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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1984

Acoustic emission evaluation of plasma-sprayed thermal barrier coatings

Acoustic emission techniques have recently been used in a number of studies to investigate the performance and failure behavior of plasma-sprayed thermal barrier coatings. Failure of the coating is a complex phenomena, especially when the composite nature of the coating is considered in the light of possible failure mechanisms. Thus it can be expected that both the metal and ceramic components (i.e., the bond coat and ceramic overlay) of a composite thermal protection system influence the macroscopic behavior and performance of the coating. The aim of the present work is to summarize the 'state-of-the-art' in terms of this initial work and indicate where future progress may be made.

Berndt, C. C.↗
DOE OSTI2024

High-Fidelity Arc-Discharge Model for Hydrogen-Plasma-Smelting-Reduction of Iron Ore

Electrification and use of renewable hydrogen is currently a necessity for decarbonizing the iron-and-steel industry. In this regard, hydrogen plasma smelting reduction (HPSR) is a novel pathway that is being explored for reduction of iron ore. HPSR provides several decarbonization merits compared to conventional blast furnaces. Firstly, the use of renewable hydrogen drastically reduces the CO2 emissions compared to the use of coke. Secondly, renewable electricity in the form of a thermal plasma for making reactive hydrogen species (radicals, ions) are more efficient at reducing iron ore compared to neutral H2. Thirdly, a molten product compatible with downstream processes is obtained from the intense heat transfer from the plasma. However, the scale-up of this technology requires fundamental exploration of hydrogen plasma dynamics and its interaction with complex solid material that include phase changing iron-ore and slag. In this work, we present a first principles continuum scale model for thermal plasmas in Ar/H2 gas mixtures typically used for HPSR. The thermal plasma governing equations for mass, momentum and energy with Lorentz force and Joule heating source terms are solved along with electromagnetic equations for electrostatic and magnetic vector potential. Our solver will be based on Pele, a suite of reacting flow solvers designed for advanced scientific computing architectures (Henry De Frahan et al., Proceedings of SIAM Parallel Processing, 13-25, 2024), and will utilize adaptive mesh generation for enhanced resolutions at locations of intense physicochemical interactions. This study will present the impact of Ar to H2 ratios on excited/dissociated hydrogen species concentrations, plasma temperature and conductivity along with the impact of outgassed species (water, metal vapor, O, OH radicals) from ore surface on gas phase chemistry. Furthermore, the heat and species flux to the surface will be quantified as a function of applied voltages in a transferred arc configuration.

hydrogen plasma↗
NASA NTRS1979

The role of energetic particle precipitation in Jovian magnetospherics. I - Secondary electrons from the ionosphere of Jupiter

Escape of photoelectrons from the Jovian ionosphere produces only a meager source of thermal plasma for the inflated centrifugally unstable magnetosphere and is unable to account for the 100 eV thermal plasma temperatures of the magnetosphere. Since the Jovian magnetosphere is well populated with highly energetic electrons, the creation of secondaries and the energy degradation of the primaries precipitating into the lower ionosphere provide additional sources of magnetospheric thermal plasma as well as of the energy for further elevating the plasma temperatures in the top side ionosphere. The efficiencies with which escaping electrons are created by precipitating electrons with energies up to several MeV are computed using energetic electron transport and thermalization codes. The more energetic incident fluxes are far less efficient in creating escaping electrons than the lower energy fluxes with only 0.001% of the secondaries escaping for a 1 MeV source versus 3% for a 1 keV source. Incident fluxes of the order of 10 to 100 per sq cm per sec per eV between 100 eV and 100 keV are required to produce 50 eV escape fluxes comparable to those generated by solar EUV.

Swartz, W. E.↗
NASA NTRS1989

Instrumented adhesion tests on plasma sprayed thermal barrier coatings

The failure mechanisms of plasma-sprayed two-layer coatings consisting of an NiCrAlY or NiCrAlZr bond coat with an yttria-stabilized zirconia overlay are presently examined by tensile adhesion tests. It has been found that adhesive failure within the bond coat exhibits greater failure strain than the cohesive failure of the ceramic overlay, supporting the view of the intermediate coatings being highly compliant. The absolute extension exhibited by failures occurring only through the ceramic coating is greater than that of adhesive failure, since the ceramic coating is much thicker than the bond coat.

Berndt, Christopher C.↗
NASA NTRS1999

DC and Wave Electric Fields and Other Plasma Parameters Observed on Two Sounding Rockets in the Dark Cusp during IMF BZ North and South Conditions

Two Black Brant IX sounding rockets were launched into the dark, dayside cusp near magnetic noon on December 2 and 3, 1997, from Ny Alesund, Spitzbergen at 79degN reaching altitudes of approximately 450 km. Real-time ground-based and Wind (interplanetary magnetic field) IMF data were used to determine the launch conditions. The first launch, with Bz north conditions, crossed into and back out of an open field region with merging poleward of the projected trajectory. The second flight, into Bz south conditions, was timed to coincide with an enhancement in the merging rate from a increase in the negative Bz, while the (Defense Meteorological Satellite Program) DMSP F13 satellite was situated slightly to the north of the rocket trajectory. Each payload returned DC electric and magnetic fields, plasma waves, energetic particles, photometer data, and thermal plasma data. Data from both flights will be shown, with an emphasis on the DC electric field results. In particular, the data gathered on December 2, 1997 will be used to discuss ionospheric signatures of merging and the open/closed character of the the cusp/low latitude boundary layer. In contrast, the data gathered on December 3, 1997 shows evidence of pulsed electric field structures which will be examined in the context of cusp plasma entry processes. Both data sets returned a rich variety of plasma waves, as well as optical emissions and thermal plasma data.

Pfaff, R. F.↗
NASA NTRS1997

DC and Wave Electric Fields and Other Plasma Parameters Observed on Two Sounding Rockets in the Dark Cusp During IMF Bz North and South Conditions

Two Black Brant IX sounding rockets were launched into the dark, dayside cusp near magnetic noon on December 2 and 3, 1997, from Ny Alesund, Spitzbergen at 79 N reaching altitudes of approximately 450 km. Real-time ground-based and Wind IMF data were used to determine the launch conditions. The first launch, with Bz north conditions, crossed into and back out of an open field region with merging poleward of the projected trajectory. The second flight, into Bz south conditions, was timed to coincide with an enhancement in the merging rate from a increase in the negative Bz, while the DMSP F13 satellite was situated slightly to the north of the rocket trajectory. Each payload returned DC electric and magnetic fields, plasma waves, energetic particles, photometer data, and thermal plasma data. Data from both flights will be shown, with an emphasis on the DC electric field results. In particular, the data gathered on December 2, 1997 will be used to discuss ionospheric signatures of merging and the open/closed character of the the cusp/low latitude boundary layer. In contrast, the data gathered on December 3, 1997 shows evidence of pulsed electric field structures which will be examined in the context of cusp plasma entry processes. Both data sets returned a rich variety of plasma waves, as well as optical emissions and thermal plasma data.

Pfaff, R. F.↗
NASA NTRS1999

DC and Wave Electric Fields and Other Plasma Parameters Observed on Two Sounding Rockets in the Dark Cusp during IMF Bz North and South Conditions

Two Black Brant IX sounding rockets were launched into the dark, dayside cusp near magnetic noon on December 2 and 3, 1997, from Ny Alesund, Spitzbergen at 79 deg N reaching altitudes of about 450 km. Real-time ground-based and Wind IMF data were used to determine the launch conditions. The first launch, with Bz north conditions, crossed into and back out of an open field region with merging poleward of the projected trajectory. The second flight, into Bz south conditions, was timed to coincide with an enhancement in the merging rate from a increase in the negative Bz, while the DMSP Fl 3 satellite was situated slightly to the north of the rocket trajectory. Each payload returned DC electric and magnetic fields, plasma waves, energetic particles, photometer data, and thermal plasma data. Data from both flights will be shown, with an emphasis on the DC electric field results. In particular, the data gathered on December 2, 1997 will be used to discuss ionospheric signatures of merging and the open/closed character of the the cusp/low latitude boundary layer. In contrast, the data gathered on December 3, 1997 shows evidence of pulsed electric field structures which will be examined in the context of cusp plasma entry processes. Both data sets returned a rich variety of plasma waves, as well as optical emissions and thermal plasma data.

Pfaff, R. F.↗
NASA NTRS1978

Quiet-time plasma irregularities at 1400 km in the cleft region

The quiet north polar cleft at 1400 km was studied by Isis-2 instruments, and data from the retarding potential analyzer and the cylindrical electrostatic probe show that thermal plasma density fluctuations are distributed in a region between 75 deg and 82 deg invariant latitude and approximately dawn to dusk. Cleft shape and shape variations are described. Thermal ions and thermal electrons usually fluctuated together, but suprathermal electrons fluctuated independently. Data on thermal plasma patterns correlates fairly well with observations of soft particles and auroral optical emissions and not as well with measurements of high-energy particles. The data suggest that the energy source for the thermal irregularities is associated with soft particles and that precipitating high-energy particles do not drive the thermal plasma at these altitudes.

Kayser, S. E.↗
DOE OSTI2024

Generation of shear flows induced by AE / EPM in LHD plasma

The generation of shear flows (SFs) by Alfven Eigenmodes (AEs) and energetic particle modes (EPMs) have important effects on the operation of future nuclear fusion reactors, because SFs regulate the saturation of the AEs/EPMs, the transport of EPs and thermal plasma, as well as the formation of transport barriers among other consequences. The aim of this study is the analysis of SFs generation during the saturation phase of AEs and EPMs in LHD plasma. Experiments performed in the 23rd and 24th LHD experimental campaigns are dedicated to explore the destabilization of AEs/EPMs in discharges with different heating patterns, thermal plasma and magnetic field configurations. In particular, the shots 176490 and 179697 show the destabilization of MHD bursts and energetic-ion-driven resistive interchange modes (EIC), respectively. Charge exchange spectroscopy measurements in both discharges indicate that the generation of SFs by AE/EPM is uncorrelated with the perturbation induced by the neutral beam injector (NBI). Nonlinear simulations performed using the gyro-fluid code FAR3d show the generation of zonal structures, especially SFs, induced during the saturation phase of Toroidal Alfven Eigenmodes (TAEs) triggered in the MHD burst as well as by the 1/1 EIC in the bursting phase. The simulations indicate that SFs are caused by the radial electric fields powered by energy transfers from the unstable AE/EPM towards the thermal plasma. The strongest SFs are measured during the EIC bursting phase once the 1/1 EPM overlaps with nearby resonances at the plasma periphery. Likewise, the largest SFs during the MHD burst are observed once TAEs radially overlap in the inner-middle plasma region.

AE↗
NASA NTRS1988

Vacuum application of thermal barrier plasma coatings

Coatings are presently applied to Space Shuttle Main Engine (SSME) turbine blades for protection against the harsh environment realized in the engine during lift off-to-orbit. High performance nickel, chromium, aluminum, and yttrium (NiCrAlY) alloy coatings, which are applied by atmospheric plasma spraying, crack and spall off because of the severe thermal shock experienced during start-up and shut-down of the engine. Ceramic coatings of yttria stabilized zirconia (ZrO2-Y2O3) were applied initially as a thermal barrier over coating to the NiCrAlY but were removed because of even greater spalling. Utilizing a vacuum plasma spraying process, bond coatings of NiCrAlY were applied in a low pressure atmosphere of argon/helium, producing significantly improved coating-to-blade bonding. The improved coatings showed no spalling after 40 MSFC burner rig thermal shock cycles, cycling between 1700 and -423 F. The current atmospheric plasma NiCrAlY coatings spalled during 25 test cycles. Subsequently, a process was developed for applying a durable thermal barrier coating of ZrO2-Y2O3 to the turbine blades of first stage high-pressure fuel turbopumps utilizing the vacuum plasma process. The improved thermal barrier coating has successfully passed 40 burner rig thermal shock cycles without spalling. Hot firing in an SSME turbine engine is scheduled for the blades. Tooling was installed in preparation for vacuum plasma spray coating other SSME hardware, e.g., the titanium main fuel valve housing (MFVH) and the fuel turbopump nozzle/stator.

Holmes, R. R.↗
NASA NTRS2007

Imaging Thermal He(+)in Geospace from the Lunar Surface

By mass, thermal plasma dominates near-earth space and strongly influences the transport of energy and mass into the earth's atmosphere. It is proposed to play an important role in modifying the strength of space weather storms by its presence in regions of magnetic reconnection in the dayside magnetopause and in the near to mid-magnetotail. Ionospheric-origin thermal plasma also represents the most significant potential loss of atmospheric mass from our planet over geological time. Knowledge of the loss of convected thermal plasma into the solar wind versus its recirculation across high latitudes and through the magnetospheric flanks into the magnetospheric tail will enable determination of the mass balance for this mass-dominant component of the Geospace system and of its influence on global magnetospheric processes that are critical to space weather prediction and hence to the impact of space processes on human technology in space and on Earth. Our proposed concept addresses this basic issue of Geospace dynamics by imaging thermal He(+) ions in extreme ultraviolet light with an instrument on the lunar surface. The concept is derived from the highly successful Extreme Ultraviolet imager (EUV) flown on the Imager for Magnetopause-to-Aurora Global Exploration (IMAGE) spacecraft. From the lunar surface an advanced EUV imager is anticipated to have much higher sensitivity, lower background noise, and higher communication bandwidth back to Earth. From the near-magnetic equatorial location on the lunar surface, such an imager would be ideally located to follow thermal He(+) ions to high latitudes, into the magnetospheric flanks, and into the magnetotail.

Gallagher, D. L.↗
NASA NTRS2003

Sintering and Interface Strain Tolerance of Plasma-Sprayed Thermal and Environmental Barrier Coatings

Ceramic thermal and environmental barrier coatings will be more aggressively designed to protect gas turbine engine hot section SiC/SiC Ceramic Matrix Composite (CMC) components in order to meet future engine higher fuel efficiency and lower emission goals. A coating system consisting of a zirconia-based oxide topcoat (thermal barrier) and a mullite/BSAS silicate inner coat (environmental barrier) is often considered a model system for the CMC applications. However, the coating sintering, and thermal expansion mismatch between the zirconia oxide layer and the silicate environmental barrier/CMC substrate will be of major concern at high temperature and under thermal cycling conditions. In this study, the sintering behavior of plasma-sprayed freestanding zirconia-yttria-based thermal barrier coatings and mullite (and/or barium-strontium-aluminosilicate, i.e., BSAS) environmental barrier coatings was determined using a dilatometer in the temperature range of 1200-1500 C. The effects of test temperature on the coating sintering kinetics were systematically investigated. The plasma-sprayed zirconia-8wt.%yttria and mullite (BSAS) two-layer composite coating systems were also prepared to quantitatively evaluate the interface strain tolerance of the coating system under thermal cycling conditions based on the dilatomentry. The cyclic response of the coating strain tolerance behavior and interface degradation as a function of cycle number will also be discussed.

Zhu, Dongming↗
NASA NTRS2003

Combined Mode I and Mode II Fracture of Plasma-Sprayed Thermal Barrier Coatings at Ambient and Elevated Temperatures

The mode I, mode II, and combined mode I-mode II fracture behavior of ZrO2 - 8wt%Y2O3 thermal barrier coatings was determined in asymmetric flexure loading at both ambient and elevated temperatures. Precracks were introduced in test specimens using the single-edge-v-notched beam (SEVNB) method incorporated with final diamond polishing to achieve sharp crack tips. A fracture envelope of KI versus KII was determined for the coating material at ambient and elevated temperatures. Propagation angles of fracture as a function of KI/KII were also determined. The mixed-mode fracture behaviors of the coating material were compared with those of monolithic advanced ceramics determined previously. The mixed-mode fracture behavior of the plasma- sprayed thermal barrier coating material was predicted in terms of fracture envelope and propagation angle using mixed-mode fracture theories.

Choi, Sung R.↗
NASA NTRS2003

Combined Mode I and Mode II Fracture of Plasma-Sprayed Thermal Barrier Coatings at Ambient and Elevated Temperatures

The mode I, mode II, and combined mode I-mode II fracture behavior of ZrO2- 8wt%Y2O3 thermal barrier coatings was determined in asymmetric flexure loading at both ambient and elevated temperatures. Precracks were introduced in test specimens using the single-edge-v-notched beam (SEVNB) method incorporated with final diamond polishing to achieve sharp crack tips. A fracture envelope of KI versus KII was determined for the coating material at ambient and elevated temperatures. Propagation angles of fracture as a function of K(sub I)/K(sub II) were also determined. The mixed-mode fracture behaviors of the coating material were compared with those of monolithic advanced ceramics determined previously. The mixed-mode fracture behavior of the plasma-sprayed thermal barrier coating material was predicted in terms of fracture envelope and propagation angle using mixed-mode fracture theories.

Choi, Sung R.↗
NASA NTRS2002

The Surface Interface Characteristics of Vertically Aligned Carbon Nanotube and Graphitic Carbon Fiber Arrays Grown by Thermal and Plasma Enhanced Chemical Vapor Deposition

The development of nano-arrays for sensors and devices requires the growth of arrays with the proper characteristics. One such application is the growth of vertically aligned carbon nanotubes (CNTs) and graphitic carbon fibers (GCFs) for the chemical attachment of probe molecules. The effectiveness of such an array is dependent not only upon the effectiveness of the probe and the interface between that probe and the array, but also the array and the underlaying substrate. If that array is a growth of vertically aligned CNTs or GCFs then the attachment of that array to the surface is of the utmost importance. This attachment provides the mechanical stability and durability of the array, as well as, the electrical properties of that array. If the detection is to be acquired through an electrical measurement, then the appropriate resistance between the array and the surface need to be fabricated into the device. I will present data on CNTs and GCFs grown from both thermal and plasma enhanced chemical vapor deposition. The focus will be on the characteristics of the metal film from which the CNTs and GCFs are grown and the changes that occur due to changes within the growth process.

Delzeit, Lance↗
NASA NTRS2003

Mode I, Mode II, and Mixed-Mode Fracture of Plasma-sprayed Thermal Barrier Coatings at Ambient and Elevated Temperatures

The mixed-mode fracture behavior of plasma-sprayed ZrO2-8 wt% Y2O3 thermal barrier coatings was determined in air at 25 and 1316 C in asymmetric four-point flexure with single edge v-notched beam (SEVNB) test specimens. The mode I fracture toughness was found to be K(sub Ic) = 1.15 plus or minus 0.07 and 0.98 plus or minus 0.13 MPa the square root of m, respectively, at 25 and 1316 C. The respective mode II fracture toughness values were K(sub IIc) = 0.73 plus or minus 0.10 and 0.65 plus or minus 0.04 MPa the square root of m. Hence, there was an insignificant difference in either K(sub Ic or K(sub IIc) between 25 and 1316 C for the coating material, whereas there was a noticeable distinction between K(sub Ic) and K(sub IIc), resulting in K(sub IIc) per K(sub Ic) = 0.65 at both temperatures. The empirical mixed-mode fracture criterion best described the coatings' mixed-mode fracture behavior among the four mixed-mode fracture theories considered. The angle of crack propagation was in reasonable agreement with the minimum strain energy density criterion. The effect of the directionality of the coating material in on K(sub Ic) was observed to be insignificant, while its sintering effect at 1316 C on K(sub Ic) was significant.

Choi, Sung R.↗
NASA NTRS2004

Effect of Sintering on Mechanical and Physical Properties of Plasma-Sprayed Thermal Barrier Coatings

The effect of sintering on mechanical and physical properties of free-standing plasma-sprayed ZrO2-8 wt% Y2O3 thermal barrier coatings (TBCs) was determined by annealing them at 1316 C in air. Mechanical and physical properties of the TBCs, including strength, modes I and II fracture toughness, elastic modulus, Poisson s response, density, microhardness, fractography, and phase stability, were determined at ambient temperature as a function of annealing time ranging from 0 to 500 h. All mechanical and physical properties, except for the amount of monoclinic phase, increased significantly in 5 to 100 h and then reached a plateau above 100 h. Annealing resulted in healing of microcracks and pores and in grain growth, accompanying densification of the TBC s body due to the sintering effect. However, an inevitable adverse effect also occurred such that the desired lower thermal conductivity and good expansivity, which makes the TBCs unique in thermal barrier applications, were degraded upon annealing. A model was proposed to assess and quantify all the property variables in response to annealing in a normalized scheme. Directionality of as-sprayed TBCs appeared to have an insignificant effect on their properties, as determined via fracture toughness, microhardness, and elastic modulus measurements.

Choi, Sung R.↗