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At least 595 records · Page 33
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Advanced low-cost intermetallic coatings for molten salt pump impeller. Final report

1.0 INTRODUCTION The use of solar energy to produce steam for the generation of electricity is an established technology, with multiple designs for concentrating solar power (CSP) steam generators available commercially and a number of such units currently operating. As part of the effort to improve the overall efficiency of this technology, designers have developed thermal energy storage (TES) mechanisms that employ molten salt to capture a portion of the solar energy available during the day-time hours and make that energy available for steam generation during periods when the sun’s energy is not available. In current TES systems, nitrate salts are used extensively as the medium of energy exchange. However, due to the chemical instability of these salts at temperatures above 600ºC, they are not being considered for use in the next more efficient generation of CSP plants, in which the energy exchange fluids will be required to operate in the range 600ºC to 800ºC. At these higher temperatures, molten chloride salts, such as KCl-MgCl2, are viewed as promising alternatives to the nitrate salts, but, of course, these chloride-based salts are highly corrosive to the engineering alloys commonly used in the construction of pressure vessels, heat exchangers, pumps and piping at high temperatures. Hence, a solution to the problem of material degradation is essential if the next generation of CSP plants is to be commercially viable (Ref 1). In order to effectively address the problem of molten chloride salt corrosion at high temperatures (≥ 750ºC) and thereby to reduce the cost of molten salt tanks and related apparatus, various options have been considered, with one of the most promising being an innovative coatings system developed and applied onto low alloy ferritic or austenitic stainless material. Development of such a coating system would reduce the capital costs of thermal energy storage (TES) and increase the overall efficiency of the concentrating solar power (CSP) system. Although high strength nickel base alloys are well suited for many high temperature applications, they have significant limitations when exposed to molten chloride salt conditions and they are very expensive. Monolithic materials such as the austenitic stainless steels (e.g., SS310 and SS347) and the more common nickel base alloys (e.g., IN625 and IN800H) have exhibited high corrosion rates in molten chloride salt environments (Ref1). Molten salt corrosion of IN625 in salts containing chlorides showed a catastrophic corrosion rate of 1.111”/year at 800ºC (Ref1). Hence, an innovative coatings solution to mitigate molten chloride salt corrosion is needed. Of the many coating techniques available in the market, no one technique appears to be capable of producing effective protection from molten salt corrosion at a relatively low cost. There are thermal spray coating techniques, in particular the twin wire-arc technology, that are attractive when considering the coating of large molten salt tanks because the coatings application rate is high, the overall application cost is low and repairs to the coating can readily be made either in the shop or in the field. However, the twin wire arc coating materials currently available in the market have certain inherent limitations, including porosity and mechanical bonding to the substrate, which limit their effectiveness in providing protection against molten chloride salt corrosion at high temperatures. What is required is an approach that combines the economy and versatility of thermal spray wire-arc technology with the superior resistance of advanced alloys to effectively combat molten chloride salt corrosion at elevated temperatures. Applied Thermal Coatings, Inc. (ATC) has investigated an innovative coatings technology to produce dual layer cermet/ceramic coatings that will be dense and impervious to any corrosive molten salts/fluids, thereby resisting the effects of molten salt corrosion. Development of coatings using this technology will make it possible to fabricate the molten salt systems using a relatively low-cost base material, which will reduce the overall cost of the power generating system and enhance the commercial viability of solar power. 2.0 PROJECT OVERVIEW Of the coating technologies available for the production of a cost-effective method of protection from the effects of high-temperature chloride attack, there are two that offer specific advantages for the CSP/TES application, particularly when used in a way that effectively complements the strengths of each coating method. The first of these is electroless nickel plating, through which a nickel-rich layer is produced on the surface of a component through chemical reduction. The second coating technology is aluminizing, in which aluminum is diffused into the surface of a component and, depending on the composition of the substrate, aluminides are formed. The objective of this project has been to demonstrate the feasibility of a low- cost coating for the protection of pump impellers used for the inductive transport of molten salts. Initial interest focused on an inter-metallic nickel aluminide coating and subsequently, for economic reasons, consideration also was given to a coating composed of iron aluminides. Applying such coatings to low alloy or austenitic stainless-steel substrates will provide the superior resistance to molten chloride salt corrosion and blade tip erosion that normally can be achieved only through the use of more highly alloyed – and, therefore, more expensive - nickel-base materials and it will do so at a substantially lower cost. The coating systems evaluated were designed to take advantage either of the combined strengths of the electroless nickel plating process and the aluminizing process to produce a nickel-aluminide intermetallic coating or to rely solely on the aluminizing process to produce, in conjunction with iron from the substrate, a protective layer consisting of iron aluminides. With respect to the nickel aluminide protection, this has been achieved by first depositing a layer of nickel-rich alloy onto an austenitic stainless substrate using the electroless nickel plating process and then aluminizing the nickel- coated surface to produce the nickel aluminide coating. With respect to the iron aluminide protection, this has been achieved by aluminizing bare austenitic stainless steel. Testing has supported the conclusion that the developed coatings will resist attack by molten chloride salts at high temperatures (550°C to 750°C) and have sufficient hardness to resist blade tip erosion.The steps taken to develop either a low-cost intermetallic nickel aluminide coating using electroless nickel plating and aluminizing or a low-cost iron aluminide coating using aluminizing only, and to demonstrate the quality of the coatings and their effectiveness against molten chloride salt corrosion and erosion at high temperatures (≤ 750ºC) have been as follows: 1. Design of the optimum electroless nickel plating and aluminizing mixtures using advanced thermodynamic analysis; 2. Development of processing parameters for the electroless nickel plating and aluminizing processes, to be used either together or separately; 3. Production of specimens coated using the designated electroless nickel plating process; 4. Production of samples with intermetallic nickel aluminide coating or iron aluminide coating; 5. Investigation of the performance of the intermetallic nickel aluminide coating and the iron aluminide coating when subjected to molten chloride salts corrosion at high temperatures (≥ 750ºC); and, 6. Metallurgical characterization of the microstructure of the coatings, both prior to and after exposure to molten salt environments at elevated temperatures.

14 SOLAR ENERGY↗
NASA NTRS1994

Capacitive Measurement Of Coating Thickness On Carbon Fibers

Technique for gauging coating thickness during prepreg processing of carbon fibers developed. Technique based on measurement of capacitance of cylindrical condenser through which bundle of prepregged fibers passed axially. Empirical results indicate capacitance linearly related to thickness of polymer coat on fibers in bundle. Capacitive transducer used successfully to measure thickness of polymer coats on several test bundles of fibers under static conditions.

Eftekhari, Abe↗
NASA NTRS2011

Phase Stability and Thermal Conductivity of Composite Environmental Barrier Coatings on SiC/SiC Ceramic Matrix Composites

Advanced environmental barrier coatings are being developed to protect SiC/SiC ceramic matrix composites in harsh combustion environments. The current coating development emphasis has been placed on the significantly improved cyclic durability and combustion environment stability in high-heat-flux and high velocity gas turbine engine environments. Environmental barrier coating systems based on hafnia (HfO2) and ytterbium silicate, HfO2-Si nano-composite bond coat systems have been processed and their stability and thermal conductivity behavior have been evaluated in simulated turbine environments. The incorporation of Silicon Carbide Nanotubes (SiCNT) into high stability (HfO2) and/or HfO2-silicon composite bond coats, along with ZrO2, HfO2 and rare earth silicate composite top coat systems, showed promise as excellent environmental barriers to protect the SiC/SiC ceramic matrix composites.

Benkel, Samantha↗
NASA NTRS1977

Research directed toward improved echelles for the ultraviolet

Low frequency gratings obtainable with present technology, can meet the grating-efficiency design goals for potential space telescope spectrographs. Gratings made with changes in the three specific parameters: the ruling tool profile, the coating material, and the lubricants used during the ruling process were compared. A series of coatings and test gratings were fabricated and were examined for surface smoothness with a Nomarski differential interference microscope and an electron microsocope. Photomicrographs were obtained to show the difference in smoothness of the various coatings and rulings. Efficiency measurements were made for those test rulings that showed good groove characteristics: smoothness, proper ruling depth, and absence of defects (e.g., streaks, feathered edges and rough sides). Higher grating efficiency should be correlated with the degree of smoothness of both the coating and the grating groove.

Source record↗
NASA NTRS1997

Gold Coating

Epner Technology Inc. responded to a need from Goddard Space Flight Center for the ultimate in electroplated reflectivity needed for the Mars Global Surveyor Mars Orbiter Laser Altimeter (MOLA). Made of beryllium, the MOLA mirror was coated by Epner Technology Laser Gold process, specially improved for the project. Improved Laser Gold- coated reflectors have found use in an epitaxial reactor built for a large semiconductor manufacturer as well as the waveguide in Braun-Thermoscan tympanic thermometer and lasing cavities in various surgical instruments.

Source record↗
DOE OSTI2026

Industrial deposition of wavelength-shifting films for liquid argon photon detection systems

The Deep Underground Neutrino Experiment (DUNE) Phase-II Far Detector is considering an approximately 2000 m 2 photon detection system to achieve a target mean light yield of 180 PE/MeV. Meeting this requirement demands scalable, cost-effective, and high-quality wavelength-shifter (WLS) coatings capable of converting 127 nm liquid-argon scintillation light into visible photons with controlled and reproducible optical performance. We report on the successful realization of an industrial physical vapor deposition (PVD) process forp-terphenyl (pTP) coatings, adapted from vacuum deposition techniques developed for OLED display manufacturing, to produce uniform WLS layers on large-area inorganic substrates, a task traditionally challenged by adhesion and uniformity issues at organic-inorganic interfaces. Surface characterization by profilometry and spectroscopic measurements demonstrates edge-region thickness variation below 10% and emission spectra consistent with high-quality pTP reference samples. The industrial process demonstrates reproducibility, scalability, and significantly reduced production time compared to laboratory-based methods, while maintaining optical characteristics consistent with established pTP reference samples. These results establish a viable pathway for mass production of high-performance pTP coatings for DUNE FD3 and future neutrino experiments, from a coating manufacturing and process standpoint. Detector-level performance validation, including quantitative VUV conversion efficiency measurements at 127 nm, is identified as future work.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Accelerated corrosion testing of cold spray coatings on 304L in chloride environments

Cold spray is an advanced metal manufacturing technique applied across many fields for a wide range of functions. Low heat input and compressive stresses induced into the substrate by the cold spray process makes it a promising choice for protective corrosion resistant coatings. One potential application for cold spray is as a protective coating against corrosion for spent nuclear fuel (SNF) interim dry storage canisters. As these canisters are currently stored at interim storage locations longer than originally intended, chloride induced stress corrosion cracking has been identified as a high priority knowledge gap, specifically with respect to prolonging or extending canister lifetimes ( Teague et al., 2019 ). The high deployability of cold spray, for which nozzles have been developed for application in constrained spaces, in conjunction with beneficial properties inherent to cold spray makes this a good candidate for a corrosion protection coating on SNF canisters. This work explores a pathway to rapidly down-select cold spray coatings for canisters by focusing on the corrosion properties. Specifically, this study examines the corrosion protection abilities of nickel and nickel-based alloy cold spray coatings on 304 L stainless steel in chloride rich environments through electrochemical scans and ferric chloride pitting tests (ASTM G48 Method A). It was shown that the porosity of the coating, the processing gas, material selection, and deformation in the substrate all impact the corrosion behavior of cold spray coatings and are areas where optimization could reduce potential materials degradation, enabling enhanced coatings development.

Karasz, Erin K.↗
NASA NTRS1981

Sputtered protective coatings for die casting dies

Three experimental research designs investigating candidate materials and processes involved in protective die surface coating procedures by sputter deposition, using ion beam technologies, are discussed. Various pre-test results show that none of the coatings remained completely intact for 15,000 test cycles. The longest lifetime was observed for coatings such as tungsten, platinum, and molybdenum which reduced thermal fatigue, but exhibited oxidation and suppressed crack initiation only as long as the coating did not fracture. Final test results confirmed earlier findings and coatings with Pt and W proved to be the candidate materials to be used on a die surface to increase die life. In the W-coated specimens, which remained intact on the surface after thermal fatigue testing, no oxidation was found under the coating, although a few cracks formed on the surface where the coating broke down. Further research is planned.

Mirtich, M. J.↗
NASA NTRS1981

Large-area silicon-on-ceramic substrates for low-cost solar cells

The SCIM (Silicon-Coating-By-Inverted Meniscus) process to produce SOC (silicon-on-ceramic) substrates has been investigated for various growth conditions and substrate velocities (4-30 cm/min). Slotted mullite-based substrates (10-cm-wide by 100-cm-long) have been coated with smooth, continuous silicon layers, with thicknesses in the range from 100 to 300 microns. Thermal stress (which can be a problem at low velocities) is prevented by proper thermal design. The highest SCIM-coated SOC cell efficiencies to date are 7.5% (AM1, AR) as compared to 10.5% (AM1, AR) for dip-coated SOC cells. Substantial improvements in cell efficiency are expected when high purity parts are installed in the SCIM-coater.

Schuldt, S. B.↗
NASA NTRS1997

Alternative Processing Method Leads to Stronger Sapphire-Reinforced Alumina Composites

The development of advanced engines for aerospace applications depends on the availability of strong, tough materials that can withstand increasingly higher temperatures under oxidizing conditions. The need for such materials led to the study of an oxide-based composite composed of an alumina matrix reinforced with zirconia-coated sapphire fibers. Because the nonbrittle behavior of this system depends on the interface and its ability to prevent fiber-to-matrix bonding and reduce interfacial shear stress, the microstructure of the zirconia must be carefully controlled during both coating application and composite processing. When it was both porous and unstabilized, zirconia (which does not react easily with alumina) was found to be the most effective material tested in reducing interfacial shear strength between the fiber and matrix.

Jaskowiak, Martha H.↗
DOE OSTI2019

Atomic Layer-Deposited Al{sub 2}O{sub 3} Interlayer for Improved Tribological and Anti-corrosion Properties of TiN Hard Coating on 316L Stainless Steel

A dense Al{sub 2}O{sub 3} interlayer was inserted into TiN to enhance the tribological and anti-corrosion properties of TiN hard coating via a hybrid process of magnetron sputtering and atomic layer deposition (ALD). The influence of the ALD-Al{sub 2}O{sub 3} layer on the microstructure, mechanical, tribological and anti-corrosion properties of TiN was examined. The TiN-Al{sub 2}O{sub 3} coating exhibits low friction coefficient and specific wear rate, due to the structure change and columnar refinement caused by the addition of amorphous ALD-Al{sub 2}O{sub 3} interlay which improves the mechanical properties of hard coating. The improved corrosion properties of TiN are attributed to the fact that the insulating ALD-Al{sub 2}O{sub 3} used as a sealing layer can prevent the corrosive chlorine ions migrating into the lower TiN layer and block the charge transport in coatings. Moreover, raising the insertion position of ALD-Al{sub 2}O{sub 3} layer away from the steel substrate results in a further increase in the anti-corrosion property of TiN-Al{sub 2}O{sub 3} composite coating.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Control of Ionomer Distribution and Porosity in Roll-to-Roll Coated Fuel Cell Catalyst Layers

As fuel cells transition from the laboratory to industrial production for vehicles and other applications there is a need to understand how manufacturing processes impact the properties and, ultimately, the performance of materials. Roll-to-roll coating enables processing at meters per second speeds with physics that can be quite different from common laboratory coating methods. In this work, we have focused on the coating of catalyst layers for proton exchange membrane fuel cells. Commonly, laboratory samples are prepared using spray coating or hand painting, which effectively coat many thin layers to achieve the desired catalyst layer thickness. This creates catalyst layers with uniform distributions of materials throughout the thickness of the full catalyst layer. In contrast, roll-to-roll methods, like slot die and gravure, coat the catalyst layer as a single wet film. As the film dries, ink constituents are able to segregate, leading to a heterogeneous distribution of materials through the thickness of the layer. It is also known that solvent and drying rate can affect the morphology of the catalyst layer. Thus, there is a need to understand how ink formulation and the drying process influence the distribution of materials and catalyst layer morphology. Here, we have explored the influence of solvent and drying rate on morphology of roll-to-roll coated catalyst layers. We show the development of the Kelvin probe method as a rapid screening technique for qualitative analysis of ionomer distribution. We also utilize nano X-ray computed tomography to visualize electrode structure and to quantify particle-size and pore-size distributions, thickness-dependent ionomer distribution, tortuosity, and effective transport properties. We find that solvent has a strong influence on ionomer distribution, with less of an effect on porosity. Conversely, drying temperature has a strong influence on porosity, but less influence on ionomer distribution. Finally, we utilize in situ fuel cell performance testing and other advanced diagnostics to quantify the impact of catalyst layer properties on fuel cell performance and demonstrate that roll-to-roll coating is capable of coating high performance catalyst layers in multi-meter lengths. have focused on the coating of catalyst layers for proton exchange membrane fuel cells. Commonly, laboratory samples are prepared using spray coating or hand painting, which effectively coat many thin layers to achieve the desired catalyst layer thickness. This creates catalyst layers with uniform distributions of materials throughout the thickness of the full catalyst layer. In contrast, roll-to-roll methods, like slot die and gravure, coat the catalyst layer as a single wet film. As the film dries, ink constituents are able to segregate, leading to a heterogeneous distribution of materials through the thickness of the layer. It is also known that solvent and drying rate can affect the morphology of the catalyst layer. Thus, there is a need to understand how ink formulation and the drying process influence the distribution of materials and catalyst layer morphology. Here, we have explored the influence of solvent and drying rate on morphology of roll-to-roll coated catalyst layers. We show the development of the Kelvin probe method as a rapid screening technique for qualitative analysis of ionomer distribution. We also utilize nano X-ray computed tomography to visualize electrode structure and to quantify particle-size and pore-size distributions, thickness-dependent ionomer distribution, tortuosity, and effective transport properties. We find that solvent has a strong influence on ionomer distribution, with less of an effect on porosity. Conversely, drying temperature has a strong influence on porosity, but less influence on ionomer distribution. Finally, we utilize in situ fuel cell performance testing and other advanced diagnostics to quantify the impact of catalyst layer properties on fuel cell performance and demonstrate that roll-to-roll coating is capable of coating high performance catalyst layers in multi-meter lengths.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS1989

Space station protective coating development

A generic list of Space Station surfaces and candidate material types is provided. Environmental exposures and performance requirements for the different Space Station surfaces are listed. Coating materials and the processing required to produce a viable system, and appropriate environmental simulation test facilities are being developed. Mass loss data from the original version of the atomic oxygen test chamber and the improved facility; additional environmental exposures performed on candidate materials; and materials properties measurements on candidate coatings to determine the effects of the exposures are discussed. Methodologies of production, and coating materials, used to produce the large scale demonstration articles are described. The electronic data base developed for the contract is also described. The test chamber to be used for exposure of materials to atomic oxygen was built.

Pippin, H. G.↗
DOE OSTI2019

Effect of Micro-Arc Oxidation on Friction–Wear Behavior of Cold-Sprayed Al Coating in 3.5 wt.% NaCl Solution

A cold-sprayed Al coating on S355 steel was processed using micro-arc oxidation (MAO). The friction–wear behavior of the obtained coating in 3.5 wt.% NaCl solution was investigated using a wear test, and the effects of wear loads and speeds on the friction–wear performances of the MAO coating were analyzed. The results show that the MAO coating is primarily composed of Al{sub 2}O{sub 3}, with no other phases. The average coefficients of friction (COFs) of the MAO coating under the wear loads of 0.5, 1.0 and 1.5 N are 0.48, 0.62, and 0.76, respectively, and the corresponding wear rates are 4.20 × 10{sup −5}, 4.21 × 10{sup −5} and 4.27 × 10{sup −5} mm{sup 3} m{sup −1} N{sup −1}, exhibiting the higher wear resistance. Under the wear load of 1.0 N, the average COFs of the MAO coating at the wear speeds of 5.0, 6.7 and 8.3 Hz are 0.32, 0.45 and 0.62, respectively; and the corresponding wear rates are 3.21 × 10{sup −5}, 3.49 × 10{sup −5} and 4.21 × 10{sup −5} mm{sup 3} m N{sup −1}, respectively, which increase with the increase in wear speeds. The wear mechanism of the MAO coating is fatigue wear and abrasive wear, and its wear resistance was better than the cold-sprayed Al coating.

36 MATERIALS SCIENCE↗
NASA NTRS2008

Low-Cost, Large C-SiC Blisk Fabrication

C-SiC composites offer unique properties for propulsion applications. However, fabrication of low-cost, thick, large scale C-SiC disk for integrally bladed disk (blisk) applications has not been established yet. MER has demonstrated a new process to address this issue. Polymer-based processing was employed for interfacial coatings, consolidation and densification. Up to 40" O.C., 2" thick C-SiC composite processing was established, yielding in excess of 1.8 g/cu cm density. Computer tomography (CT) scans on the 40" O.D., 2" thick C-SiC disk showed no visible delamination, and good density uniformity. Stress-rupture testing in air was conducted at 2200 F, 2400 F and 2550 F.

Kowbel, W.↗