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NASA NTRS2007

Joint Test Report For Validation of Alternatives to Aliphatic Isocyanate Polyurethanes

National Aeronautics and Space Administration (NASA) and Air Force Space Command (AFSPC) have similar missions and therefore similar facilities and structures in similar environments. The standard practice for protecting metallic substrates in atmospheric environments is the application of an applied coating system. The most common topcoats used in coating systems are polyurethanes that contain isocyanates. Isocyanates are classified as potential human carcinogens and are known to cause cancer in animals. The primary objective of this effort was to demonstrate and validate alternatives to aliphatic isocyanate polyurethanes resulting in one or more isocyanate-free coatings qualified for use at AFSPC and NASA installations participating in this project. This joint Test Report (JTR) documents the results of the laboratory and field testing as well as any test modifications made during the execution of the testing. The technical stakeholders agreed upon test procedure modifications documented in this document. This JTR is made available as a reference for future pollution prevention endeavors by other NASA centers, the Department of Defense and commercial users to minimize duplication of effort. All coating system candidates were tested using approved NASA and AFSPC standard coating systems as experimental controls. This study looked at eight alternative coating systems and two control coating systems and was divided into Phase I Screening Tests, Phase II Tests, and Field Testing. The Phase I Screening Tests were preliminary tests performed on all the selected candidate coating systems. Candidate coating systems that did not meet the acceptance criteria of the screening tests were eliminated from further testing. Phase I Screening Tests included: Ease of Application, Surface Appearance, Dry-To-Touch (Sanding), Accelerated Storage Stability, Pot Life (Viscosity), Cure Time (Solvent Rubs), Cleanability, Knife Test, Tensile (pull-off) Adhesion, and X-Cut Adhesion by Wet Tape After a review of the Phase I test results, four of the alternative coating systems showed substandard performance in relation to the Control Systems and were eliminated from the Phase II testing. Due to the interest of stakeholders and time constraints, however, all eight alternatives were subjected to the following Phase II tests, along with field testing at Stennis Space Center (SSC), Mississippi: Hypergol Compatibility, Liquid Oxygen Compatibility, 18-Month Marine Exposure (Gloss Retention, Color Retention, Blistering, Visual Corrosion, Creepage from Scribe, Heat Adhesion), and Field Exposure (6- and 12-month Evaluation for Coating Condition, Color Retention, Gloss Retention). The remaining four alternative coating systems determined to be the best viable alternatives were carried on to Phase II testing that included: Removability, Repairability, Abrasion Resistance, Gravelometer, Fungus Resistance, Accelerated Weathering, Mandrel Bend Flexibility, and Cyclic Corrosion Resistance. Of the systems that continued to Phase II, three (3) alternative coating systems meet the performance requirements as identified by stakeholders. Two (2) other systems, that were not included in Phase II testing, performed well enough on the 18-Month Marine Exposure, the primary requirement for NASA technical standard NASA-STD-5008, Protective Coating of Carbon Steel, Stainless Steel, and Aluminum on Launch Structures, Facilities, and Ground Support Equipment, that they were also considered to be successful candidates. In total, five (5) alternative coating systems were approved for inclusion in the NASA-STD- 5008 Qualified Products List (QPL). The standard is intended to provide a common framework for consistent practices across NASA and is often used by other entities. The standard's QPL does not connote endorsement of the products by NASA, but lists those products that have been tested and meet the requirements as specified.

Lewis, Pattie↗

NASA NTRS2007

Cost-Benefit Analysis for Alternatives to Aliphatic Isocyanate Polyurethanes

NASA and Air Force Space Command (AFSPC) have similar missions and therefore similar facilities and structures in similar environments. The standard practice for protecting metallic substrates in atmospheric environments is the application of an applied coating system. The most common topcoats used in coating systems are polyurethanes that contain isocyanates. Isocyanates are classified as potential human carcinogens and are known to cause cancer in animals. The primary objective of this effort was to demonstrate and validate alternatives to aliphatic isocyanate polyurethanes resulting in one or more isocyanate-free coatings qualified for use at AFSPC and NASA installations participating in this project. This Cost-Benefit Analysis (CBA) quantifies the estimated capital and process costs of coating alternatives and cost savings relative to the current coatings. The estimates in this CBA are to be used for assessing the relative merits of the selected alternatives. The actual economic effects at any specific facility will depend on the alternative material or technology implemented, the number of actual applications converted, future workloads, and other factors . The participants initially considered eighteen (18) alternative coatings as described in the Potential Alternatives Report entitled Potential Alternatives Report for Validation of Alternatives to Aliphatic Isocyanate Polyurethanes, prepared by ITB. Of those, 8 alternatives were selected for testing in accordance with the Joint Test Protocol entitled Joint Test Protocol for Validation of Alternatives to Aliphatic Isocyanate Polyurethanes, and the Field Test Plan entitled Field Evaluations Test Plan for Validation of Alternatives 10 Aliphatic Isocyanate Polyurethanes, both of which were prepared by ITB. A joint Test Report entitled Joint Test Report for Validation of Alternatives to Aliphatic Isocyanate Polyurethanes, prepared by ITB, documents the results of the laboratory and field testing, as well as any test modifications made during the execution of the testing. The coatings selected for evaluation in this CBA are shown in the table below. Only one control coating system is considered in this analysis. These coatings were either downselected for Phase II or performed well enough to be included in the Qualified Products List in the NASA technical standard NASA-STD-5008, Protective Coating of Carbon Steel, Stainless Steel, and Aluminum on Launch Structures, Facilities, and Ground Support Equipment.

Lewis, Pattie↗

NASA NTRS2009

QuEST: Qualifying Environmentally Sustainable Technologies

In 2004, in one of their first collaborative efforts, Centro Para Prevencao da Poluicao (Portuguese Center for Pollution Prevention or C3P). teamed with Technology Evaluation for Environmental Risk Mitigation Principal Center (TEERM) and two Portuguese entities, TAP Portugal (Portuguese National Airline) and OGMA Indtistria Aeron utica de Portugal (Portuguese Aeronautics Industry), to target the reduction of hexavalent chromium, cadmium, and volatile organic compounds (VOCs) in aircraft maintenance operations. This project focused on two coating systems that utilize non-chrome pretreatments and low-VOC primers and topcoats.

Lewis, Pattie L.↗

NASA NTRS2014

A Five-year Performance Study of Low VOC Coatings over Zinc Thermal Spray for the Protection of Carbon Steel at the Kennedy Space Center

The launch facilities at the Kennedy Space Center (KSC) are located approximately 1000 feet from the Atlantic Ocean where they are exposed to salt deposits, high humidity, high UV degradation, and acidic exhaust from solid rocket boosters. These assets are constructed from carbon steel, which requires a suitable coating to provide long-term protection to reduce corrosion and its associated costs. While currently used coating systems provide excellent corrosion control performance, they are subject to occupational, safety, and environmental regulations at the Federal and State levels that limit their use. Many contain high volatile organic compounds (VOCs), hazardous air pollutants, and other hazardous materials. Hazardous waste from coating operations include vacuum filters, zinc dust, hazardous paint related material, and solid paint. There are also worker safety issues such as exposure to solvents and isocyanates. To address these issues, top-coated thermal spray zinc coating systems were investigated as a promising environmentally friendly corrosion protection for carbon steel in an acidic launch environment. Additional benefits of the combined coating system include a long service life, cathodic protection to the substrate, no volatile contaminants, and high service temperatures. This paper reports the results of a performance based study to evaluate low VOC topcoats (for thermal spray zinc coatings) on carbon steel for use in a space launch environment.

Zinc Thermal Spray↗

NASA NTRS2014

High Temperature Multilayer Environmental Barrier Coatings Deposited Via Plasma Spray-Physical Vapor Deposition

Si-based ceramic matrix composites (CMCs) require environmental barrier coatings (EBCs) in combustion environments to avoid rapid material loss. Candidate EBC materials have use temperatures only marginally above current technology, but the addition of a columnar oxide topcoat can substantially increase the durability. Plasma Spray-Physical Vapor Deposition (PS-PVD) allows application of these multilayer EBCs in a single process. The PS-PVD technique is a unique method that combines conventional thermal spray and vapor phase methods, allowing for tailoring of thin, dense layers or columnar microstructures by varying deposition conditions. Multilayer coatings were deposited on CMC specimens and assessed for durability under high heat flux and load. Coated samples with surface temperatures ranging from 2400-2700F and 10 ksi loads using the high heat flux laser rigs at NASA Glenn. Coating morphology was characterized in the as-sprayed condition and after thermomechanical loading using electron microscopy and the phase structure was tracked using X-ray diffraction.

Plasma↗

NASA NTRS2015

NASA and ESA Collaboration on Hexavalent Chrome Alternatives - Pretreatments with Primers Screening Final Test Report

Hexavalent chromium (hex chrome or Cr(VI)) is a widely used element within applied coating systems because of its self-healing and corrosion-resistant properties. The replacement of hex chrome in the processing of aluminum for aviation and aerospace applications remains a goal of great significance. Aluminum is the major manufacturing material of structures and components in the space flight arena. The National Aeronautics and Space Administration (NASA) and the European Space Agency (ESA) are engaged in a collaborative effort to test and evaluate alternatives to hexavalent chromium containing corrosion coating systems. NASA and ESA share common risks related to material obsolescence associated with hexavalent chromium used in corrosion-resistant coatings. In the United States, Occupational Safety and Health Administration (OSHA) studies have concluded that hexavalent chromium is carcinogenic and poses significant risk to human health. On May 5, 2011, amendments to the Defense Federal Acquisition Regulation Supplement (DFARS) were issued in the Federal Register. Subpart 223.73 prohibits contracts from requiring hexavalent chromium in deliverables unless certain exceptions apply. Subpart 252.223-7008 provides the contract clause prohibiting contractors and subcontractors from using or delivering hexavalent chromium in a concentration greater than 0.1 percent by weight for all new contracts associated with supplies, maintenance and repair services, and construction materials. ESA faces its own increasingly stringent regulations within European directives such as Registration, Evaluation, Authorization and Restriction of Chemical (REACH) substances and the Restriction of Hazardous Substances Directive (RoHS) which have set a mid-2017 sunset date for hexavalent chromium. NASA and ESA continue to search for an alternative to hexavalent chromium in coatings applications that meet their performance requirements in corrosion protection, cost, operability, and health and safety, while typically specifying that performance must be equal to or greater than existing systems. The overall objective of the collaborative effort between NASA TEERM and ESA is to test and evaluate coating systems (pretreatments, pretreatments with primer, and pretreatments with primer and topcoat) as replacements for hexavalent chrome coatings in aerospace applications. This objective will be accomplished by testing promising coatings identified from previous NASA, ESA, Department of Defense (DOD), and other project experience. Additionally, several new materials will be analyzed according to ESA-identified specifications.

coating↗

NASA NTRS2017

NASA-STD-6001B Test 7: Impact of Test Methodology and Detection Advancements on the Obsolescence of Historical Offgas Data

NASA-STD-6001B states "all nonmetals tested in accordance with NASA-STD-6001 should be retested every 10 years or as required by the responsible program/project." The retesting of materials helps ensure the most accurate data are used in material selection. Manufacturer formulas and processes can change over time, sometimes without an update to product number and material information. Material performance in certain NASA-STD-6001 tests can be particularly vulnerable to these changes, such as material offgas (Test 7). In addition, Test 7 analysis techniques at NASA White Sands Test Facility were dramatically enhanced in the early 1990s, resulting in improved detection capabilities. Low level formaldehyde identification was improved again in 2004. Understanding the limitations in offgas analysis data prior to 1990 puts into question the validity and current applicability of that data. Case studies on Super Koropon (Registered trademark) and Aeroglaze (Registered trademark) topcoat highlight the importance of material retesting.

Buchanan, Vanessa D.↗

NASA NTRSDate not supplied

Varying Processing Parameters in the Development of Slurry-Based Oxide Bond Coat for Environmental Barrier Coatings

Silicon carbide (SiC)-based ceramic matrix composites (CMCs) are replacing nickel-base superalloys in some hot-section aircraft engine materials due to their lower density and higher working temperature. CMCs require an environmental barrier coating (EBC) for protection from corrosive combustion species. Current-generation EBCs consist of a rare earth silicate topcoat and a silicon bond coat; however, the relatively low melting point of silicon (1414°C) limits the upper use temperature of these coatings. To extend the capability of next-generation EBCs, an oxide-based bond coat capable of withstanding temperatures of up to 1480°C has been developed at NASA Glenn Research Center. In this study, the oxide-based bond coat was applied to monolithic SiC via a slurry coating process. Parameters including slurry particle size and viscosity were varied, and coating performance was evaluated after steam cycling at 1480°C. The effect of including different rare earth constituents in the bond coat was also explored.

R. I. Webster↗

NASA NTRSDate not supplied

Measuring the Wear and Abrasive Resistance of Air Plasma Sprayed Aluminum Oxide for Lunar Exploration

Lunar regolith, especially finer dust particles traveling at high velocities, can cause significant wear and abrasive damage to structural components that ensure a prolongated presence on the surface of the Moon. With the absence of an atmosphere and lower gravity than on Earth, regolith particles maintain high velocities at large distances from where they were generated, for example next to lunar landers. Wear-resistant ceramic and ceramic composite materials can improve the durability of spacecraft components during long missions on the Moon’s surface. Aluminum oxide coatings are lightweight, have multifunctional properties, and have high strength including high hardness and wear resistance. These properties can help improve the durability of structures used in space exploration. Air plasma sprayed (APS) aluminum oxide coatings have demonstrated the potential to protect critical structures. This study investigated the abrasive wear resistance of APS aluminum oxide coatings via Taber abrasion experiments. Taber abrasion offers the advantage of quantifying the abrasive wear behavior of particles with different shapes on a surface. In this work, an abrasive wheel made of silicon carbide was utilized to evaluate wear properties of specimens progressively over 5000 cycles. This experiment focused on testing two series of specimens to determine whether a bond coat composed of nickel, chromium, aluminum, and yttrium (NiCrAlY) improved the protective behavior of the APS aluminum oxide coating. The specimens varied in topcoat thickness and were made with and without an approximately 100 µm bond coat layer. The mass of the specimens was measured at 400 cycles, 800 cycles, 3800 cycles, and 5000 cycles. Increasing thickness was found to result in higher wear for samples with and without a bond coat. Increased mass loss in samples with a bond coat was observed indicating a need for further studies on the overall impact of the use of a bond coat on the protective behavior of the coatings. To continue designing wear resistant coatings for structural protection in space missions, the multifunctional properties of the APS aluminum oxide coating will be studied. Future experiments will determine whether the APS aluminum oxide coating can protect the structures from other aspects of the harsh space environment, such as extreme temperature variations and ionizing radiation.

aluminum oxide↗

NASA NTRSDate not supplied

Evaluation of Particle Degradation of a Ytterbium Disilicate Gas Turbine Coating in a Combustion Environment

Ytterbium disilicate (Yb2Si2O7) is a state-of-the-art topcoat material used in environmental barrier coatings (EBCs) to protect SiC-SiC composites from water vapor corrosion in gas turbine engines. However, it’s degradation by thermochemical and thermomechanical particle interactions may limit its use in next generation engine systems. Several static furnace tests have been performed on Yb2Si2O7 to elucidate methods of degradation, although dynamic testing in an engine-relevant environment has not been carried out. Ultimately, testing and evaluation of materials that incorporates all environmental damage modes will allow for an accurate assessment of long-term durability and operating lifetime. This work details the investigation of particle-induced erosion and corrosion of Yb2Si2O7 in NASA Glenn’s Erosion Burner Rig Facility. Coating durability was investigated as a function of test temperature, particle size, and deposition rate. Thermal cycling was also incorporated into testing to determine the interplay of heating/cooling cycles with particle degradation. Overall, these analyses will be used to determine coating robustness in an engine relevant environment.

Jamesa L Stokes↗

NASA NTRSDate not supplied

Evaluation of Particle Degradation of a Ytterbium Disilicate Gas Turbine Coating in a Combustion Environment

Jamesa L Stokes↗

NASA NTRSDate not supplied

Polymeric Materials Application and Testing for Space Missions

The EM41 Non-metallics polymers team performs polymeric materials screening, characterization, development, qualification, verification and validation testing for flight hardware and in-space applications. They perform insight, testing and application of polymeric materials for launch vehicles and space environments. Personnel have a deep understanding of the technologies associated with cryogenic insulation, high temperature thermal protection materials, paints, primers, coatings, and adhesive materials. Numerous TPS material characterization tests can also be performed by the Lab. The team has both internal and partner test capabilities to subject polymeric materials to Aerospace and Space environments Material properties, response and performance are tested within environments from the launch pad, through the launch environment and into space. A primary role of the team is to select materials and organize test regimen then analyze test results. Test regiment are established to confirm the materials meet the performance requirements levied by customers within the environments that are expected for the mission.

Thermal↗