Development of Advanced Pipeline Materials: Metallic Coatings and Composite Liners
2021 Carbon Management and Oil and Gas Research Project Review Meeting, Virtual, August 23-27, 2021
Belarbi, Zineb↗
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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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Optical coating technology for the EUV
Advances in optical coating and materials technology are one of the key motivators for the development of missions such as the Far Ultraviolet Spectroscopic Explorer recently selected by NASA for an Explorer class mission in the mid 1990's. The performance of a range of candidate coatings are reviewed for normal-incidence and glancing-incidence applications, and attention is given to strengths and problem areas for their use in space. The importance of recent developments in multilayer films, chemical-vapor deposited SiC (CVD-SiC) mirrors, and SiC films are discussed in the context of EUV instrumentation design. For example, the choice of optical coatings is a design driver for the selection of the average glancing angle for the FUSE telescope, and impacts efficiency, short-wavelength cut-off, and physical size.
Osantowski, J. F.↗
Oil-Free Rotor Support Technologies for Long Life, Closed Cycle Brayton Turbines
The goal of this study is to provide technological support to ensure successful life and operation of a 50-300 kW dynamic power conversion system specifically with response to the rotor support system. By utilizing technical expertise in tribology, bearings, rotordynamic, solid lubricant coatings and extensive test facilities, valuable input for mission success is provided. A discussion of the history of closed cycle Brayton turboalternators (TA) will be included. This includes the 2 kW Mini-Brayton Rotating Unit (Mini-BRU), the 10kW Brayton Rotating Unit (BRU) and the 125 kW turboalternator-compressor (TAC) designed in mid 1970's. Also included is the development of air-cycle machines and terrestrial oil-free gas turbine power systems in the form of microturbines, specifically Capstone microturbines. A short discussion of the self-acting compliant surface hydrodynamic fluid film bearings, or foil bearings, will follow, including a short history of the load capacity advances, the NASA coatings advancements as well as design model advances. Successes in terrestrial based machines will be noted and NASA tribology and bearing research test facilities will be described. Finally, implementation of a four step integration process will be included in the discussion.
Lucero, John M.↗
Adhesion, structure, and mechanical properties of Cr HiPIMS and cathodic arc deposited coatings on SiC
Chromium deposited by high-power impulse magnetron sputtering (HIPIMS) versus cathodic arc (CA) processes exhibits very different mechanical properties. Combining the two can result in a single-phase with superior performance that can be tailored for use in coating SiC for advanced nuclear fuel cladding. Coating morphology, residual stress, elemental depth profiles, and mechanical testing by scratch, pull-off adhesion, and microcantilevers are shown for HiPIMS, CA, and combined coatings. CA coatings were likely to spall and had lower adhesion strength due to tensile residual stresses but had desirable material properties. Additionally, by depositing an initial layer of Cr by HiPIMS followed by a layer of Cr by CA, a more adherent coating was achieved and some of the stress issues with CA morphology were resolved. Combined coatings withstood at least 80 MPa in pull-off adhesion tests and had maximum failure stress values of 5GPa in microcantilever tests. These results were better than either individual deposition method and point to a hybrid approach being a path forward for a more robust coating.
36 MATERIALS SCIENCE↗
Microstructure Investigation and Mechanical Properties of Coated Zircaloy Cladding
Accident Tolerant Fuel concepts have been developed and tested in diverse research programs presently around the world. Industry teams have developed proprietary coating compositions and geometries, but significant knowledge gaps exist in terms of the resulting properties of the coating and the cladding and how those components impact each other in reactor conditions. Furthermore, the national laboratory and university teams currently studying the industry concepts are limited in their ability to freely disseminate and discuss results obtained on commercial coatings. The Advanced Fuels Campaign is therefore working to develop an understanding of ‘generic’ coatings applied to commercial nuclear cladding alloys free of these constraints. This milestone report provides insights in the microstructure of a 7-micrometer Cr coating on Zircaloy-2 and a 5- micrometer coating on Zry-4 as reference materials. SEM and TEM methods were utilized to describe and identify the interface, while nanoindentation was used to determine hardness and E-Moduli of coating and cladding material. This milestone summarizes the acquired knowledge to build a necessary verified foundation for future simulation and qualification efforts.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Phase Stability and Thermal Conductivity of Composite Environmental Barrier Coatings on SiC/SiC Ceramic Matrix Composites
Advanced environmental barrier coatings are being developed to protect SiC/SiC ceramic matrix composites in harsh combustion environments. The current coating development emphasis has been placed on the significantly improved cyclic durability and combustion environment stability in high-heat-flux and high velocity gas turbine engine environments. Environmental barrier coating systems based on hafnia (HfO2) and ytterbium silicate, HfO2-Si nano-composite bond coat systems have been processed and their stability and thermal conductivity behavior have been evaluated in simulated turbine environments. The incorporation of Silicon Carbide Nanotubes (SiCNT) into high stability (HfO2) and/or HfO2-silicon composite bond coats, along with ZrO2, HfO2 and rare earth silicate composite top coat systems, showed promise as excellent environmental barriers to protect the SiC/SiC ceramic matrix composites.
Benkel, Samantha↗
Low Conductivity Thermal Barrier Coatings
Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. In this presentation, thermal barrier coating development considerations and requirements will be discussed. An experimental approach is established to monitor in real time the thermal conductivity of the coating systems subjected to high-heat-flux, steady-state and cyclic temperature gradients. Advanced low conductivity thermal barrier coatings have also been developed using a multi-component defect clustering approach, and shown to have improved thermal stability. The durability and erosion resistance of low conductivity thermal barrier coatings have been improved utilizing advanced coating architecture design, composition optimization, in conjunction with more sophisticated modeling and design tools.
Zhu, Dong-Ming↗
Advanced Environmentally Resistant Lithium Fluoride Mirror Coatings for the Next Generation of Broadband Space Observatories
Recent advances in the physical vapor deposition (PVD) of protective fluoride films have raised the far-ultraviolet (FUV: 912-1600 A) reflectivity of aluminum-based mirrors closer to the theoretical limit. The greatest gains, at more than 20%, have come for lithium fluoride-protected aluminum, which has the shortest wavelength cutoff of any conventional overcoat. Despite the success of the NASA FUSE mission, the use of lithium fluoride (LiF)-based optics is rare, as LiF is hygroscopic and requires handling procedures that can drive risk. With NASA now studying two large mission concepts for astronomy, Large UV-Optical-IR Surveyor (LUVOIR) and the Habitable Exoplanet Imaging Mission (HabEx), which mandate throughput down to 1000 , the development of LiF-based coatings becomes crucial. This paper discusses steps that are being taken to qualify these new enhanced LiF-protected aluminum (eLiF) mirror coatings for flight. In addition to quantifying the hygroscopic degradation, we have developed a new method of protecting eLiF with an ultrathin (10-20 A) capping layer of a nonhygroscopic material to increase durability. We report on the performance of eLiF-based optics and assess the steps that need to be taken to qualify such coatings for LUVOIR, HabEx, and other FUV-sensitive space missions.
Fleming, Brian↗
Advancements in Lunar Dust Mitigation and Leveraging the Contamination Control Community
Lunar Dust Contamination: As we get closer to putting landers, rovers, payloads, and astronauts on the Moon, dust mitigation is becoming more critical than ever. To address the many challenges of dust mitigation on the surface, engineers and scientists are looking at various technologies that may have relevance for the contamination control community. This includes active, passive, architectural, and operational solutions. There have been advances in coatings for dust mitigation at NASA and through commercial partnerships (see Wiesner, Wohl, et al). There have been advancements to previous solutions as well as novel solutions to address dust mitigation on the surface and on-orbit. There have been several efforts to better understand the effectiveness of various terrestrial and dust mitigation solutions with much of this data published in recent years. In the area of dust mitigation, dust contamination or infiltration refers to the impingement or contact of planetary dust with items not normally dusty and whose operation may therefore be compromised. Recent Advancements in Dust Mitigation: Dust mitigation strategies are becoming more common for hardware heading to the Moon, with most major programs implementing lunar dust contamination requirements for human health and equipment. In the last couple of years, NASA has created more guidance to assist hardware developers with dust mitigation. This includes NASA-STD-1008 (Classifications and Requirements for Testing Systems and Hardware to be Exposed to Dust in Planetary) and NASA TP 20220018746 (Lunar Dust Mitigation Guide and Reference). Several projects are testing hardware in relevant dusty environments to understand their tolerance to lunar dust. There has been a significant increase in the amount of testing with lunar simulants, with the NASA Simulant Advisory Committee serving a resource for NASA and our partners. There are new solutions for detecting and monitoring the dust internally and externally. Learning from the contamination control community: In addition to sharing potentially relevant solutions at the workshop, the dust mitigation community is also interested in learning from the contamination control community on ways to address lunar dust. For instance, a major aspect of managing the dust is monitoring and detection. This is critical for understanding when maintenance is needed and to inform future missions. Another challenge of working with lunar dust is quantifying and characterizing the smallest of particles. There are also challenges in modeling lunar dust and its behavior. The dust mitigation community can also leverage lessons learned from the planetary protection community.
dust mitagation↗
Thermal Barrier Coatings Overview: Design, Manufacturing, and Applications in High-Temperature Industries
Today’s competitive world economy is creating an indispensable demand for increased efficiency of engineering components that operate in harsh environments (i.e., very high-temperature, corrosive, or neutron irradiation environments), for applications in the energy, automotive, aerospace, electronics, and power industries. Increased research is being done on thermal barrier coatings (TBCs) for protecting such components, since the versatility of manufacturing techniques and the scale of deployment result in increased life, economics, performance, and durability. This review focuses on the advances that led to using TBCs for component life extension and, more recently, as an integral part of advanced component design for high-temperature and other types of harsh environments, such as those found in nuclear-related applications. Furthermore, factors that led to state-of-the-art advanced coating-fabrication techniques [e.g., electron-beam physical vapor deposition (EB-PVD), plasma spray deposition, and electrophoretically deposited TBCs, as well as functionally graded material (FGM) manufacturing] have also been emphasized in current coating R&D. This review explores the current state of TBCs, i.e., the latest advances regarding their fabrication and performance, associated challenges, and recommendations for their future use in aerospace, nuclear, high-temperature, or otherwise harsh environments.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Determining bonding, thickness, and density via thermal wave impedance NDE
Bonding, density, and thickness of coatings have a vital effect on their performance in many applications. Pioneering development work on thermal wave nondestructive evaluation (NDE) methods during the past 25 years has resulted in an array of useful techniques for performing bonding, density, and thickness measurements in a practical shop environment. The most useful thermal wave methods for this purpose are based on thermal wave surface impedance measurement or scanning. A pulse of heat from either a thermal transducer or a hot gas pulse is projected onto the surface, and the resulting temperature response is analyzed to unfold the bonding, density, and thickness of the coating. An advanced emissivity independent infrared method was applied to detect the temperature response. These methods were recently completely computerized and can automatically provide information on coating quality in near real-time using the proper equipment. Complex shapes such as turbine blades can be scanned. Microscopic inhomogeneities such as microstructural differences and small, normal, isolated voids do not cause problems but are seen as slight differences in the bulk thermal properties. Test objects with rough surfaces can be effectively nondestructively evaluated using proper thermal surface impedance methods. Some of the basic principles involved, as well as metallographic results illustrating the ability of the thermal wave surface impedance method to detect natural nonbonds under a two-layer thermally sprayed coating, will be presented.
Green, D. R.↗
High reflectance coatings for space applications in the EUV
Advances in optical coating and materials technology have made possible the development of instruments with substantially improved efficiency and made possible to consider more complex optical designs in the EUV. The importance of recent developments in chemical vapor deposited silicon carbide (CVD-SiC), SiC films and multilayer coatings is discussed in the context of EUV instrumentation design. The EUV performance of these coatings as well as some strengths and problem areas for their use in space will be addressed.
Keski-Kuha, Ritva A. M.↗
NASA-427: A New Aluminum Alloy
NASA's Marshall Space Flight Center researchers have developed a new, stronger aluminum alloy, ideal for cast aluminum products that have powder or paint-baked thermal coatings. With advanced mechanical properties, the NASA-427 alloy shows greater tensile strength and increased ductility, providing substantial improvement in impact toughness. In addition, this alloy improves the thermal coating process by decreasing the time required for heat treatment. With improvements in both strength and processing time, use of the alloy provides reduced materials and production costs, lower product weight, and better product performance. The superior properties of NASA-427 can benefit many industries, including automotive, where it is particularly well-suited for use in aluminum wheels.
Nabors, Sammy A.↗
Short-term stability of high-silica glasses
The devitrification characteristics of high-silica (70-90%) glasses for use in potential higher temperature coatings on advanced insulation systems for space vehicles were determined at 1260 C after 24 h. These data indicate that additives can be used to maintain the stability of these coatings relative to cristobalite formation.
Leiser, D. B.↗
Nb₃Sn Coating of Twin Axis Cavity for SRF Applications
The twin axis cavity with two identical accelerating beams has been proposed for energy recovery linac (ERL) applications. Nb₃Sn is a superconducting material with a higher critical temperature and a higher critical field as compared to Nb, which promises a lower operating cost due to higher quality factors. Two niobium twin axis cavities were fabricated at JLab and were proposed to be coated with Nb₃Sn. Due to their more complex geometry, the typical coating process used for basic elliptical cavi-ties needs to be improved to coat these cavities. This development advances the current coating system at JLab for coating complex cavities. Two twin axis cavities were coated recently for the first time. This contribution dis-cusses initial results from coating of twin axis cavities, RF testing and witness sample analysis with an overview of the current challenges towards high performance Nb₃Sn coated twin axis cavities.
43 PARTICLE ACCELERATORS↗
Progress in advanced high temperature turbine materials, coatings, and technology
Several NASA-sponsored benefit-cost studies have shown that very substantial benefits can be obtained by increasing material capability for aircraft gas turbines. Prealloyed powder processing holds promise for providing superalloys with increased strength for turbine disk applications. The developement of advanced powder metallurgy disk alloys must be based on a design of optimum processing and heat treating procedures. Materials considered for high temperature application include oxide dispersion strengthened (ODS) alloys, directionally solidified superalloys, ceramics, directionally solidified eutectics, materials combining the high strength of a gamma prime strengthened alloy with the elevated temperature strength of an ODS, and composites. Attention is also given to the use of high pressure turbine seals, approaches for promoting environmental protection, and turbine cooling technology.
Freche, J. C.↗
Selected advanced aerodynamic and active control concepts development
A summary is presented of results obtained during analysis, design and test activities on six selected technical tasks directed at exploratory improvement of fuel efficiency for new and derivative transports. The work included investigations into the potential offered by natural laminar flow, improved surface coatings and advanced high lift concepts. Similar investigations covering optimum low-energy flight path control, integrated application of active controls and evaluation of primary flight control systems reliability and maintenance are also summarized. Recommendations are included for future work needed to exploit potential advancements.
Source record↗
Oil-Free Turbomachinery Being Developed
NASA and the Army Research Laboratory (ARL) along with industry and university researchers, are developing Oil-Free technology that will have a revolutionary impact on turbomachinery systems used in commercial and military applications. System studies have shown that eliminating an engine's oil system can yield significant savings in weight, maintenance, and operational costs. The Oil-Free technology (foil air bearings, high-temperature coatings, and advanced modeling) is being developed to eliminate the need for oil lubrication systems on high-speed turbomachinery such as turbochargers and gas turbine engines that are used in aircraft propulsion systems. The Oil-Free technology is enabled by recent breakthroughs in foil bearing load capacity, solid lubricant coatings, and computer-based analytical modeling. During the past fiscal year, a U.S. patent was awarded for the NASA PS300 solid lubricant coating, which was developed at the NASA Glenn Research Center. PS300 has enabled the successful operation of foil air bearings to temperatures over 650 C and has resulted in wear lives in excess of 100,000 start/stop cycles. This leapfrog improvement in performance over conventional solid lubricants (limited to 300 C) creates new application opportunities for high-speed, high-temperature Oil-Free gas turbine engines. On the basis of this break-through coating technology and the world's first successful demonstration of an Oil-Free turbocharger in fiscal year 1999, industry is partnering with NASA on a 3-year project to demonstrate a small, Oil-Free turbofan engine for aeropropulsion.
DellaCorte, Christopher↗