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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1984

Thermal barrier coating life prediction model development

Thermal barrier coatings (TBCs) for turbine airfoils in high-performance engines represent an advanced materials technology that has both performance and durability benefits. In order to achieve these benefits, however, the TBC system must be reliable. Prediction of the lives of two types of strain-tolerant and oxidation-resistant TBC systems that are produced by commercial coating suppliers to the gas turbine industry is examined. The plasma sprayed TBC system, composed of a low-pressure plasma spray (LPPS) applied oxidation resistant NiCrAlY bond coating and an air-plasma-sprayed yttria (8 percent) partially stabilized zirconia insulative layer is applied by both Chromalloy and Klock. The second type of TBC is applied by the electron beam-physical vapor depositon (EB-PVD) process by Temescal.

Strangman, T. E.↗
NASA NTRS1986

Thermal barrier coating life-prediction model development

The program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant thermal barrier coating (TBC) systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma-spray (LPPS) or an argon shrouded plasma-spray (ASPS) applied oxidation resistant NiCrAlY or (CoNiCrAlY) bond coating and an air-plasma-sprayed yttria partially stabilized zirconia insulative layer, is applied by both Chromalloy, Klock, and Union Carbide. The second type of TBS is applied by the electron beam-physical vapor deposition (EB-PVD) process by Temescal. The second year of the program was focused on specimen procurement, TMC system characterization, nondestructive evaluation methods, life prediction model development, and TFE731 engine testing of thermal barrier coated blades. Materials testing is approaching completion. Thermomechanical characterization of the TBC systems, with toughness, and spalling strain tests, was completed. Thermochemical testing is approximately two-thirds complete. Preliminary materials life models for the bond coating oxidation and zirconia sintering failure modes were developed. Integration of these life models with airfoil component analysis methods is in progress. Testing of high pressure turbine blades coated with the program TBS systems is in progress in a TFE731 turbofan engine. Eddy current technology feasibility was established with respect to nondestructively measuring zirconia layer thickness of a TBC system.

Strangman, T. E.↗
NASA NTRS1986

Thermal barrier coating life prediction model development

Thermal barrier coatings (TBCs) for turbine airfoils in high-performance engines represent an advanced materials technology with both performance and durability benefits. The foremost TBC benefit is the reduction of heat transferred into air-cooled components, which yields performance and durability benefits. This program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant TBC systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma-spray (LPPS) or an argon shrouded plasma-spray (ASPS) applied oxidation resistant NiCrAlY (or CoNiCrAlY) bond coating and an air-plasma-sprayed yttria (8 percent) partially stabilized zirconia insulative layer, is applied by Chromalloy, Klock, and Union Carbide. The second type of TBC is applied by the electron beam-physical vapor deposition (EB-PVD) process by Temescal.

T E Strangman↗
NASA NTRS1988

Adhesion scratch testing - A round-robin experiment

Six sets of samples, TiN coated by chemical or physical vapor deposition methods (CVD or PVD) onto cemented carbide or high-speed steel (HSS), and TiC coated by CVD onto cemented carbide have been scratch tested using three types of commercially available scratch adhesion tester. With exception of one cemented carbide set, the reproducibility of the critical loads for any given set with a given stylus is excellent, about + or - 5 percent, and is about + or - 20 percent for different styli. Any differences in critical loads recorded for any given sample set can be attributed to the condition of the stylus (clean, new, etc.), the instrument used, the stylus itself (friction coefficient, etc.), and the sample set itself. One CVD set showed remarkably large differences in critical loads for different styli, which is thought to be related to a mechanical interaction between stylus and coating which is enhanced by a plastic deformability in the film related to the coating microstructure. The critical load for TiN on HSS increases with coating thickness, and differences in frictional conditions led to a systematic variation in the critical loads depending on the stylus used.

Perry, A. J.↗
NASA NTRS1991

Novel applications for TAZ-8A

Recent needs in the non-aerospace industrial sector have revitalized interest in high performance alloys. TAZ-8A has a combination of properties that makes it unique: a high temperature strength, oxidation resistance, abrasion resistance, and exceptional thermal shock resistance. The major drawback for the utilization of this alloy is the relatively high cost compared with the more common iron base alloys. Reduced material consumption and lower costs are possible by using coatings of TAZ-8A on a low cost substrate. Coatings were applied using plasma spray techniques developed by NASA as well as modified plasma vapor deposition (PVD) techniques.

Riddlebaugh, Stephen M.↗
NASA NTRS1991

Chemical vapor deposition coatings for oxidation protection of titanium alloys

Results of an experimental investigation of the oxidation protection afforded to Ti-14Al-21Nb and Ti-14Al-23Nb-2V titanium aluminides and Ti-17Mo-3Al-3Nb titanium alloy by aluminum-boron-silicon and boron-silicon coatings are presented. These coatings are applied by a combination of physical vapor deposition (PVD) and chemical vapor deposition (CVD) processes. The former is for the application of aluminum, and the latter is for codeposition of boron and silicon. Coating thickness is in the range of 2 to 7 microns, and coating weights are 0.6 to 2.0 mg/sq cm. Oxidation testing was performed in air at temperatures to 1255 K in both static and hypersonic flow environments. The degree of oxidation protection provided by the coatings is determined from weight change measurements made during the testing and post test compositional analyses. Temperature-dependent total normal emittance data are also presented for four coating/substrate combinations. Both types of coatings provided excellent oxidation protection for the exposure conditions of this investigation. Total normal emittances were greater than 0.80 in all cases.

Cunnington, G. R.↗
NASA NTRS1995

Mechanical properties testing and results for thermal barrier coatings

Thermal Barrier Coatings (TBC's) provide a significant challenge in the evaluation of their mechanical properties in ways that provide data that is not specimen dependent. The paper reviews various developments of the principal author over the past several years for both plasma sprayed and physical vapor deposited (PVD) materials, as well as new data on the fatigue behavior of one material system. The test methods that have been employed address tensile and compressive modulus and ultimate strength, tensile and compressive fatigue strength, and interfacial strength. This testing is now underway. Property testing is especially difficult for TBC's owing to the limitation on fabrication thickness of the coating. Bending tests are not used as these tests do not provide sufficiently uniform states of strain for property evaluations. Test specimens with uniform states of axial stress have been devised for each material system. The results show that the material property results between various experimenters and experimental methods are not yet consistent. However, the results provide critical design data at a suitable level of accuracy for life prediction. The paper will review both tensile and compressive mechanical testing of uniaxial specimens showing property dependencies on material density and temperatures for both material systems. Successful test results for both tensile and compressive fatigue loadings will be given. The test data shows that the fatigue strength of the TBC's is highly stress dependent in both loading conditions and is likely to depend on stress range and not mean stress. The fatigue strength of the plasma sprayed TBC's appears to increase with elevated temperatures in a range of temperatures below the creep activation temperature for the materials. The plasma sprayed TBC materials have been confirmed to have cyclic hysteresis at all temperature levels down to room temperature. Limited failure analysis data for various specimens suggest that the failure modes are driven by normal geometric discontinuities in the TBC's.

Cruse, T. A.↗
NASA NTRS1995

Thermal barrier coating life modeling in aircraft gas turbine engines

Analytical models useful for predicting ceramic thermal barrier coating (TBC) spalling life in aircraft gas turbine engines are presented. Electron beam-physical vapor deposited (EB-PVD) and plasma sprayed TBC systems are discussed. TBC spalling was attributed to a combination of mechanisms such as metal oxidation at the ceramic-metal interface, ceramic-metal interface stress concentrations at free surfaces due to dissimilar materials, ceramic-metal interface stresses caused by local radius of curvature and interface roughness, material properties and mechanical behavior, transient temperature gradients across the ceramic layer and component design features. TBC spalling life analytical models were developed based on observations of TBC failure modes and plausible failure theories. TBC failure was assumed to occur when the imposed stresses exceeded the material strength (at or near the ceramic-metal interface). TBC failure knowledge gaps caused by lack of experimental evidence and analytical understanding are noted. The analytical models are considered initial engineering approaches that capture observed TBC failure trends.

Nissley, D. M.↗
NASA NTRS1995

The effect of interface properties on nickel base alloy composites

This program was performed to assess the extent to which mechanical behavior models can predict the properties of sapphire fiber/nickel aluminide matrix composites and help guide their development by defining improved combinations of matrix and interface coating. The program consisted of four tasks: 1) selection of the matrices and interface coating constituents using a modeling-based approach; 2) fabrication of the selected materials; 3) testing and evaluation of the materials; and 4) evaluation of the behavior models to develop recommendations. Ni-50Al and Ni-20AI-30Fe (a/o) matrices were selected which gave brittle and ductile behavior, respectively, and an interface coating of PVD YSZ was selected which provided strong bonding to the sapphire fiber. Significant fiber damage and strength loss was observed in the composites which made straightforward comparison of properties with models difficult. Nevertheless, the models selected generally provided property predictions which agreed well with results when fiber degradation was incorporated. The presence of a strong interface bond was felt to be detrimental in the NiAI MMC system where low toughness and low strength were observed.

Groves, M.↗
NASA NTRS1995

Thermal barrier coating life modeling in aircraft gas turbine engines

Analytical models for predicting ceramic thermal barrier coating (TBC) spalling life in aircraft gas turbine engines are presented. Electron beam-physical vapor deposited (EB-PVD) and plasma sprayed TBC systems are discussed. An overview of the following TBC spalling mechanisms is presented: metal oxidation at the ceramic-metal interface, ceramic-metal interface stress singularities at edges and corners, ceramic-metal interface stresses caused by radius of curvature and interface roughness, material properties and mechanical behavior, temperature gradients, component design features and object impact damage. TBC spalling life analytical models are proposed based on observations of TBC spalling and plausible failure theories. TBC spalling was assumed to occur when the imposed stresses exceed the material strength (at or near the ceramic-metal interface). TBC failure knowledge gaps caused by lack of experimental evidence and analytical understanding are noted. The analytical models are considered initial engineering approaches that capture observed TBC failure trends.

Nissley, David M.↗
NASA NTRS1996

Soft X-Ray Optics by Pulsed Laser Deposition

Mo/Si and C/Co multilayers for soft x-ray optics were designed for spectral regions of interest in possible applications. Fabrication was effected by Pulsed Laser Deposition using Nd:YAG (355 nm) or excimer (248 nm) lasers in order to evaluate the suitability of this technique. Results for Mo/Si structures were not considered satisfactory due mainly to problems with particulate production and target surface modification during Si ablation. These problems may be alleviated by a two-wavelength approach, using separate lasers for each target. Results for C/Co multilayers are much more encouraging, since indication of good layering was observed for extremely thin layers. We expect to continue investigating this possibility. In order to compete with traditional PVD techniques, it is necessary to achieve film coverage uniformity over large enough areas. It was shown that this is feasible, and novel means of achieving it were devised.

Fernandez, Felix E.↗
NASA NTRS2004

Defect Clustering and Nano-phase Structure Characterization of Multicomponent Rare Earth-Oxide-Doped Zirconia-Yttria Thermal Barrier Coatings

Advanced thermal barrier coatings (TBCs) have been developed by incorporating multicomponent rare earth oxide dopants into zirconia-based thermal barrier coatings to promote the creation of the thermodynamically stable, immobile oxide defect clusters and/or nanophases within the coating systems. In this paper, the defect clusters, induced by Nd, Gd, and Yb rare earth dopants in the zirconia-yttria thermal barrier coatings, were characterized by high-resolution transmission electron microscopy (TEM). The TEM lattice imaging, selected area diffraction (SAD), and electron energy-loss spectroscopy (EELS) analyses demonstrated that the extensive nanoscale rare earth dopant segregation exists in the plasma-sprayed and electron-physical-vapor-deposited (EB PVD) thermal barrier coatings. The nanoscale concentration heterogeneity and the resulting large lattice distortion promoted the formation of parallel and rotational defective lattice clusters in the coating systems. The presence of the 5-to 100-nm-sized defect clusters and nanophases is believed to be responsible for the significant reduction of thermal conductivity, improved sintering resistance, and long-term high temperature stability of the advanced thermal barrier coating systems.

Zhu, Dongming↗
NASA NTRS2003

Differential Sputtering Behavior of Pyrolytic Graphite and Carbon-Carbon Composite Under Xenon Bombardment

A differential sputter yield measurement technique is described, which consists of a quartz crystal monitor that is swept at constant radial distance from a small target region where a high current density xenon ion beam is aimed. This apparatus has been used to characterize the sputtering behavior of various forms of carbon including polycrystalline graphite, pyrolytic graphite, and PVD-infiltrated and pyrolized carbon-carbon composites. Sputter yield data are presented for pyrolytic graphite and carbon-carbon composite over a range of xenon ion energies from 200 eV to 1 keV and angles of incidence from 0 deg (normal incidence) to 60 deg .

Williams, John D.↗
NASA NTRS2004

Development of Advanced Low Conductivity Thermal Barrier Coatings

Advanced multi-component, low conductivity oxide thermal barrier coatings have been developed using an approach that emphasizes real-time monitoring of thermal conductivity under conditions that are engine-like in terms of temperatures and heat fluxes. This is in contrast to the traditional approach where coatings are initially optimized in terms of furnace and burner rig durability with subsequent measurement in the as-processed or furnace-sintered condition. The present work establishes a laser high-heat-flux test as the basis for evaluating advanced plasma-sprayed and electron beam-physical vapor deposited (EB-PVD) thermal barrier coatings under the NASA Ultra-Efficient Engine Technology (UEET) Program. The candidate coating materials for this program are novel thermal barrier coatings that are found to have significantly reduced thermal conductivities and improved thermal stability due to an oxide-defect-cluster design. Critical issues for designing advanced low conductivity coatings with improved coating durability are also discussed.

Zhu, Dong-Ming↗
NASA NTRS2005

Development of a Thin-Film Solar Cell Interconnect for the Powersphere Concept

Dual junction amorphous silicon (a-Si) solar cells produced on polyimide substrate have been selected as the best candidate to produce a lightweight solar array for the PowerSphere program. The PowerSphere concept features a space-inflatable, geodetic solar array approximately 0.6 meters in diameter and capable of generating about 20W of electrical power. Trade studies of various wiring concepts and connection methods led to an interconnect design with a copper contact that wraps around the edge, to the back of the solar cell. Applying Plasma Vapor Deposited (PVD) copper film to both sides and the edge of the solar cell produces the wrap around contact. This procedure results in a contact pad on the back of the solar cell, which is then laser welded to a flex circuit material. The flex circuit is constructed of copper in a custom designed routing pattern, and then sandwiched in a Kapton insulation layer. The flex circuit then serves as the primary power distribution system between the solar cells and the spacecraft. Flex circuit material is the best candidate for the wiring harness because it allows for low force deployment of the solar cells by the inflatable hinges on the PowerSphere. An additional frame structure, fabricated and assembled by ILC Dover, will reinforce the wrap around contact-flex blanket connection, thus providing a mechanically robust solar cell interconnect for the PowerSphere multifunctional program. The PowerSphere team will use the wraparound contact design approach as the primary solution for solar cell integration and the flex blanket for power distribution.

Simburger, Edward J.↗
NASA NTRS2006

Diffusion Bonding of Silicon Carbide Ceramics using Titanium Interlayers

Robust joining approaches for silicon carbide ceramics are critically needed to fabricate leak free joints with high temperature mechanical capability. In this study, titanium foils and physical vapor deposited (PVD) titanium coatings were used to form diffusion bonds between SiC ceramics using hot pressing. Silicon carbide substrate materials used for bonding include sintered SiC and two types of CVD SiC. Microscopy results show the formation of well adhered diffusion bonds. The bond strengths as determined from pull tests are on the order of several ksi, which is much higher than required for a proposed application. Microprobe results show the distribution of silicon, carbon, titanium, and other minor elements across the diffusion bond. Compositions of several phases formed in the joint region were identified. Potential issues of material compatibility and optimal bond formation will also be discussed.

Halbig, Michael C.↗
NASA NTRS2007

Detecting Thermal Barrier Coating Delamination Using Visible and Near-Infrared Luminescence from Erbium-Doped Sublayers

Nondestructive diagnostic tools are needed to monitor early stages of delamination progression in thermal barrier coatings (TBCs) because the risk of delamination induced coating failure will compromise engine performance and safety. Previous work has demonstrated that for TBCs composed of yttria-stabilized zirconia (YSZ), luminescence from a buried europium-doped sublayer can be utilized to identify the location of TBC delamination from the substantially higher luminescence intensity observed from the delaminated regions of the TBC. Luminescence measurements from buried europium-doped layers depend on sufficient transmittance of the 532 nm excitation and 606 nm emission wavelengths through the attenuating undoped YSZ overlayer to produce easily detected luminescence. In the present work, improved delamination indication is demonstrated using erbium-doped YSZ sublayers. For visible-wavelength luminescence, the erbium-doped sublayer offers the advantage of a very strong excitation peak at 517 nm that can be conveniently excited a 514 nm Ar ion laser. More importantly, the erbium-doped sublayer also produces near-infrared luminescence at 1550 nm that is effectively excited by a 980 nm laser diode. Both the 980 nm excitation and the 1550 nm emission are transmitted through the TBC with much less attenuation than visible wavelengths and therefore show great promise for delamination monitoring through thicker or more highly scattering TBCs. The application of this approach for both electron beam physical vapor deposited (EB-PVD) and plasma-sprayed TBCs is discussed.

Eldridge, J. I.↗
NASA NTRS2007

Diffusion Bonding of Silicon Carbide for MEMS-LDI Applications

A robust joining approach is critically needed for a Micro-Electro-Mechanical Systems-Lean Direct Injector (MEMS-LDI) application which requires leak free joints with high temperature mechanical capability. Diffusion bonding is well suited for the MEMS-LDI application. Diffusion bonds were fabricated using titanium interlayers between silicon carbide substrates during hot pressing. The interlayers consisted of either alloyed titanium foil or physically vapor deposited (PVD) titanium coatings. Microscopy shows that well adhered, crack free diffusion bonds are formed under optimal conditions. Under less than optimal conditions, microcracks are present in the bond layer due to the formation of intermetallic phases. Electron microprobe analysis was used to identify the reaction formed phases in the diffusion bond. Various compatibility issues among the phases in the interlayer and substrate are discussed. Also, the effects of temperature, pressure, time, silicon carbide substrate type, and type of titanium interlayer and thickness on the microstructure and composition of joints are discussed.

Halbig, Michael C.↗