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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 NTRS1979

Development of a plasma sprayed ceramic gas path seal for high pressure turbine applications

Development of the plasma sprayed graded, layered ZrO2/CoCrAlY seal system for gas turbine engine blade tip seal application up to 1589 K (2400 F) surface temperature was continued. Methods of improvement of the cyclic thermal shock resistance of the sprayed zirconia seal system were investigated. The most promising method, reduction of the ceramic thickness and metallic substrate stiffness were selected based upon potential and feasibility. Specimens were fabricated and experimentally evaluated to: (1) substantiate the capacity of the geometry changes to reduce operating stresses in the sprayed structure; and (2) define the abradability, erosion, thermal shock and physical property characteristic for the sprayed ceramic seal system. Thermal stress analysis was performed and correlated with thermal shock test results.

Shiembob, L. T.↗

NASA NTRS1951

Elevated Temperature Properties of Titanium Carbide Base Ceramals Containing Nickel or Iron

Elevated-temperature properties of titanium carbide base ceramals containing nickel or iron were determined in oxidation, modulus of rupture, tensile strength, and thermal-shock resistance. These materials followed the general growth law and exhibited two stages in oxidation. The following tensile strengths were found at 2000 degrees F: 13.3 weight percent nickel, 16, 150 pounds per square inch; 11.8 weight percent iron, 12,500 pounds per square inch; unalloyed titanium carbide, 16,450 pounds per square inch. Nickel or iron additions to titanium carbide improved the thermal-shock resistance, nickel more. The path of fracture in tensile and thermal-shock specimens was found to progress approximately 50 percent intergranularly and 50 percent transgranularly.

MATERIALS - TEMPERATURES, HIGH↗

NASA NTRS1993

Testing and evaluation of oxide-coated iridium/rhenium chambers

Iridium-coated rhenium provides long life operation of radiation-cooled rockets at temperatures up to 2200 C. Ceramic oxide coatings could be used to increase iridium/rhenium rocket lifetimes and allow operation in highly oxidizing environments. Ceramic oxide coatings promise to serve as both thermal and diffusion barriers for the iridium layer. Seven ceramic oxide-coated iridium/rhenium, 22 N rocket chambers were tested on gaseous hydrogen/gaseous oxygen propellants. Five chambers had thick (over 10 mils), monolithic coatings of either hafnia or zirconia. Two chambers had coatings with thicknesses less than 5 mils. One of these chambers had a thin-walled coating of zirconia infiltrated with sol gel hafnia. The other chamber had a coating composed of an iridium/oxide composite. The purpose of this test program was to assess the ability of the oxide coatings to withstand the thermal shock of combustion initiation, adhere under repeated thermal cycling, and operate in aggressively oxidizing environments. All of the coatings survived the thermal shock of combustion and demonstrated operation at mixture ratios up to 11. The iridium/oxide composite coated chamber included testing for over 29 minutes at mixture ratio 16. The thicker-walled coatings provided the larger temperature drops across the oxide layer (up to 570 C), but were susceptible to macrocracking and eventual chipping at a stress concentrator. The cracks apparently resealed during firing, under compression of the oxide layer. The thinner-walled coatings did not experience the macrocracking and chipping of the chambers seen with the thick, monolithic coatings. However, burnthroughs in the throat region did occur in both of the thin-walled chambers at mixture ratios well above stochiometric. The burn-throughs were probably the result of oxygen-diffusion through the oxide coating that allowed the underlying iridium and rhenium layers to be oxidized. The results of this test program indicated that the thin-walled oxide coatings are better suited for repeated thermal cycling than the thick-walled coating, while thicker coatings may be required for operation in aggressively oxidizing environments.

Reed, Brian D.↗

NASA NTRS1994

Evaluation of oxide-coated iridium-rhenium chambers

Iridium-coated rhenium (Ir-Re) provides long life operation of radiation-cooled rockets at temperatures up to 2200 C. Ceramic oxide coatings could be used to increase Ir-Re rocket lifetimes and allow operation in highly oxidizing environments. Ceramic oxide coatings promise to serve as both thermal and diffusion barriers for the iridium layer. Seven ceramic oxide-coated Ir-Re, 22-N rocket chambers were tested with gaseous hydrogen/gaseous oxygen (GHz/G02) propellants. Five chambers had thick (over 10 mils), monolithic coatings of either hafnia (HfO2) or zirconia (ZrO2). Two chambers had coatings with thicknesses less than 5 mils. One of these chambers had a thin-walled coating of ZrO2 infiltrated with sol gel HfO2. The other chamber had a coating composed of an Ir-oxide composite. The purpose of this test program was to assess the ability of the oxide coatings to withstand the thermal shock of combustion initiation, adhere under repeated thermal cycling, and operate in aggressively oxidizing environments. All of the coatings survived the thermal shock of combustion and demonstrated operation at mixture ratios up to 11. Testing the Ir-oxide composite-coated chamber included over 29 min at mixture ratio 16. The thicker walled coatings provided the larger temperature drops across the oxide layer (up to 570 C), but were susceptible to macrocracking and eventual chipping at a stress concentrator. The cracks apparently resealed during firing, under compression of the oxide layer. The thinner walled coatings did not experience the macrocracking and chipping of the chambers that was seen with the thick, monolithic coatings. However, burn-throughs in the throat region did occur in both of the thin-walled chambers at mixture ratios well above stoichiometric. The burn-throughs were probably the result of oxygen diffusion through the oxide coating that allowed the underlying Ir and Re layers to be oxidized. The results of this test program indicated that the thin-walled oxide coatings are better suited for repeated thermal cycling than the thick-walled coating, while thicker coatings may be required for operation in aggressively oxidizing environments.

Reed, Brian D.↗

NASA NTRS1988

Thermal effects on the mechanical properties of SiC fiber reinforced reaction bonded silicon nitride matrix (SiC/RBSN) composites

The elevated temperature four-point flexural strength and the room temperature tensile and flexural strength properties after thermal shock were measured for ceramic composites consisting of 30 vol pct uniaxially aligned 142 micron diameter SiC fibers in a reaction bonded Si3N4 matrix. The elevated temperature strengths were measured after 15 min of exposure in air at temperatures to 1400 C. Thermal shock treatment was accomplished by heating the composite in air for 15 min at temperatures to 1200 C and then quenching in water at 25 C. The results indicate no significant loss in strength properties either at temperature or after thermal shock when compared with the strength data for composites in the as-fabricated condition.

Bhatt, R. T.↗

NASA NTRS1990

Thermal effects on the mechanical properties of SiC fibre reinforced reaction-bonded silicon nitride matrix composites

Bhatt, R. T.↗

NASA NTRS1988

The structure of shocks with thermal conduction and radiative cooling

A general analysis is presented of the structure of a steady state, plane-parallel shock wave in which both thermal conduction and radiative cooling are important. The fluid is assumed to have a perfect-gas equation of state, with radiative cooling a function only of its temperature and density. Conduction in both diffusive and saturated regimes is treated. For the case of a strong shock, with conductivity and cooling function varying as power laws in temperature, approximate analytic solutions describing the shock wave are derived. For a plasma of solar composition, conduction is found to have a significant effect on the shock temperature and overall thickness of the postshock layer only for shock velocities greater than about 30,000 km/s, corresponding to shock temperatures greater than about 10 to the 10th K, but it affects the local structure of parts of the shock wave at much lower velocities. The effects of conduction are greatly enhanced if the heavy-element abundance is increased.

Lacey, Cedric G.↗

NASA NTRS2006

Chromite-Plagioclase Assemblages as a New Shock Indicator; Implications for the Shock and Thermal Histories of Ordinary Chondrites

Chromite in ordinary chondrites (OC) can be used as a shock indicator. A survey of 76 equilibrated H, L and LL chondrites shows that unshocked chromite grains occur in equant, subhedral and rounded morphologies surrounded by silicate or intergrown with metallic Fe-Ni and/or troilite. Some unmelted chromite grains are fractured or crushed during whole-rock brecciation. Others are transected by opaque veins; the veins form when impacts cause localized heating of metal-troilite intergrowths above the Fe-FeS eutectic (988 C), mobilization of metal-troilite melts, and penetration of the melt into fractures in chromite grains. Chromite-plagioclase assemblages occur in nearly every shock-stage S3-S6 OC; the assemblages range in size from 20-300 microns and consist of 0.2-20-micron-size euhedral, subhedral, anhedral and rounded chromite grains surrounded by plagioclase or glass of plagioclase composition. Plagioclase has a low impedance to shock compression. Heat from shock-melted plagioclase caused adjacent chromite grains to melt; chromite grains crystallized from this melt. Those chromite grains in the assemblages that are completely surrounded by plagioclase are generally richer in Al2O3, than unmelted, matrix chromite grains in the same meteorite. Chromite veinlets (typically 0.5-2 microns thick and 10-300 microns long) occur typically in the vicinity of chromite-plagioclase assemblages. The veinlets formed from chromite-plagioclase melts that were injected into fractures in neighboring silicate grains; chromite crystallized in the fractures and the residual plagioclase-rich melt continued to flow, eventually pooling to form plagioclase-rich melt pockets. Chromite-rich chondrules (consisting mainly of olivine, plagioclase-normative mesostasis, and 5-15 vol.% chromite) occur in many shocked OC and OC regolith breccias but they are absent from primitive type-3 OC. They may have formed by impact melting chromite, plagioclase and adjacent mafic silicates during higher-energy shock events. The melt was jetted from the impact site and formed droplets due to surface tension. Crystallization of these droplets may have commenced in flight, prior to landing on the parent-body surface. Chromite-plagioclase assemblages and chromite veinlets occur in 25 out of 25 shock-stage S1 OC of petrologic type 5 and 6 that I examined. Although these rocks contain unstrained olivine with sharp optical extinction, most possess other shock indicators such as extensive silicate darkening, numerous occurrences of metallic Cu, polycrystalline troilite, and opaque veins. It seems likely that these rocks were shocked to levels at least as high as shock-stage S3 and then annealed by heat generated during the shock event. During annealing, the olivine crystal lattices healed but other shock indicators survived. Published Ar-Ar age data for some SI OC indicate that many shock and annealing events occurred very early in the history of the parent asteroids. The common occurrence of shocked and annealed OC is consistent with collisions being a major mechanism responsible for metamorphosing OC.

Rubin, Alan E.↗

NASA NTRS1991

Evidence for a thermally unstable shock wave in the Vela supernova remnant

The emission and absorption line signatures of supernova remnant shock waves provide complementary diagnostic capabilities. This paper presents IUE spectra of the nebulosity and new spectra of HD 72088. Models of the emission and absorption lines from shocked gas are used to derive a shock velocity and elemental depletions. There is evidence from the absorption-line strengths and widths for thermally unstable cooling behind a 150 km/s shock. The shock velocity and swept-up column density estimates of Wallerstein and Balick (1990) are confirmed, and evidence is found for a nonthermal contribution to the pressure.

Raymond, John C.↗

NASA NTRS2003

Mercury Conditions for the MESSENGER Mission Simulated in High- Solar-Radiation Vacuum Tests

The MESSENGER (Mercury Surface, Space Environment, Geochemistry, and Ranging) spacecraft, planned for launch in March 2004, will perform two flybys of Mercury before entering a year-long orbit of the planet in September 2009. The mission will provide opportunities for detailed characterization of the surface, interior, atmosphere, and magnetosphere of the closest planet to the Sun. The NASA Glenn Research Center and the MESSENGER spacecraft integrator, the Johns Hopkins University Applied Physics Laboratory, have partnered under a Space Act Agreement to characterize a variety of critical components and materials under simulated conditions expected near Mercury. Glenn's Vacuum Facility 6, which is equipped with a solar simulator, can simulate the vacuum and high solar radiation anticipated in Mercury orbit. The MESSENGER test hardware includes a variety of materials and components that are being characterized during the Tank 6 vacuum tests, where the hardware will be exposed to up to 11 suns insolation, simulating conditions expected in Mercury orbit. In 2002, ten solar vacuum tests were conducted, including beginning of life, end of life, backside exposure, and solar panel thermal shock cycling tests. Components tested include candidate solar array panels, sensors, thermal shielding materials, and communication devices. As an example, for the solar panel thermal shock cycling test, two candidate solar array panels were suspended on a lift mechanism that lowered the panels into a liquid-nitrogen-cooled box. After reaching -140 C, the panels were then lifted out of the box and exposed to the equivalent of 6 suns (8.1 kilowatts per square meters). After five cold soak/heating cycles were completed successfully, there was no apparent degradation in panel performance. An anticipated 100-hr thermal shield life test is planned for autumn, followed by solar panel flight qualification tests in winter. Glenn's ongoing support to the MESSENGER program has been instrumental in identifying design solutions and validating thermal performance models under a very aggressive development schedule. The test data have assisted Johns Hopkins engineers in selecting a flight solar array vendor and a thermal shield design. MESSENGER is one in a series of missions in NASA's Discovery Program. Infrared thermography provides data on the thermal gradients in the MESSENGER components during high solar insolation vacuum testing.

Wong, Wayne A.↗

NASA NTRS1988

Fiber reinforced superalloys for rocket engines

High-pressure turbopumps for advanced reusable liquid-propellant rocket engines such as that for the Space Shuttle Main Engine (SSME) require turbine blade materials that operate under extreme conditions of temperature, hydrogen environment, high-cycle fatigue loading, thermal fatigue and thermal shock. Such requirements tax the capabilities of current blade materials. Based on projections of properties for tungsten fiber reinforced superalloy (FRS) composites, it was concluded that FRS turbine blades offer the potential of a several-fold increase in life and over a 200C increase in temperature capability over current SSME blade material. FRS composites were evaluated with respect to mechanical property requirements for SSME blade applications. Compared to the current blade material, the thermal shock resistance of FRS materials is excellent, two to nine times better, and their thermal fatigue resistance is equal to or higher than the current blade material. FRS materials had excellent low and high-cycle fatigue strengths, and thermal shock-induced surface microcracks had no influence on their fatigue strength. The material also exhibited negligible embrittlement when exposed to a hydrogen environment.

Petrasek, Donald W.↗

NASA NTRS1989

Fiber reinforced superalloys for rocket engines

High pressure turbopumps for advanced reusable liquid propellant rocket engines such as that for the Space Shuttle Main Engine (SSME) require turbine blade materials that operate under extreme conditions of temperature, hydrogen environment, high-cycle fatigue loading, thermal fatigue and thermal shock. Such requirements tax the capabilities of current blade materials. Based on projections of properties for tungsten fiber reinforced superalloy (FRS) composites, it was concluded that FRS turbine blades offer the potential of a several fold increase in life and over a 200 C increase in temperature capability over the current SSME blade material. FRS composites were evaluated with respect to mechanical property requirements for SSME blade applications. Compared to the current blade material, the thermal shock resistance of FRS materials is excellent, two to nine times better, and their thermal fatigue resistance is equal to or higher than the current blade material. FRS materials had excellent low and high-cycle fatigue strengths, and thermal shock-induced surface microcracks had no influence on their fatigue strength. The material also exhibited negligible embrittlement when exposed to a hydrogen environment.

Petrasek, Donald W.↗

NASA NTRS1977

The tantalum-cased tantalum capacitor

Tantalum-cased tantalum capacitors were tested with regard to temperature stability, capacitance ratio, surge current capabilities, shock, vibration, and thermal shock. They were found to be superior to the conventional wet slug tantalum capacitor cased in silver, since they are more resistant to sulfuric acid. The tantalum-cased tantalum capacitors are widely accepted for use in critical electronic equipment because of their excellent performance and reliability.

Moynihan, J. D.↗

NASA NTRS1997

Plasma-Sprayed Refractory Oxide Coatings on Silicon-Base Ceramics

Silicon-base ceramics are promising candidate materials for high temperature structural applications such as heat exchangers, gas turbines and advanced internal combustion engines. Composites based on these materials are leading candidates for combustor materials for HSCT gas turbine engines. These materials possess a combination of excellent physical and mechanical properties at high temperatures, for example, high strength, high toughness, high thermal shock resistance, high thermal conductivity, light weight and excellent oxidation resistance. However, environmental durability can be significantly reduced in certain conditions such as when molten salts, H2 or water vapor are present. The oxidation resistance of silicon-base materials is provided by SiO2 protective layer. Molten salt reacts with SiO2 and forms a mixture of SiO2 and liquid silicate at temperatures above 800C. Oxygen diffuses more easily through the chemically altered layer, resulting in a catastrophic degradation of the substrate. SiC and Si3N4 are not stable in pure H2 and decompose to silicon and gaseous species such as CH4, SiH, SiH4, N2, and NH3. Water vapor is known to slightly increase the oxidation rate of SiC and Si3N4. Refractory oxides such as alumina, yttria-stabilized zirconia, yttria and mullite (3Al2O3.2SiO2) possess excellent environmental durability in harsh conditions mentioned above. Therefore, refractory oxide coatings on silicon-base ceramics can substantially improve the environmental durability of these materials by acting as a chemical reaction barrier. These oxide coatings can also serve as a thermal barrier. The purpose of this research program has been to develop refractory oxide chemical/thermal barrier coatings on silicon-base ceramics to provide extended temperature range and lifetime to these materials in harsh environments.

Tewari, Surendra↗

NASA NTRS2001

Feasibility of Actively Cooled Silicon Nitride Airfoil for Turbine Applications Demonstrated

Nickel-base superalloys currently limit gas turbine engine performance. Active cooling has extended the temperature range of service of nickel-base superalloys in current gas turbine engines, but the margin for further improvement appears modest. Therefore, significant advancements in materials technology are needed to raise turbine inlet temperatures above 2400 F to increase engine specific thrust and operating efficiency. Because of their low density and high-temperature strength and thermal conductivity, in situ toughened silicon nitride ceramics have received a great deal of attention for cooled structures. However, the high processing costs and low impact resistance of silicon nitride ceramics have proven to be major obstacles for widespread applications. Advanced rapid prototyping technology in combination with conventional gel casting and sintering can reduce high processing costs and may offer an affordable manufacturing approach. Researchers at the NASA Glenn Research Center, in cooperation with a local university and an aerospace company, are developing actively cooled and functionally graded ceramic structures. The objective of this program is to develop cost-effective manufacturing technology and experimental and analytical capabilities for environmentally stable, aerodynamically efficient, foreign-object-damage-resistant, in situ toughened silicon nitride turbine nozzle vanes, and to test these vanes under simulated engine conditions. Starting with computer aided design (CAD) files of an airfoil and a flat plate with internal cooling passages, the permanent and removable mold components for gel casting ceramic slips were made by stereolithography and Sanders machines, respectively. The gel-cast part was dried and sintered to final shape. Several in situ toughened silicon nitride generic airfoils with internal cooling passages have been fabricated. The uncoated and thermal barrier coated airfoils and flat plates were burner rig tested for 30 min without and with air cooling. Without cooling, the surface temperature of the flat plate reached approximately 2350 F. Starting with computer aided design (CAD) files of an airfoil and a flat plate with internal cooling passages, the permanent and removable mold components for gel casting ceramic slips were made by stereolithography and Sanders machines, respectively. The gel-cast part was dried and sintered to final shape. Several in situ toughened silicon nitride generic airfoils with internal cooling passages have been fabricated. The uncoated and thermal barrier coated airfoils and flat plates were burner rig tested for 30 min without and with air cooling. Without cooling, the surface temperature of the flat plate reached approximately 2350 F. With cooling, the surface temperature decreased to approximately 1910 F--a drop of approximately 440 F. This preliminary study demonstrates that a near-net-shape silicon nitride airfoil can be fabricated and that silicon nitride can sustain severe thermal shock and the thermal gradients induced by cooling and, thus, is a viable candidate for cooled components.

Bhatt, Ramakrishna T.↗

NASA NTRS1983

Heterogeneous shock-induced thermal radiation in minerals

A 500-channel optical imaging intensifying and spectral digital recording system is used for recording the shock-induced radiation emitted from 406 to 821 nm from transparent minerals during the time interval that a shock wave propagates through the sample. The initial results obtained for single crystals of gypsum, calcite and halite in the 30 to 40 GPa (300 to 400 kbar) pressure range reveal grey-body emission spectra corresponding to temperatures in the 3000 to 4000 K range and emissivities ranging from 0.003 to 0.02. With gypsum and calcite, distinctive line spectra are superimposed on the thermal radiation. The observed color temperatures are greater than the Hugoniot temperature by a factor of 2 to 10; this is calculable on the basis of continuum thermodynamics and equation of state models for the shock states achieved in the three minerals. These observed high temperatures are thought to be real. It is concluded that a large number of closed spaced high temperature shear-band regions are being detected immediately behind the shock front.

Kondo, K.-I.↗

NASA NTRS2003

Sharp Refractory Composite Leading Edges on Hypersonic Vehicles

On-going research of advanced sharp refractory composite leading edges for use on hypersonic air-breathing vehicles is presented in this paper. Intense magnitudes of heating and of heating gradients on the leading edge lead to thermal stresses that challenge the survivability of current material systems. A fundamental understanding of the problem is needed to further design development. Methodology for furthering the technology along with the use of advanced fiber architectures to improve the thermal-structural response is explored in the current work. Thermal and structural finite element analyses are conducted for several advanced fiber architectures of interest. A tailored thermal shock parameter for sharp orthotropic leading edges is identified for evaluating composite material systems. The use of the tailored thermal shock parameter has the potential to eliminate the need for detailed thermal-structural finite element analyses for initial screening of material systems being considered for a leading edge component.

Walker, Sandra P.↗