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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 703 records · Page 39
All sourcesNASA NTRSDOE OSTI
DOE OSTI2011

Phase transformation and wear studies of plasma sprayed yttria stabilized zirconia coatings containing various mol% of yttria

Plasma sprayable grade zirconia powders doped with various mol% of yttria (0, 2, 3, 4, 6, 8 and 12 mol%) were synthesized by a chemical co-precipitation route. The coprecipitation conditions were adjusted such that the powders possessed good flowability in the as calcined condition and thus avoiding the agglomeration step like spray drying. Identical plasma spray parameters were used for plasma spraying all the powders on stainless steel plates. The powders and plasma sprayed coatings were characterized by X-ray diffractometry, Scanning Electron Microscopy and Raman spectroscopy. Zirconia powders are susceptible to phase transformations when subjected to very high temperatures during plasma spraying and XRD is insensitive to the presence of some non crystalline phases and hence Raman spectroscopy was used as an important tool. The microstructure of the plasma sprayed coatings showed a bimodal distribution containing fully melted and unmelted zones. The microhardness and wear resistance of the plasma sprayed coatings were determined. Among the plasma sprayed coatings, 3 mol% yttria stabilized zirconia coating containing pure tetragonal zirconia showed the highest wear resistance. - Research Highlights: {yields} Preparation plasma sprayable YSZ powders without any agglomeration process and plasma spraying {yields} Phase transformation studies of plasma sprayed YSZ coatings by XRD and Raman spectroscopy {yields} Microstructure of the plasma sprayed coatings exhibited bimodal distribution {yields} Plasma sprayed 3 mol% YSZ coating exhibited the highest wear resistance {yields} Higher wear resistance is due to the higher fracture toughness of tetragonal 3 mol% YSZ phase.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Revealing the nanostructure of calcium phosphate coatings using HRTEM/FIB techniques

Herein, we report on the micro- and nanostructure of the calcium phosphate coating produced by pulsed laser deposition (PLD), using focused ion beam (FIB) lamella sample preparation and transmission electron microscopy (TEM) as the characterization technique. The initial selected area electron diffraction (SAED) data demonstrated the presence of hydroxyapatite (HA) over any other possible calcium phosphate crystalline structure and the polycrystalline nature of the coating. Moreover, the SAED analyses showed clear textured ring patterns coherent with the presence of a preferred orientation in the HA nano-crystal growth. The SAED data also indicated that the coating appears to be textured in the 〈002〉 crystalline direction. Dark-field images obtained using 002 as the working reflection showed a clear oriented crystal growth in columns, from bottom to top. These columns have a peculiar arrangement of nano-crystals since, in some cases, the preferred orientation appears to start at a certain distance from the substrate. Direct d-spacing measurements on high-resolution TEM images provided further proof of the presence of an HA nano-crystal structure. The reported data may be of interest in the future to adjust the microstructure of the HA coatings. - Highlights: •The FIB lift-out technique allows a very site-specific sample preparation method for HRTEM analysis. •It also permits a fast assessment of the HA coating thickness and elemental composition (EDS). •The coatings exhibit a nano-crystalline nature, with a texturing effect along the 002 planes. •PLD is suitable for the production of crystalline c-axis oriented hydroxyapatite coatings. •The crystalline HA phase in the PLD coating is very similar to the present in bone.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Novel concept of functional oxide coatings providing enhanced oxidation resistance to Ni-based superalloys

Graphical abstract: - Highlights: • New concept for providing extended oxidation resistance to Ni-based superalloys. • Oxygen-defective nanostructured oxide coatings reduce the oxygen partial pressure at the substrate interface. • Pre-oxidation of the substrate during annealing with the formation of alpha-alumina. • Growth of CeAlO{sub 3} perovskite enhancing the adherence of the ceria top coat. • Microstructural stability of the coating system with no SRZ formation upon exposure. - Abstract: Aluminide-coated Ni-based superalloys are prone to microstructural instabilities during long-term exposure at high temperature with the growth of a secondary reaction zone (SRZ) detrimental from a mechanical viewpoint. This has been since overcome by the use of thermodynamically stable coatings (γ-Ni/γ′-Ni{sub 3}Al). However, additions of Pt and Hf are required to provide the formation of an exclusive α-Al{sub 2}O{sub 3} scale and improved oxidation resistance in cyclic and isothermal regimes. The present work proposes a new coating system that relies on the use of a superficial nanostructured functional oxide providing the establishment of a stable alumina while avoiding SRZ formation. Tailored oxygen-defective and multi-cracked coatings were designed for 2nd generation Ni-based superalloys and generated by electrosynthesis using a water-based solution. Cyclic oxidation tests were carried out at 1100 °C in air and the oxidation properties and the microstructural stability of the coating system were demonstrated.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Electrochemically reduced graphene oxide nanosheet coatings as solid lubricants in humid air

Highlights: • A facile, low cost and green approach to fabricate ERGO coatings is reported. • The feasibility of using ERGO coatings as solid lubricants is demonstrated. • ERGO coatings reduce copper’s COF to 1/6 and wear rate to more than 1/260. - Abstract: A facile, low cost and green approach to fabricating graphene nanosheet coatings is reported. It is composed of spraying graphene oxide (GO) suspension to form GO nanosheet coatings followed by a low voltage electrochemical reduction process. The tribological performance of the as-prepared electrochemically reduced graphene oxide (ERGO) nanosheet coatings on copper disk are evaluated by sliding against steel ball in humid air. The friction coefficient of copper is reduced to 1/6 its value, and its specific wear rate is reduced more than two orders of magnitude when copper disk is coated with ERGO nanosheet coatings. These improved tribological performance are attributed to the presence of ERGO nanosheets in the sliding interface of steel vs. copper friction pair. They not only provide easy shearing, reducing the friction coefficient, but also effectively suppress abrasive wear and adhesive wear, decreasing the wear rate of copper disk.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2022

Ultrasonic nondestructive evaluation of additively manufactured wear coatings

Here, this work pertains to the nondestructive evaluation of additively deposited coatings using ultrasound measurements. The specific objective was to evaluate using ultrasound surface wave measurements the quality of Stellite 21 coatings deposited on Inconel 718 substrates by the directed energy deposition (DED) additive manufacturing (AM) process. The surface wave speed and diffuse backscatter amplitude of the ultrasound waves were correlated with both cracking and warpage of the coating. This research is important, because, the integrity of DED-processed coatings currently requires a combination of destructive metallographic studies and X-ray computed tomography analysis, which are both expensive and time consuming. Instead of using a normal incidence configuration for the ultrasound measurements, the surface-wave approach allows the inspection of the near surface coating integrity. Three different frequencies were used to excite surface waves because each frequency has a different penetration depth. The signals obtained were used to quantify and compare the surface wave speed and surface wave-diffuse ultrasonic backscatter amplitude from five different DED-processed Stellite coated samples. Considering destructive metallurgical characterization as a reference, surface wave measurements were found to be effective for examining coating integrity. Further, the backscatter amplitude of the surface waves was correlated with the crack density and warpage. These flaws also change the stress state of the Stellite coating and consequently the surface wave propagation speed and its scattering behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Levelized cost of energy (LCOE) metric to characterize solar absorber coatings for the CSP industry

The contribution of each component of a power generation plant to the levelized cost of energy (LCOE) can be estimated and used to increase the power output while reducing system operation and maintenance costs. The LCOE is used in order to quantify solar receiver coating influence on the LCOE of solar power towers. Two new parameters are introduced: the absolute levelized cost of coating (LCOC) and the LCOC efficiency. Depending on the material properties, aging, costs, and temperature, the absolute LCOC enables quantifying the cost-effectiveness of absorber coatings, as well as finding optimal operating conditions. The absolute LCOC is investigated for different hypothetic coatings and is demonstrated on Pyromark 2500 paint. Results show that absorber coatings yield lower LCOE values in most cases, even at significant costs. Optimal reapplication intervals range from one to five years. At receiver temperatures greater than 700 °C, non-selective coatings are not always worthwhile while durable selective coatings consistently reduce the LCOE—up to 12% of the value obtained for an uncoated receiver. Moreover the absolute LCOC is a powerful tool to characterize and compare different coatings, not only considering their initial efficiencies but also including their durability.

14 SOLAR ENERGY↗
DOE OSTI2019

Infrared emissivity of copper-alloyed spinel black coatings for concentrated solar power systems

The directional spectral emissivities of four new copper-alloyed spinel coatings for concentrated solar power applications were measured up to 800 °C and compared Pyromark 2500 ® , deposited in the same conditions on Inconel 625. Reproducible results were found for all coatings at all temperatures, with similar spectral features at working temperatures. The temperature and angular dependences are related to the morphology and composition of the samples. The total hemispherical emissivity increases up to 400 °C for all coatings and then stabilizes, with similar values for most materials, except for the porous Cu 0.5 Cr 1.1 Mn 1.4 O 4 coating. This coating offers a reduced total hemispherical emissivity due to increased semitransparency at high angles arising from its porosity. This porosity is linked to an increase in both the solar absorptance and the emissivity in the normal direction due to enhanced light trapping, which means that this coating shows signs of directional selectivity. These results, together with the data dispersion reported for Pyromark, suggest that structural properties are key for the high-temperature emissivity of the coatings and highlight the importance of direct emissivity characterization. Combined with absorptance measurements, these emissivity measurements allow for accurate calculations of the high-temperature efficiencies of the coatings, which reach values up to 0.929.

14 SOLAR ENERGY↗
DOE OSTI2019

Amorphous and partially-amorphous metal coatings for corrosion resistance in molten chloride salt

In this study, amorphous metal coatings were developed to improve the corrosion resistance of structural alloys in molten salts for use as salt-facing materials in concentrating solar power (CSP) and molten salt reactor (MSR) applications. Three coatings were tested. One Fe-based, fully amorphous coating, and two Ni-based partially amorphous coatings. The candidate coatings were applied to samples made from Ni-based alloy 230, and exposed to KCl–MgCl 2 at 750 °C for 300 h in sealed Mo capsules. After exposure, uncoated alloy 230 samples were depleted in chromium near the surface, as measured by SEM-EDS. The attack had an average depth of 33 μm. Lastly, all three coatings performed well, showing no observable degradation during exposure, despite chromium contents between 20% and 40%. XRD and TEM measurements showed the coatings were fully crystallized after exposure, so the excellent corrosion resistance can likely be attributed to the recrystallized microstructure of the coatings.

14 SOLAR ENERGY↗
DOE OSTI2021

Hydrophobic versus Hydrophilic Interfacial Coatings on Silicon Nanoparticles Teach Us How to Design the Solid Electrolyte Interphase in Silicon-Based Li-Ion Battery Anodes

Herein, we evaluate the effect of covalently attached molecular coating hydrophobicity on the surface of the silicon nanoparticle (Si NP) active anode material for Li-ion batteries. The experiments are a means to identify the interfacial properties that help minimize electrochemical side reactions during cycling. Preformed coatings on the Si NP surfaces prior to electrode fabrication mimic the ionically conducting and electronically insulating properties of the solid electrolyte interphase (SEI). Hydrophilic oligomers such as polyethylene oxide (PEO) and other related structures are commonly identified as Li+-conducting components of the SEI. Here, we study the effect of such hydrophilic PEO versus hydrophobic alkyl molecular coatings on Si NP anode electrochemical performance. We also study the effect of the PEO oligomer length and the resulting effective thickness of the interfacial coating on the electrochemical performance. We find that PEO oligomers electrochemically isolate Si NPs when the PEO coating thickness approaches the electron tunneling distance of ~2.5 nm. Surprisingly, the thickness of the PEO-based coatings has a negligible effect on their ability to minimize electrochemical side reactions as measured by Coulombic efficiency. These results reveal how the interfacial coating on silicon anode materials should differ from an operando-formed SEI layer and discuss design strategies for an ideal interfacial active material coating based on these results.

25 ENERGY STORAGE↗
DOE OSTI2019

Advanced X-ray Scattering and Spectroscopy Characterization of an Antisoiling Coating for Solar Module Glass

When dust and other particulates accumulate on the surface of solar modules, the power output of these soiled modules is significantly reduced. To combat this issue, antisoiling coatings can be placed on the top glass surface of solar modules. While there exists some understanding of how antisoiling coatings reduce soiling and reflection losses, approaches to characterize the durability and stability of the chemistry and morphology of antisoiling PV glass module coatings and how they evolve in response to soiling interactions are currently underdeveloped. Here we present the use of small-angle X-ray scattering (SAXS), X-ray photoelectron spectroscopy (XPS), and X-ray absorption spectroscopy (XAS) as a methodology for studying the morphology and chemistry of pristine and soiled antisoiling coatings. Here, this work demonstrates the effectiveness of SAXS in observing coating morphology despite the presence of soil surface layers—a capability which sets it apart as a strong characterization tool for antisoiling coatings on PV glass. XPS and XAS are used as complementary techniques to characterize the evolution of coating surface chemistry before and after soiling. XAS is shown to detect subtle chemical changes in the coating surface that cannot be detected by XPS.

14 SOLAR ENERGY↗
DOE OSTI2015

Hydroxyapatite coating on biodegradable AZ31 and Mg-Ca alloys prepared by RF-magnetron sputtering

A thin film of hydroxyapatite (HA) was deposited on AZ31 and Mg-Ca alloys by using radio frequency (RF) magnetron sputtering. The thickness of the HA coating was determined to be 750 nm. The phase composition, microstructure, and surface morphology of the HA coatings were investigated using X-ray diffraction and scanning electron microscopy. In vitro degradation behaviour of the HA coated alloys was evaluated in simulated body fluid (SBF) and 3.5wt.% NaCl solution using electrochemical method. The coatings homogeneously covered the entire surface of the substrates. The coating structure corresponded to a nanostructured HA. The ultrathin coating significantly improved the degradation resistance of the alloy. Nanocrystalline HA coating significantly improved the corrosion resistance of the Mg-Ca and AZ31 magnesium alloys. The polarization resistance (Rp) of the coated Mg-Ca alloy was more than two-order of magnitude higher and the corrosion current density I{sub corr} reduced by ∼ 98% as compared to the base alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2016

TANGO1/cTAGE5 receptor as a polyvalent template for assembly of large COPII coats

The supramolecular cargo procollagen is loaded into coat protein complex II (COPII)-coated carriers at endoplasmic reticulum (ER) exit sites by the receptor molecule TANGO1/cTAGE5. Electron microscopy studies have identified a tubular carrier of suitable dimensions that is molded by a distinctive helical array of the COPII inner coat protein Sec23/24•Sar1; the helical arrangement is absent from canonical COPII-coated small vesicles. In this study, we combined X-ray crystallographic and biochemical analysis to characterize the association of TANGO1/cTAGE5 with COPII proteins. The affinity for Sec23 is concentrated in the proline-rich domains (PRDs) of TANGO1 and cTAGE5, but Sec23 recognizes merely a PPP motif. The PRDs contain repeated PPP motifs separated by proline-rich linkers, so a single TANGO1/cTAGE5 receptor can bind multiple copies of coat protein in a close-packed array. We propose that TANGO1/cTAGE5 promotes the accretion of inner coat proteins to the helical lattice. As a result, we show that PPP motifs in the outer coat protein Sec31 also bind to Sec23, suggesting that stepwise COPII coat assembly will ultimately displace TANGO1/cTAGE5 and compartmentalize its operation to the base of the growing COPII tubule.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Evaluating steam oxidation kinetics of environmental barrier coatings

Environmental barrier coatings (EBCs) are a commercially proven means of protecting SiC-based materials in gas turbine environments. However, there are little specific data in the literature on the impact of coatings like Yb 2 Si 2 O 7 on preventing accelerated SiO 2 growth in the presence of H 2 O. Quantification of reduced rates are necessary for evaluating and comparing EBC effectiveness and incorporation of silica growth rates into future EBC lifetime models. In this study, baseline kinetics of silica formation on bare Si and chemically vapor deposited (CVD) SiC in the 1250–1425 °C range were obtained via 100 h isothermal exposures in dry air and steam environments utilizing a SiC reaction tube to mitigate specimen volatility. An Arrhenius plot of the resulting rates was constructed, representing baseline minimum and maximum rates for Si and SiC oxidation at ambient pressure. Various EBC systems on CVD SiC substrates including air plasma sprayed (APS) EBCs with and without a Si bond coating and with surface roughening to enhance Yb 2 Si 2 O 7 adhesion were subjected to 1-h furnace cycle testing in air with 90vol%H 2 O at 1250–1350°C for up to 500 cycles. After exposure, silica formation rates were measured and compared to the baseline rates to assess EBC effectiveness, where EBC effectiveness is gauged as the propensity to reduce underlying rates of silica formation. With a Si bond coating, a ~180 µm Yb 2 Si 2 O 7 (YbDS) top coating reduced rates over the entire 1250°-1350°C range. Without a Si bond coating, ~60 µm (YbDS) coatings deposited directly onto CVD SiC exhibited poor adhesion, and had to be deposited onto substrates with enhanced roughness at 1350°C. Finally, while exhibiting good adhesion at 1350°C, overall the single layer YbDS coating exhibited a decreasing effectiveness from 1250° to 1350°C.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Low Group Delay Dispersion Optical Coating for Broad Bandwidth High Reflection at 45° Incidence, P Polarization of Femtosecond Pulses with 900 nm Center Wavelength

We describe an optical coating design suitable for broad bandwidth high reflection (BBHR) at 45° angle of incidence (AOI), P polarization (Ppol) of femtosecond (fs) laser pulses whose wavelengths range from 800 to 1000 nm. The design process is guided by quarter-wave HR coating properties. Our design must afford low group delay dispersion (GDD) for reflected light over the broad, 200 nm bandwidth in order to minimize temporal broadening of the fs pulses due to dispersive alteration of relative phases between their frequency components. The design should also be favorable to high laser-induced damage threshold (LIDT). We base the coating on TiO 2 /SiO 2 layer pairs produced by means of e-beam evaporation with ion-assisted deposition, and use OptiLayer Thin Film Software to explore designs starting with TiO 2 /SiO 2 layers having thicknesses in a reverse chirped arrangement. This approach led to a design with R > 99% from 800 to 1000 nm and GDD < 20 fs 2 from 843 to 949 nm (45° AOI, Ppol). The design’s GDD behaves in a smooth way, suitable for GDD compensation techniques, and its electric field intensities show promise for high LIDTs. Reflectivity and GDD measurements for the initial test coating indicate good performance of the BBHR design. Subsequent coating runs with improved process calibration produced two coatings whose HR bands satisfactorily meet the design goals. Lastly, for the sake of completeness, we summarize our previously reported transmission spectra and LIDT test results with 800 ps, 8 ps and 675 fs pulses for these two coatings, and present a table of the LIDT results we have for all of our TiO 2 /SiO 2 BBHR coatings, showing the trends with test laser pulse duration from the ns to sub-ps regimes.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Hydrothermal Corrosion of Coatings on Silicon Carbide in Boiling Water Reactor Conditions

SiC/SiC ceramic matrix composites are an attractive material for use as accident tolerant fuel cladding. However, despite its resistance to corrosion in high-temperature steam, SiC is known to dissolve in high-temperature water, necessitating the use of corrosion-resistant coatings. Here, samples were exposed in 288°C water with 2 ppmw dissolved oxygen to simulate boiling water reactor (BWR) normal water chemistry (NWC) and 288°C water with 150 ppbw dissolved hydrogen to simulate BWR hydrogen water chemistry. Several candidate coatings were tested: Cr, CrN, TiN, and ZrN. All coatings were applied by physical vapor deposition onto chemical vapor deposition SiC (CVD-SiC) substrates. Two uncoated SiC/SiC variants were also exposed and degraded more rapidly compared to CVD-SiC, especially in NWC. Cr and CrN coated specimens were found to have low mass change, suggesting they are promising candidate coatings. Lastly, TiN coatings were found to oxidize rapidly, suggesting that coatings would fully oxidize during service in BWR environments. ZrN coatings dissolved completely during exposure.

36 MATERIALS SCIENCE↗
NASA NTRS1996

Evaluation of Oxidation Damage in Thermal Barrier Coating Systems

A method based on the technique of dilatometry has been established to quantitatively evaluate the interfacial damage due to the oxidation in a thermal barrier coating system. Strain isolation and adhesion coefficients have been proposed to characterize the thermal barrier coating (TBC) performance based on its thermal expansion behavior. It has been found that, for a thermal barrier coating system consisting of ZrO2-8%Y2O3/FeCrAlY/4140 steel substrate, the oxidation of the bond coat and substrate significantly reduced the ceramic coating adherence, as inferred from the dilatometry measurements. The in-situ thermal expansion measurements under 30 deg C to 700 deg C thermal cycling in air showed that the adhesion coefficient, A(sub i) decreased by 25% during the first 35 oxidation cycles. Metallography showed that delamination occurred at both the ceramic/bond coat and bond coat/substrate interfaces. In addition, the strain isolation effect has been improved by increasing the FeCrAlY bond coat thickness. The strain isolation coefficient, Si, increased from about 0.04 to 0.25, as the bond coat thickness changed from 0.1 mm to 1.0 mm. It may be possible to design optimum values of strain isolation and interface adhesion coefficients to achieve the best TBC performance.

THERMAL PROPERTIES↗
NASA NTRS2013

Absolute Thickness Measurements on Coatings Without Prior Knowledge of Material Properties Using Terahertz Energy

This study investigates the applicability of a novel noncontact single-sided terahertz electromagnetic measurement method for measuring thickness in dielectric coating systems having either dielectric or conductive substrate materials. The method does not require knowledge of the velocity of terahertz waves in the coating material. The dielectric coatings ranged from approximately 300 to 1400 m in thickness. First, the terahertz method was validated on a bulk dielectric sample to determine its ability to precisely measure thickness and density variation. Then, the method was studied on simulated coating systems. One simulated coating consisted of layered thin paper samples of varying thicknesses on a ceramic substrate. Another simulated coating system consisted of adhesive-backed Teflon adhered to conducting and dielectric substrates. Alumina samples that were coated with a ceramic adhesive layer were also investigated. Finally, the method was studied for thickness measurement of actual thermal barrier coatings (TBC) on ceramic substrates. The unique aspects and limitations of this method for thickness measurements are discussed.

Nondestructive evaluation↗
NASA NTRS2016

Environmental Barrier Coating Development for SiC/SiC Ceramic Matrix Composites: Recent Advances and Future Directions

This presentation briefly reviews the SiC/SiC major environmental and environment-fatigue degradations encountered in simulated turbine combustion environments, and thus NASA environmental barrier coating system evolution for protecting the SiC/SiC Ceramic Matrix Composites for meeting the engine performance requirements. The presentation will review several generations of NASA EBC materials systems, EBC-CMC component system technologies for SiC/SiC ceramic matrix composite combustors and turbine airfoils, highlighting the temperature capability and durability improvements in simulated engine high heat flux, high pressure, high velocity, and with mechanical creep and fatigue loading conditions. This paper will also focus on the performance requirements and design considerations of environmental barrier coatings for next generation turbine engine applications. The current development emphasis is placed on advanced NASA candidate environmental barrier coating systems for SiC/SiC CMCs, their performance benefits and design limitations in long-term operation and combustion environments. The efforts have been also directed to developing prime-reliant, self-healing 2700F EBC bond coat; and high stability, lower thermal conductivity, and durable EBC top coats. Major technical barriers in developing environmental barrier coating systems, the coating integrations with next generation CMCs having the improved environmental stability, erosion-impact resistance, and long-term fatigue-environment system durability performance will be described. The research and development opportunities for turbine engine environmental barrier coating systems by utilizing improved compositions, state-of-the-art processing methods, and simulated environment testing and durability modeling will be briefly discussed.

Environmental Barrier Coatings↗