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DOE OSTI2018

Advancing Core Safety of Gen IV and Gen IV + Reactors by Encompassing High-Temperature Resistant Materials - 18673

The paper focuses on the development of materials for Gen IV/IV+ reactor core. It discusses the advancement of materials studied and their application in different components of the reactor core and other auxiliary components which will help in the development of future generation reactors. The paper summarizes the material study showing the characteristic behavior of different materials (coated with FeB and FeB{sub 2}), towards irradiation at near high temperatures and high energy neutron flux condition. The project includes different materials which are coated on the boundaries with varied thickness of FeB and FeB{sub 2}. The samples included Carbon steel, Stainless steel 310, Stainless steel 316, Inconel 718. All above-mentioned samples were received by Prof. J. Szpunar, through an industry with coatings of FeB and FeB{sub 2} with varied thickness along with a bare sample of each material. The samples were irradiated at the University of Saskatchewan reactor, with fast neutron flux of 1.1x10{sup 11} n.cm{sup -2}.sec{sup -1}. I worked on all the samples but the paper particularly focuses on, two carbon steel samples results, received so far. The methodology for the project been followed for all the samples is as follow: 1. Received samples were first polished. 2. Vickers Hardness Test. 3. Mirror polished. 4. Etched with the appropriate etchant for the material. 5. Microscopic study of the etched surface. 6. SEM imaging. 7. Sent for irradiation. 8. The same set of material testing done after irradiation, with an EBSD run on the boundary and main surface. The two Carbon Steel samples (sample 21 and 19) analyzed, were irradiated for 14 hrs. Sample 21 was a bare sample and sample 19 had a coating of FeB, FeB{sub 2} with a ∼0.0010'' thickness. The methodology was followed for material testing before and after the irradiation. The advantage of FeB and FeB{sub 2} coatings are: 1. Higher hardness - 10 times (FeB-1775 and FeB{sub 2}-1450), 2. High-stress capacity, 3. Lower abrasion, 4. Low corrosion. Through the test results obtained before and after the irradiation, I was able to get a view of coating damage at the boundaries of sample 19. The bare sample don't show any difference after irradiation but the coated sample do show cracks in the FeB layer. Which can be seen in the SEM images of sample 19. The hardness results are promising, as hardness didn't change significantly. The hardness test was done on the substrate as the coating was significantly narrow to perform the test. Though the hardness test on coatings was performed by the possessor company which show hardness higher by a factor of 10 when compared to uncoated surfaces. The XRD results, reveal irradiation effect on the crystal lattice, making it deformed, which though is usual during irradiation. The overall analysis along with EBSD done on the two samples are favorable and promising. Though it still needs to be cleared out, whether the cracks on the coating were due to irradiation or due to etching after the samples were irradiated.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1992

Life prediction and constitutive models for engine hot section anisotropic materials program

This report presents the results from a 35 month period of a program designed to develop generic constitutive and life prediction approaches and models for nickel-based single crystal gas turbine airfoils. The program is composed of a base program and an optional program. The base program addresses the high temperature coated single crystal regime above the airfoil root platform. The optional program investigates the low temperature uncoated single crystal regime below the airfoil root platform including the notched conditions of the airfoil attachment. Both base and option programs involve experimental and analytical efforts. Results from uniaxial constitutive and fatigue life experiments of coated and uncoated PWA 1480 single crystal material form the basis for the analytical modeling effort. Four single crystal primary orientations were used in the experiments: (001), (011), (111), and (213). Specific secondary orientations were also selected for the notched experiments in the optional program. Constitutive models for an overlay coating and PWA 1480 single crystal material were developed based on isothermal hysteresis loop data and verified using thermomechanical (TMF) hysteresis loop data. A fatigue life approach and life models were selected for TMF crack initiation of coated PWA 1480. An initial life model used to correlate smooth and notched fatigue data obtained in the option program shows promise. Computer software incorporating the overlay coating and PWA 1480 constitutive models was developed.

Nissley, D. M.↗

NASA NTRS1992

Life prediction and constitutive models for engine hot section anisotropic materials program

This report presents a summary of results from a 7 year program designed to develop generic constitutive and life prediction approaches and models for nickel-based single crystal gas turbine airfoils. The program was composed of a base program and an optional program. The base program addressed the high temperature coated single crystal regime above the airfoil root platform. The optional program investigated the low temperature uncoated single crystal regime below the airfoil root platform including the notched conditions of the airfoil attachment. Both base and option programs involved experimental and analytical efforts. Results from uniaxial constitutive and fatigue life experiments of coated and uncoated PWA 1480 single crystal material formed the basis for the analytical modeling effort. Four single crystal primary orientations were used in the experiments: group of zone axes (001), group of zone axes (011), group of zone axes (111), and group of zone axes (213). Specific secondary orientations were also selected for the notched experiments in the optional program. Constitutive models for an overlay coating and PWA 1480 single crystal materials were developed based on isothermal hysteresis loop data and verified using thermomechanical (TMF) hysteresis loop data. A fatigue life approach and life models were developed for TMF crack initiation of coated PWA 1480. A life model was developed for smooth and notched fatigue in the option program. Finally, computer software incorporating the overlay coating and PWA 1480 constitutive and life models was developed.

Nissley, D. M.↗

NASA NTRS1998

Cyclic Fiber Push-In Test Monitors Evolution of Interfacial Behavior in Ceramic Matrix Composites

SiC fiber-reinforced ceramic matrix composites are being developed for high-temperature advanced jet engine applications. Obtaining a strong, tough composite material depends critically on optimizing the mechanical coupling between the reinforcing fibers and the surrounding matrix material. This has usually been accomplished by applying a thin C or BN coating onto the surface of the reinforcing fibers. The performance of these fiber coatings, however, may degrade under cyclic loading conditions or exposure to different environments. Degradation of the coating-controlled interfacial behavior will strongly affect the useful service lifetime of the composite material. Cyclic fiber push-in testing was applied to monitor the evolution of fiber sliding behavior in both C- and BN-coated small-diameter (15-mm) SiC-fiber-reinforced ceramic matrix composites. The cyclic fiber push-in tests were performed using a desktop fiber push-out apparatus. At the beginning of each test, the fiber to be tested was aligned underneath a 10- mm-diameter diamond punch; then, the applied load was cycled between selected maximum and minimum loads. From the measured response, the fiber sliding distance and frictional sliding stresses were determined for each cycle. Tests were performed in both room air and nitrogen. Cyclic fiber push-in tests of C-coated, SiC-fiber-reinforced SiC showed progressive increases in fiber sliding distances along with decreases in frictional sliding stresses for continued cycling in room air. This rapid degradation in interfacial response was not observed for cycling in nitrogen, indicating that moisture exposure had a large effect in immediately lowering the frictional sliding stresses of C-coated fibers. These results indicate that matrix cracks bridged by C-coated fibers will not be stable, but will rapidly grow in moisture-containing environments. In contrast, cyclic fiber push-in tests of both BN-coated, SiC-fiber-reinforced SiC and BNcoated, SiC-fiber-reinforced barium strontium aluminosilicate showed no significant changes in fiber sliding behavior with continued short-term cycling in either room air or nitrogen. Although the composites with BN-coated fibers showed stable short-term cycling behavior in both environments, long-term (several-week) exposure of debonded fibers to room air resulted in dramatically increased fiber sliding distances and decreased frictional sliding stresses. These results indicate that although matrix cracks bridged by BNcoated fibers will show short-term stability, such cracks will show substantial growth with long-term exposure to moisture-containing environments. Newly formulated BN coatings, with higher moisture resistance, will be tested in the near future.

Eldridge, Jeffrey I.↗

DOE OSTI2018

Improving the Fatigue Crack Propagation Resistance and Damage Tolerance of 2524-T3 Alloy with Amorphous Electroless Ni-P Coating

The surface microhardness, as well as the fatigue crack propagation (FCP) resistance of 2524-T3 alloy, is improved by producing a 20-μm-thick amorphous electroless Ni-12% P coating on its surface. Compared to the substrate, this deposited EN coating possesses higher strength properties and exhibits a greater ability of accommodating the plastic deformation at the fatigue crack tip, thereby remarkably improving the FCP resistance in near-threshold and early Paris regimes. Regardless of the similar FCP rates in Paris regime (ΔK ≥ 16.2 MPa m{sup 0.5}), the coated sample exhibits extended Paris regime and enhanced damage tolerance.

36 MATERIALS SCIENCE↗

NASA NTRS2014

Sintering Characteristics of Multilayered Thermal Barrier Coatings Under Thermal Gradient and Isothermal High Temperature Annealing Conditions

Pyrochlore oxides have most of the relevant attributes for use as next generation thermal barrier coatings such as phase stability, low sintering kinetics and low thermal conductivity. One of the issues with the pyrochlore oxides is their lower toughness and therefore higher erosion rate compared to the current state-of-the-art TBC material, yttria (6 to 8 wt%) stabilized zirconia (YSZ). In this work, sintering characteristics were investigated for novel multilayered coating consisted of alternating layers of pyrochlore oxide viz Gd2Zr2O7 and t' low k (rare earth oxide doped YSZ). Thermal gradient and isothermal high temperature (1316 C) annealing conditions were used to investigate sintering and cracking in these coatings. The results are then compared with that of relevant monolayered coatings and a baseline YSZ coating.

Thermal Barrier Coatings↗

NASA NTRS1985

Thermal barrier coating life prediction model development

A methodology was established to predict thermal barrier coating life in an environment simulative of that experienced by gas turbine airfoils. Specifically, work is being conducted to determine failure modes of thermal barrier coatings in the aircraft engine environment. Analytical studies coupled with appropriate physical and mechanical property determinations are being employed to derive coating life prediction model(s) on the important failure mode(s). An initial review of experimental and flight service components indicates that the predominant mode of TBC failure involves thermomechanical spallation of the ceramic coating layer. This ceramic spallation involves the formation of a dominant crack in the ceramic coating parallel to and closely adjacent to the metal-ceramic interface. Initial results from a laboratory test program designed to study the influence of various driving forces such as temperature, thermal cycle frequency, environment, and coating thickness, on ceramic coating spalling life suggest that bond coat oxidation damage at the metal-ceramic interface contributes significantly to thermomechanical cracking in the ceramic layer. Low cycle rate furnace testing in air and in argon clearly shows a dramatic increase of spalling life in the non-oxidizing environments.

Sheffler, K. D.↗

NASA NTRS1988

Fatigue damage modeling for coated single crystal superalloys

A high temperature, low-cycle fatigue life prediction method for coated single crystal nickel-base superalloys is being developed. The method is being developed for use in predicting crack initiation life of coated single crystal turbine airfoils. Although the models are being developed using coated single crystal PWA 1480, they should be readily adaptable to other coated nickel-base single crystal materials. The coatings choosen for this effort were of two generic types: a low pressure plasma sprayed NiCoCrAlY overlay, designated PWA 286, and an aluminide diffusion, designated PWA 273. In order to predict the useful crack initiation life of airfoils, the constitutive and failure behavior of the coating/substrate combination must be taken into account. Coatings alter the airfoil surface microstructure and are a primary source from which cracks originate. The adopted life prediction approach addresses this complexity by separating the coating and single crystal crack initiation regimes. This provides a flexible means for using different life model formulations for the coating and single crystal materials. At the completion of this program, all constitutive and life model formulations will be available in equation form and as software. The software will use the MARC general purpose finite element code to drive the constitutive models and calculate life parameters.

Nissley, David M.↗

DOE OSTI2018

Microstructure and Performance of Nano-WC Particle-Strengthened Ni Coatings by Electro-brush Plating

Nano-WC particle-strengthened Ni composite coatings were prepared by electro-brush plating. A series of artificial neural network models was developed for the analysis and prediction of the coating performance. The microstructure and phase structure were studied with SEM, XRD and EDS. Nano-WC particles as the hard phase were distributed evenly and dispersed in the coatings, which was conducive to the hardness enhancement of the coatings. Additionally, nano-WC particles as microballs inserted in the coatings could reduce the friction when wear of the coating surface occurred. Furthermore, the addition of nano-WC particles delayed the time of crack initiation and propagation in the coatings, which increased the service lifetime when they worked in a thermal shock environment.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2020

Investigating the Interaction between Persistent Slip Bands and Surface Hard Coatings via Crystal Plasticity Simulations

Fatigue cracks often initiate from the surface extrusion/intrusions formed due to the operation of persistent slip bands (PSBs). Suppression of these surface topographical features by hard surface coatings can significantly extend fatigue lives under lower stress amplitudes (i.e., high cycle fatigue), while cracks initiate early in the coating or in the coating–substrate interface under higher stress amplitudes (i.e., low cycle fatigue), deteriorating the fatigue performance. However, both beneficial and detrimental effects of the coatings appear to be affected by the coating–substrate material combination and coating thickness. A quantitative understanding of the role of these factors in the fatigue performance of materials is still lacking. In this study, crystal plasticity simulations were employed to elucidate the dependence of the coating’s effects on two factors—i.e., the coating thickness and loading amplitudes. The results revealed that the thicker coatings more effectively suppress the operation of the PSBs, but generate higher tensile and shear stresses, normal and parallel to the interfaces, respectively, promoting interfacial delamination. The tensile stresses parallel to the interface within the coating, which favors coating fracture, are not sensitive to the coating thickness.

36 MATERIALS SCIENCE↗

NASA NTRS2004

Atomic Oxygen Durability Evaluation of a UV Curable Ceramer Protective Coating

The exposure of most silicones to atomic oxygen in low Earth orbit (LEO) results in the oxidative loss of methyl groups with a gradual conversion to oxides of silicon. Typically there is surface shrinkage of oxidized silicone protective coatings which leads to cracking of the partially oxidized brittle surface. Such cracks widen and branch crack with continued atomic oxygen exposure ultimately allowing atomic oxygen to reach any hydrocarbon polymers under the silicone coating. A need exists for a paintable silicone coating that is free from such surface cracking and can be effectively used for protection of polymers and composites in LEO. A new type of silicone based protective coating holding such potential was evaluated for atomic oxygen durability in an RF atomic oxygen plasma exposure facility. The coating consisted of a UV curable inorganic/organic hybrid coating, known as a ceramer, which was fabricated using a methyl substituted polysiloxane binder and nanophase silicon-oxo-clusters derived from sol-gel precursors. The polysiloxane was functionalized with a cycloaliphatic epoxide in order to be cured at ambient temperature via a cationic UV induced curing mechanism. Alkoxy silane groups were also grafted onto the polysiloxane chain, through hydrosilation, in order to form a network with the incorporated silicon-oxo-clusters. The prepared polymer was characterized by H-1 and Si-29 NMR, FT-IR, and electrospray ionization mass spectroscopy. The paper will present the results of atomic oxygen protection ability of thin ceramer coatings on Kapton H as evaluated over a range of atomic oxygen fluence levels.

Banks, Bruce A.↗

NASA NTRS2008

Impact Resistance of EBC Coated SiC/SiC Composites

Impact performance of 2-D woven SiC/SiC composites coated with 225 and 525 m thick environmental barrier coating (EBC) was investigated. The composites were fabricated by melt infiltration and the EBC was deposited by plasma spray. Impact tests were conducted at room temperature and at 1316 C in air using 1.59-mm diameter steel-balls at projectile velocities ranging from 110 to 375 m/s. Both microscopy and nondestructive evaluation (NDE) methods were used to determine the extent of damage in the substrate and coating with increasing projectile velocity. The impacted specimens were tensile tested at room temperature to determine their residual mechanical properties. At projectile velocities less than 125 m/s, no detectable damage was noticed in the MI SiC/SiC composites coated with 525 m EBC. With increase in projectile velocity beyond this value, spallation of EBC layers, delamination of fiber plies, and fiber fracture were detected. At a fixed projectile velocity, the composites coated with 525 m EBC showed less damage than the composite coated with 225 m EBC. Both types of EBC coated composites retained a large fraction of the baseline properties of as-fabricated composites and exhibited non-brittle failure after impact testing at projectile velocities up to 375 m/s. Exposure of impact tested specimens in a moisture environment at 1316 C for 500 hr indicated that the through-the-thickness cracks in the EBC coating and delamination cracks in the substrate generated after impact testing acted as conduits for internal oxidation.

Fox, Dennis S.↗

NASA NTRS2013

Method for repairing cracks in structures

A first material with a known maximum temperature of operation is coated with a second material on at least one surface of the first material. The coating has a melting temperature that is greater than the maximum temperature of operation of the first material. The coating is heated to its melting temperature until the coating flows into any cracks in the first material's surface.

Smith, Stephen W.↗

NASA NTRS2014

System for Repairing Cracks in Structures

Smith, Stephen W.↗

NASA NTRS1972

Evaluation of nondestructive testing techniques for the space shuttle nonmetallic thermal protection system

A program was conducted to evaluate nondestructive analysis techniques for the detection of defects in rigidized surface insulation (a candidate material for the Space Shuttle thermal protection system). Uncoated, coated, and coated and bonded samples with internal defects (voids, cracks, delaminations, density variations, and moisture content), coating defects (holes, cracks, thickness variations, and loss of adhesion), and bondline defects (voids and unbonds) were inspected by X-ray radiography, acoustic, microwave, high-frequency ultrasonic, beta backscatter, thermal, holographic, and visual techniques. The detectability of each type of defect was determined for each technique (when applicable). A possible relationship between microwave reflection measurements (or X-ray-radiography density measurements) and the tensile strength was established. A possible approach for in-process inspection using a combination of X-ray radiography, acoustic, microwave, and holographic techniques was recommended.

Tiede, D. A.↗

NASA NTRS1992

Durability evaluation of photovoltaic blanket materials exposed on LDEF tray S1003

Several candidate protective coatings on Kapton and uncoated Kapton were exposed to the low Earth orbital (LEO) environment on the Long Duration Exposure Facility (LDEF) to determine if the coatings could be used to protect polymeric substrates from degradation in the LEO environment. The coatings that were evaluated were 700 A of aluminum oxide, 650 A of silicon dioxide, and 650 A of a 4 percent polytetrafluoroethylene-96 percent silicon dioxide mixed coating. All of the coatings evaluated were ion beam sputter deposited. These materials were exposed to a very low atomic oxygen fluence (4.8 x 10 exp 19 atoms/sq. cm) as a result of the experiment tray being located 98 degrees from the ram direction. As a result of the low atomic oxygen fluence, determination of a change in mass was not possible for any of the samples including the uncoated Kapton. There was no evidence of spalling of any of the coatings after the approximately 33,600 thermal cycles recorded for LDEF. The surface of the uncoated Kapton, however, did show evidence of grazing incidence texturing. There was a 7-8 percent increase in solar absorptance for the silicon dioxide and aluminum oxide coated Kapton and only a 4 percent increase for the mixed coating. It appears that the addition of a small amount of fluoropolymer may reduce the magnitude of absorptance increase due to environmental exposure. Thermal emittance did not change significantly for any of the exposed samples. Scanning electron microscopy revealed few micrometeoroid or debris impacts, but the impact sites found indicated that the extent of damage or cracking of the coating around the defect site did not extend beyond a factor of three of the impact crater diameter. This limiting of impact damage is of great significance for the durability of thin film coatings used for protection against the LEO environment.

Sharon K Rutledge↗

NASA NTRS1981

Development of improved high temperature coatings for IN-792 + HF

The development for t-55 l712 engine of high temperature for integral turbine nozzles with improved thermal fatigue resistance without sacrificing oxidation/corrosion protection is discussed. The program evaluated to coating systems which comprised one baseline plasma spray coating (12% Al-NiCoCrALY), three aluminide coatings including the baseline aluminide (701), two CoNiCrAly (6% Al) + aluminide systems and four NiCoCrY + aluminide coating were evaluated. The two-step coating processes were investigated since it offered the advantage of tailoring the composition as well as properly coating surfaces of an integral or segmented nozzle. Cyclic burner rig thermal fatigue and oxidation/corrosion tests were used to evaluate the candidate coating systems. The plasma sprayed 12% Al-NiCoCrAlY was rated the best coating in thermal fatigue resistance and outperformed all coatings by a factor between 1.4 to 2.5 in cycles to crack initiation. However, this coatings is not applicable to integral or segmented nozzles due to the line of sight limitation of the plasma spray process. The 6% Al-CoNiCrAlY + Mod. 701 aluminide (32 w/o Al) was rated the best coating in oxidation/corrosion resistance and was rated the second best in thermal fatigue resistance.

Profant, D. D.↗

NASA NTRS1986

Thermal barrier coating life prediction model development

A methodology is established to predict thermal barrier coating life in a environment similar to that experienced by gas turbine airfoils. Experiments were conducted to determine failure modes of the thermal barrier coating. Analytical studies were employed to derive a life prediction model. A review of experimental and flight service components as well as laboratory post evaluations indicates that the predominant mode of TBC failure involves thermomechanical spallation of the ceramic coating layer. This ceramic spallation involves the formation of a dominant crack in the ceramic coating parallel to and closely adjacent to the topologically complex metal ceramic interface. This mechanical failure mode clearly is influenced by thermal exposure effects as shown in experiments conducted to study thermal pre-exposure and thermal cycle-rate effects. The preliminary life prediction model developed focuses on the two major damage modes identified in the critical experiments tasks. The first of these involves a mechanical driving force, resulting from cyclic strains and stresses caused by thermally induced and externally imposed mechanical loads. The second is an environmental driving force based on experimental results, and is believed to be related to bond coat oxidation. It is also believed that the growth of this oxide scale influences the intensity of the mechanical driving force.

Demasi, J. T.↗