcements. The problem is particularly acute for small diameter (-20 tim) polymer derived SiC fibers used for weavable toes. This research explored opportunities for reinforcing Si3N4 matrices with fibers having improved environmental stability; the findings should also be applicable to SiC matrix CMCs.

Saleh, T.↗
NASA NTRS2002

Coated article and method of making

An article includes a silicon-containing substrate and a modified mullite coating. The modified mullite coating comprises mullite and a modifier component that reduces cracks in the modified mullite coating. The article can further comprise a thermal barrier coating applied to the modified mullite coating. The modified mullite coating functions as a bond coating between the external environmental/thermal barrier coating and the silicon-containing substrate. In a method of forming an article, a silicon-containing substrate is formed and a modified mullite coating is applied. The modified mullite coating comprises mullite and a modifier component that reduces cracks in the modified mullite coating.

Wang, Hongyu↗
NASA NTRS2003

Coated article and method of making

An article includes a silicon-containing substrate and a modified mullite coating. The modified mullite coating comprises mullite and a modifier component that reduces cracks in the modified mullite coating. The article can further comprise a thermal barrier coating applied to the modified mullite coating. The modified mullite coating functions as a bond coating between the external environmental/thermal barrier coating and the silicon-containing substrate. In a method of forming an article, a silicon-containing substrate is formed and a modified mullite coating is applied. The modified mullite coating comprises mullite and a modifier component that reduces cracks in the modified mullite coating.

Wang, Hongyu↗
NASA NTRS2002

Environmental Barrier Coatings Having a YSZ Top Coat

Environmental barrier coatings (EBCs) with a Si bond coat, a yttria-stabilized zirconia (YSZ) top coat, and various intermediate coats were investigated. EBCs were processed by atmospheric pressure plasma spraying. The EBC durability was determined by thermal cycling tests in water vapor at 1300 C and 1400 C, and in air at 1400 C and 1500 C. EBCs with a mullite (3Al2O3 (dot) 2SiO2) + BSAS (1 - xBaO (dot) xSrO (dot) Al2O3 (dot) 2SiO2) intermediate coat were more durable than EBCs with a mullite intermediate coat, while EBCs with a mullite/BSAS duplex intermediate coat resulted in inferior durability. The improvement with a mullite + BSAS intermediate coat was attributed to enhanced compliance of the intermediate coat due to the addition of a low modulus BSAS second phase. Mullite + BSAS/YSZ and BSAS/YSZ interfaces produced a low melting (less than 1400 C) reaction product, which is expected to degrade the EBC performance by increasing the thermal conductivity. EBCs with a mullite + BSAS / graded mullite + YSZ intermediate coat showed the best durability among the EBCs investigated in this study. This improvement was attributed to diffused CTE (Coefficient of Thermal Expansion) mismatch stress and improved chemical stability due to the compositionally graded mullite+YSZ layer.

Lee, Kang N.↗
NASA NTRS2004

Multilayer article having stabilized zirconia outer layer and chemical barrier layer

A multilayer article includes a substrate that includes at least one of a ceramic compound and a Si-containing metal alloy. An outer layer includes stabilized zirconia. Intermediate layers are located between the outer layer and the substrate and include a mullite-containing layer and a chemical barrier layer. The mullite-containing layer includes 1) mullite or 2) mullite and an alkaline earth metal aluminosilicate. The chemical barrier layer is located between the mullite-containing layer and the outer layer. The chemical barrier layer includes at least one of mullite, hafnia, hafnium silicate and rare earth silicate (e.g., at least one of RE.sub.2 SiO.sub.5 and RE.sub.2 Si.sub.2 O.sub.7 where RE is Sc or Yb). The multilayer article is characterized by the combination of the chemical barrier layer and by its lack of a layer consisting essentially of barium strontium aluminosilicate between the mullite-containing layer and the chemical barrier layer. Such a barium strontium aluminosilicate layer may undesirably lead to the formation of a low melting glass or unnecessarily increase the layer thickness with concomitant reduced durability of the multilayer article. In particular, the chemical barrier layer may include at least one of hafnia, hafnium silicate and rare earth silicate.

Lee, Kang N.↗
DOE OSTI2020

Thermal, mechanical, and electrical properties of LSCo/mullite composite contact materials for solid oxide fuel cells

Lanthanum strontium cobaltite (LSCo) is considered as a good candidate cathode contact material for solid oxide fuel cells, due to high electrical conductivity. However, LSCo has a very large coefficient of thermal expansion (CTE) than the cells and metallic interconnects. As a result, poor mechanical stability is expected during thermal cycling. To minimize the CTE mismatch, we investigate a composite approach involving mixing LSCo with an inert material of low CTE, such as mullite at volume fractions from 0.1 to 0.4. Composite’s CTE shows a decreasing trend with increasing mullite volume fractions, and is consistent with model predictions. X-ray powder diffraction analysis of sintered LSCo/mullite composites exhibits no presence of other phases for samples aged for 500h at 800oC, indicating chemical compatibility. Electrical conductivity by a 4-pt method shows a decreasing trend with increasing mullite content. Contact strength of as-sintered and thermally cycled samples show that only the composite with 0.4 volume fraction has a measurable strength; the other composites have no strength. Overall, the composite approach is demonstrated in the LSCo/mullite system to lower the CTE and hence achieve thermal cycle stability. The addition of the inert phase to the LSCo matrix; however, also reduces the electrical conductivity.

Contact materials, LSCo, mullite, CTE, electrical ↗