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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 1,153 records · Page 64
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Evaluation of critical heat flux of ATF candidate coating materials in pool boiling

The critical heat flux (CHF) of potential accident tolerant fuel (ATF) cladding materials and concepts, Cr and FeCrAl coatings on zirconium-alloy substrates, was investigated experimentally. A cold spray process, which involves the propulsion of high velocity powder particles on to the substrate surface to form a coating upon impact, was used to create the coatings. Surface parameters such as contact angle, surface roughness, and morphology that are associated with CHF in pool boiling were characterized. Non-hydrodynamic effects of newly developed ATF candidate coating materials on CHF were also evaluated. The effects of thermal properties and coating thickness and expected challenges for evaluation of CHF for new ATF cladding materials development are discussed.

36 MATERIALS SCIENCE↗
NASA NTRS1979

Internal coating of air cooled gas turbine blades

Six coating systems were evaluated for internal coating of decent stage (DS) eutectic high pressure turbine blades. Sequential deposition of electroless Ni by the hydrazine process, slurry Cr, and slurry Al, followed by heat treatment provided the coating composition and thickness for internal coating of DS eutectic turbine blades. Both NiCr and NiCrAl coating compositions were evaluated for strain capability and ductile to brittle transition temperature.

Ahuja, P. L.↗
NASA NTRS1980

Investigation of proposed process sequence for the array automated assembly task, phases 1 and 2

Progress was made on the process sequence for module fabrication. A shift from bonding with a conformal coating to laminating with ethylene vinyl acetate and a glass superstrate is recommended for further module fabrication. The processes that were retained for the selected process sequence, spin-on diffusion, print and fire aluminum p+ back, clean, print and fire silver front contact and apply tin pad to aluminum back, were evaluated for their cost contribution.

Mardesich, N.↗
DOE OSTI2019

CORROSION RESISTANCE OF LASER-INTERFERENCE STRUCTURED ALUMINUM ALLOY 2024 COATED WITH MIL-PRF-85582 PRIMER

The use of aluminum alloys in aerospace industry requires more effective and reliable joining techniques. The lubricant contaminants from prior rolling operations affect surface energies and the quality of coating adhe-sion and adhesive bonded joints. In this study, a new laser-based technique is investigated as a surface treatment for coating applications. The laser interference power profile was created by splitting the beam and guiding both beams towards the specimen and overlapping them on the specimen surface, creating a line-interference pattern on the specimen surface. The laser-interference structuring (LIS) was used without any chemical treatments, such as those in chemical conversion coating (CCC) and sulfuric acid anodizing (SAA), which is a much simpler process than those chemical-based. To assess the effect of LIS on corrosion re-sistance of coating, Al 2024 panels prepared by LIS, CCC and SAA were coated with MIL-PRF-85582, Type I, Class N primer and exposed to salt spray environment according to ASTM B117. The exposure is currently in progress and the corrosion attack on the coated panels will be evaluated by the degree of blister formation and rust creepage.

Sabau, Adrian↗
DOE OSTI2022

Spray coating for washout tooling by binder jet additive manufacturing

We report washout tooling is a process in which a removable mold or fixture is disintegrated using a solvent. Binder Jet (BJ) additive manufacturing holds promise for creating customized washout molds from common materials. BJ-based washout tooling provides an advanced strategy in manufacturing fiber-reinforced composites (FRCs), especially for customized hollow FRCs. However, washout tools formed by BJ require an impermeable barrier between the porous tooling surface and the parts laid up on the surface to prevent the resin from infiltrating the tooling surface and bonding the tool to the FRC. The conventional method for preventing resin migration into the washout mold from the FRC is winding Teflon® tape over the entire surface, which is labor-intensive and very difficult to deploy for specific geometries. Here, we report the development of a polymer spray coating method to seal the tooling surface and prevent resin infiltration without affecting the washout properties needed for sacrificial tooling. Two water-soluble polymers, poly(sodium 4-styrenesulfonate) (PSS–Na) and poly(vinylsulfonic acid, sodium salt) (PVS–Na), were investigated for spray coating. PVS-Na maintained tighter geometric tolerances and provided excellent thermal stability with the onset of decomposition at 320 °C and glass transition temperature of 280 °C. Spray coating with PVS-Na streamlines the process of forming a protective layer for the washout molds by BJ, reduces migration of the resins from the FRC, and significantly improves the production efficiency of complex washout tools.

42 ENGINEERING↗
DOE OSTI2018

Fabrication of highly efficient carbon coated exfoliated tungsten disulfide nanosheets core-shell nanostructure as a promising solar-light driven photocatalyst

Highlights: • Investigated the benefits of exfoliation mechanism of WS{sub 2} nanosheets. • C@e-WS{sub 2} was successfully synthesized via two step exfoliation -hydrothermal process. • C@e-WS{sub 2} core-shell confirmed by HRTEM. • C@e-WS{sub 2} core-shell photocatalyst exhibited excellent photocatalytic activity. • Photodegradation mechanism of C@e-WS{sub 2} photocatalyst is elucidated and discussed. - Abstract: Exfoliated Tungsten disulfide (e-WS{sub 2}) nanosheets were obtained from bulk Tungsten disulfide (WS{sub 2}) in a liquid-phase ultrasonic exfoliation method using a DMF solvent. Core-shell mannered carbon coating was developed by hydrothermal process on exfoliated Tungsten disulfide (e-WS{sub 2}) to enhance the efficient charge separation, specific surface area with mesoporosity and stability for chemical processes and mechanical strains. The carbon coated e-WS{sub 2} nanosheets (C@e-WS{sub 2}) was performed by series of characterization techniques and explored to the photocatalytic degradation of malachite green (MG) dye by comparing with bulk WS{sub 2} and e-WS{sub 2}. Among all the photocatalysts highest performance was observed for the C@e-WS{sub 2}. C@e-WS{sub 2} catalyst displays more than 11 fold enhancements in the photocomposition rate of MG over bulk WS{sub 2} and nearly 8 fold improvements over e-WS{sub 2} for 90 min irradiation. In addition, for complete degradation of MG dye over the bulk WS{sub 2}, e-WS{sub 2}, and C@e-WS{sub 2} catalysts were observed at 150, 130, and 90 min under simulated solar light irradiation. The results obtained using core-shell mannered C@e-WS{sub 2} are stepping stone for developing cost-effective and noble metal-free catalysts for photodegradation.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2018

Tribological and Corrosion Properties of Coatings Produced by Plasma Electrolytic Oxidation on the ZA27 Alloy

In this paper, a continuous and dense coating was deposited on samples of the ZA27 alloy through the plasma electrolytic oxidation (PEO) process to improve its wear and corrosion performance. A nontoxic and environmentally friendly inorganic salt, Na{sub 2}SiO{sub 3}, is chosen as electrolytes with different concentrations. The effect of the concentration of Na{sub 2}SiO{sub 3} aqueous solutions on the coating performances was investigated. The coatings with 3Al{sub 2}O{sub 3}·2SiO{sub 2} (mullite), Zn{sub 2}SiO{sub 4} and Al{sub 2}O{sub 3} (either crystal phase or with some amorphous SiO{sub 2} phases) were formed by the PEO processes. It was found that the coating thickness increased with the increase in electrolyte concentration. However, the wear and corrosion resistance performance of the coatings did not improve as the coating’s thickness increased. This was due to the fact that the coating produced with electrolytes of 10 g/L has a porous structure with large pore size. Among all the samples, coating produced by 15 g/L Na{sub 2}SiO{sub 3} has the best wear and corrosion resistance, which is attributed to its continuous and dense structure with thickness of about 47 μm.

36 MATERIALS SCIENCE↗
DOE OSTI2018

An inorganic coating and flexible regulating in situ of stent endothelialization by the controllable ion releasing

Highlights: • The Cu/Ti film with regulating the various responses of ECs and SMCs has been prepared. • The hemocompatibility could be adjusted via the ratio of Cu/Ti. • The volume and velocity of copper ion released from film was designed via the preparation processing. - Abstract: A facile approach to fabricate an inorganic coating with favorable blood compatibility and accelerating endothelialization is reported. The inorganic coating with various ratios of Cu and Ti atom are prepared on 316 L stainless steel by physical vapor deposition method. The phase composition and structure as well as the element concentration of the coating are investigated by X-ray diffraction and X-photoelectron energy spectrum. The hemolysis ratio, clotting time and platelet adhesion are utilized to characterize the materials’ hemocompatibility, the copper ion releasing was also investigated via immersing test. The result indicates that copper-titanium coating show good compatibility; however, as the ratio of Cu to Ti increases, the hemolysis ratio also increases. The endothelialization degree was accelerated owing to maintain less than 7.0 μg/ml of Cu{sup 2+} concentrate, and endothelial cells proliferate more readily than smooth muscle cells. The results demonstrate that this degradable copper-containing coating is suitable as a new surface modification for vascular stents.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Development and Understanding of Nb 3 Sn films for radiofrequency applications through a sample-host 9-cell cavity

Nb 3 Sn is a promising advanced material under development for superconducting radiofrequency cavities. Past efforts have been focused primarily on small development-scale cavities, but large, often multi-celled cavities, are needed for particle accelerator applications. In this work, we report on successful Nb 3 Sn coatings on Nb in a 1 m-long 9-cell Nb sample-host cavity at Fermilab. The geometry of the first coating with only one Sn source made it possible to study the influence of Sn flux on the microstructure. Based on these results, we postulate a connection between recently observed anomalously large thin grains and uncovered niobium spots observed in the past by other authors (Trenikhina et al 2018 Supercond. Sci. Technol. 32 015004). A phenomenological model to explain how these anomalously large grains could form is proposed. Overall, this model is invoked to provide possible explanations for literature results from several groups and to guide key process parameters to achieve uniform vapor-diffusion coatings, when applied to complex structures as the multi-cell cavity under study.

43 PARTICLE ACCELERATORS↗
DOE OSTI2017

Chemical weathering of layered Ni-rich oxide electrode materials: Evidence for cation exchange

Lithiated ternary oxides containing nickel, cobalt, and manganese are intercalation compounds that are used as positive electrodes in high-energy lithium-ion batteries. These materials undergo compositional changes that adversely affect their cycling performance when they are stored in humid air or exposed to moisture. There is a new urgency to better understanding of these “weathering” processes as manufacturing moves towards a more environmentally benign aqueous processing of the positive electrode. Delithiation in the oxide subsurface regions and the formation of lithium salts (such as hydroxides and carbonates) coating the surface, have been suggested as chemical drivers for these processes, but the mechanistic details remain poorly known. The redox reactions which follow oxide delithiation are believed to cause all of the observed transformations. In this article we suggest another possibility: namely, the proton – lithium exchange. We argue that this hypothesis provides a simple, comprehensive rationale for our observations from X-ray diffraction, X-ray photoelectron spectroscopy, scanning transmission electron microscopy, and electrochemical measurements. These observations include contraction of the c-axis (unit cell) lattice parameter, strain in the crystalline oxide bulk, directionality of the chemical damage, formation of amorphous surface films, and the partial recovery of capacity loss by electrochemical relithiation of the material. Lastly, these effects need to be mitigated before aqueous processing of the positive electrode can find widespread adoption during cell manufacturing.

25 ENERGY STORAGE↗
NASA NTRS1981

Charging control techniques

Transparent conductive thin films of indium oxide and indium-tin oxide were evaluated for their properties to control charge buildup on satellite materials. Both oxide coatings were evaluated for their uniformity, stability, reproducibility and characteristics on various substrate materials such as FEP Teflon, Kapton, and glass. The process development toward optimization and characterization of these thin semiconductor oxide coatings and the evaluation on large sizes performed for qualification for use on thermal control satellite materials is described. The materials have been characterized in multiple energy electron plasma environment and at low temperatures. All radiation measurements of the coatings under simulated substorm conditions have exhibited the characteristics of stable charge control. Measurement of surface potential during and after irradiation by electrons up to 30 KeV and ionizing gamma radiation show an effective stable grounding surface.

Schmidt, R. E.↗
NASA NTRS1976

Coatings for directional eutectics

Coatings developed to provide oxidation protection for the directionally-solidified eutectic alloy NiTaC-B (4.4 weight percent Cr) were evaluated. Of seven Co-, Fe- and Ni-base coatings that were initially investigated, best resistance to cyclic oxidation was demonstrated by duplex coatings fabricated by depositing a layer of NiCrAl(Y) by vacuum evaporation from an electron beam source followed by deposition of an Al overlayer using the pack cementation process. It was found that addition of carbon to the coating alloy substantially eliminated the problem of fiber denudation in TaC-type eutectic alloys. Burner rig cycled NiTaC-B samples coated with Ni-20Cr-5Al-0.1C-0.1Y+Al and rupture-tested at 1100 deg C performed as well as or better than uncoated, vacuum cycled and air-tested NiTaC-13; however, a slight degradation with respect to uncoated material was noted in air-stress rupture tests at 870 deg C for both cycled and uncycled samples.

Rairden, J. R.↗
NASA NTRS2000

Dry Ribbon for Heated Head Automated Fiber Placement

Ply-by-ply in situ processes involving automated heated head deposition are being developed for fabrication of high performance, high temperature composite structures from low volatile content polymer matrices. This technology requires (1) dry carbon fiber towpreg, (2) consolidation of towpreg to quality, placement-grade unidirectional ribbon or tape, and (3) rapid, in situ, accurate, ply-by-ply robotic placement and consolidation of this material to fabricate a composite structure. In this study, the physical properties of a candidate thermoplastic ribbon, PIXA/IM7, were evaluated and screened for suitability in robotic placement. Specifically, towpreg was prepared from PIXA powder. Various conditions (temperatures) were used to convert the powder-coated towpreg to ribbons with varying degrees of processability. Ribbon within preset specifications was fabricated at 3 temperatures: 390, 400 and 410 C. Ribbon was also produced out-of-spec by purposely overheating the material to a processing temperature of 450 C. Automated placement equipment at Cincinnati Milacron and NASA Langley was used to fabricate laminates from these experimental ribbons. Ribbons were placed at 405 and 450 C by both sets of equipment. Double cantilever beam and wedge peel tests were used to determine the quality of the laminates and, especially, the interlaminar bond formed during the placement process. Ribbon made under conditions expected to be non-optimal (overheated) resulted in poor placeability and composites with weak interlaminar bond strengths, regardless of placement conditions. Ribbon made under conditions expected to be ideal showed good processability and produced well-consolidated laminates. Results were consistent from machine to machine and demonstrated the importance of ribbon quality in heated-head placement of dry material forms. Preliminary screening criteria for the development and evaluation of ribbon from new matrix materials were validated.

Hulcher, A. Bruce↗
NASA NTRS1997

Computational Modeling in Structural Materials Processing

High temperature materials such as silicon carbide, a variety of nitrides, and ceramic matrix composites find use in aerospace, automotive, machine tool industries and in high speed civil transport applications. Chemical vapor deposition (CVD) is widely used in processing such structural materials. Variations of CVD include deposition on substrates, coating of fibers, inside cavities and on complex objects, and infiltration within preforms called chemical vapor infiltration (CVI). Our current knowledge of the process mechanisms, ability to optimize processes, and scale-up for large scale manufacturing is limited. In this regard, computational modeling of the processes is valuable since a validated model can be used as a design tool. The effort is similar to traditional chemically reacting flow modeling with emphasis on multicomponent diffusion, thermal diffusion, large sets of homogeneous reactions, and surface chemistry. In the case of CVI, models for pore infiltration are needed. In the present talk, examples of SiC nitride, and Boron deposition from the author's past work will be used to illustrate the utility of computational process modeling.

Meyyappan, Meyya↗
NASA NTRS2004

Conversion Coatings for Aluminum Alloys by Chemical Vapor Deposition Mechanisms

With the rise of environmental awareness and the renewed importance of environmentally friendly processes, the United States Environmental Protection Agency has targeted surface pre-treatment processes based on chromates. Indeed, this process has been subject to regulations under the Clean Water Act as well as other environmental initiatives, and there is today a marked movement to phase the process out in the near future. Therefore, there is a clear need for new advances in coating technology that could provide practical options for replacing present industrial practices. Depending on the final application, such coatings might be required to be resistant to corrosion, act as chemically resistant coatings, or both. This research examined a chemical vapor deposition (CVD) mechanism to deposit uniform conversion coatings onto aluminum alloy substrates. Robust protocols based on solutions of aryl phosphate ester and multi-oxide conversion coating (submicron) films were successfully grown onto the aluminum alloy samples. These films were characterized by X-ray Photoelectron Spectroscopy (XPS). Preliminary results indicate the potential of this technology to replace aqueous-based chromate processes.

Reye, John T.↗
DOE OSTI2017

Enhanced Flux and Electrochemical Cleaning of Silicate Scaling on Carbon Nanotube-Coated Membrane Distillation Membranes Treating Geothermal Brines

The desalination of inland brackish groundwater offers the opportunity to provide potable drinking water to residents and industrial cooling water to industries located in arid regions. Geothermal brines are used to generate electricity, but often contain high concentrations of dissolved salt. Here in this paper, we demonstrate how the residual heat left in spent geothermal brines can be used to drive a membrane distillation (MD) process and recover desalinated water. Porous polypropylene membranes were coated with a carbon nanotube (CNT)/poly(vinyl alcohol) layer, resulting in composite membranes having a binary structure that combines the hydrophobic properties critical for MD with the hydrophilic and conductive properties of the CNTs. We demonstrate that the addition of the CNT layer increases membrane flux due to enhanced heat transport from the bulk feed to the membrane surface, a result of CNT's high thermal transport properties. Furthermore, we show how hydroxide ion generation, driven by water electrolysis on the electrically conducting membrane surface, can be used to efficiently dissolve silicate scaling that developed during the process of desalinating the geothermal brine, negating the need for chemical cleaning.

15 GEOTHERMAL ENERGY↗
NASA NTRS2005

Sprayable Phase Change Coating Thermal Protection Material

NASA has expressed a need for reusable, environmentally friendly, phase change coating that is capable of withstanding the heat loads that have historically required an ablative thermal insulation. The Space Shuttle Program currently relies on ablative materials for thermal protection. The problem with an ablative insulation is that, by design, the material ablates away, in fulfilling its function of cooling the underlying substrate, thus preventing the insulation from being reused from flight to flight. The present generation of environmentally friendly, sprayable, ablative thermal insulation (MCC-l); currently use on the Space Shuttle SRBs, is very close to being a reusable insulation system. In actual flight conditions, as confirmed by the post-flight inspections of the SRBs, very little of the material ablates. Multi-flight thermal insulation use has not been qualified for the Space Shuttle. The gap that would have to be overcome in order to implement a reusable Phase Change Coating (PCC) is not unmanageable. PCC could be applied robotically with a spray process utilizing phase change material as filler to yield material of even higher strength and reliability as compared to MCC-1. The PCC filled coatings have also demonstrated potential as cryogenic thermal coatings. In experimental thermal tests, a thin application of PCC has provided the same thermal protection as a much thicker and heavier application of a traditional ablative thermal insulation. In addition, tests have shown that the structural integrity of the coating has been maintained and phase change performance after several aero-thermal cycles was not affected. Experimental tests have also shown that, unlike traditional ablative thermal insulations, PCC would not require an environmental seal coat, which has historically been required to prevent moisture absorption by the thermal insulation, prevent environmental degradation, and to improve the optical and aerodynamic properties. In order to reduce the launch and processing costs of a reusable space vehicle to an affordable level, refurbishment costs must be substantially reduced. A key component of such a cost effective approach is the use of a reusable, phase change, thermal protection coating.

Richardson, Rod W.↗