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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS1978

NASA thermal barrier coatings: Summary and update

A durable, two-layer, plasma-sprayed coating consisting of a ceramic layer over a metallic layer was developed that has the potential of insulating hot engine parts and thereby reducing metal temperatures and coolant flow requirements and/or permitting use of less costly and complex cooling configurations and materials. The results are summarized of analytical and experimental investigations of the coatings on flat metal specimens, turbine vanes and blades, and combustor liners. Discussed are results of investigations to determine coating adherence and durability, coating thermal, strength and fatigue properties, and chemical reactions of the coating with oxides and sulfates. Also presented are the effect of the coating on aerodynamic performance of a turbine vane, measured vane and combustor liner temperatures with and without the coating, and predicted turbine metal temperatures and coolant flow reductions potentially possible with the coating. Included also are summaries of some current research related to the coating and potential applications for the coating.

Stepka, F. S.↗
NASA NTRS1978

NASA thermal barrier coatings - Summary and update

The work conducted at the NASA Lewis Research Center to evolve and evaluate a thermal-barrier coating system will be discussed. A durable, two-layer, plasma-sprayed coating consisting of a ceramic layer over a metallic layer was developed that has the potential of insulating hot engine parts and thereby reducing metal temperatures and coolant flow requirements and/or permitting use of less costly and complex cooling configurations and materials. The paper summarizes the results of analytical and experimental investigations of the coatings on flat metal specimens, turbine vanes and blades, and combustor liners. Discussed are results of investigations to determine coating adherence and durability, coating thermal, strength and fatigue properties, and chemical reactions of the coating with oxides and sulfates. Also presented are the effect of the coating on aerodynamic performance of a turbine vane, measured vane and combustor liner temperatures with and without the coating, and predicted turbine metal temperatures and coolant flow reductions potentially possible with the coating. Included also are summaries of some current research related to the coating and potential applications for the coating.

Stepka, F. S.↗
NASA NTRS1998

The Successful Transfer of Space Derived Convergent Spray: An Application for Industrial Roof Coatings and Interstate Bridge Repair

A partnership was formed between the National Aeronautics and Space Administration (NASA), the Environmental Protection Agency (EPA), and United Technologies USBI Company to develop, demonstrate, and evaluate a technology that uses a solventless spray process for depositing a lightweight, highly filled roof coating on low-sloped commercial roofs. Although the levels of volatile organic compound (VOC) emissions from industrial roof coating's and paint operations have been reduced in recent years, this partnership,was an effort to further reduce VOC emission levels and to also demonstrate the use of reclaimed automobile tire rubber as a filler material in roof coating systems. Different materials and coatings were evaluated and tested before the final selection used to coat the roofs of two small buildings at NASA's Marshall Space Flight Center during fiscal year 1997. The project successfully leveraged the investment of EPA, NASA and private sector resources to demonstrate a pre-commercial roofing coating process. This process utilizes the Convergent Spray Technologies process, which was initially developed by USBI to apply highly-filled, thermal protection coatings to the Space Shuttle Solid Rocket Boosters. A second partnership between the NASA, Federal Highway Administration, Alabama Department of Transportation and USBI Company was formed to develop and demonstrate the Convergent Spray Technology as a method of applying a skid resistant coating to interstate roads and concrete bridge decking's. Again, different materials and coatings were evaluated and tested before the final selection of ground flint and resin. Two field demonstrations were performed during fiscal year 1997 for the purpose of evaluating the coating system under actual highway conditions. These coatings were applied on Interstate 65 near Huntsville Alabama, and in the Mobile Bankhead tunnel. The system performed this task without the use of harmful solvents, and accomplished the process in a single application. This project successfully leveraged the investment of NASA, Federal Highway Administration, the Alabama Department of Transportation, and private sector funding.

McMillan, Vernotto C.↗
NASA NTRS1990

The effect of atomic oxygen on altered and coated Kapton surfaces for spacecraft applications in low earth orbit

A commercially applied silicon oxide coating on Kapton and an alternative material with Si groups on the surface were evaluated for durability with respect to atomic oxygen in both a random plasma and a directed atomic oxygen beam system. It is found that the alternative to Kapton, DuPont 93-1, is not adequately protecting to last 15 years in LEO, the desired operation time of the Space Station Freedom. The coated Kapton is considered to be promising due to the adherence of the coating and lack of extensive tearing at undercut defect sites. Fewer defects in the coating and elimination of long scratches and uncoated areas would substantially improve the durability of this material.

Rutledge, Sharon K.↗
NASA NTRS2002

Comparison of Several Different Sputtered Molybdenum Disulfide Coatings for Use in Space Applications

Tribology experiments on different types of sputtered molybdenum disulfide (MoS2) coatings (obtained from different vendors) using accelerated testing techniques were conducted. The purpose was to determine which would be the best coating for use with auxiliary journal bearings for spacecraft energy storage flywheels. Experiments were conducted in moist air (50% relative humidity) and in dry air (<100 PPM water vapor content) on a Pin-on-Disk Tribometer to determine how well the coatings would perform in air. Experiments were also conducted on a Block-on-Ring Tribometer in dry nitrogen (<100 PPM water vapor) to simulate how well the coatings would perform in vacuum. Friction, counterface wear, coating wear, endurance life and surface morphology were investigated.

Fusaro, Robert L.↗
NASA NTRS1993

Thermal infrared emission spectroscopy of natural surfaces: Application to desert varnish coatings on rocks

Thermal infrared spectroscopy has become an increasingly important tool for remote compositional analysis and geologic mapping. Most published laboratory measurements have been obtained in bidirectional reflection or transmission, whereas remotely sensed thermal infrared data are obtained by measuring the emitted energy. Section 2 of this paper describes a laboratory technique for determining calibrated emissivities of natural surfaces. Equations are developed to account for the energy reflected from the environment and to determine directly the sample temperature from measurements of hot and cold blackbody targets. Two methods for determining emissivity are developed: one in which only a hot sample measurement is made and the reflected background energy is removed by modeling, and a second in which the sample is cooled and the reflected energy is measured directly. Relative emissivity can be obtained to approximately 1% and absolute emissivities can be obtained to 2-15%, depending on the validity of the assumption that the emissivity of the sample is unity at some wavelength. The emission data agree well within the hemispherically integrated reflection data but point out probelms associated with bidirectional reflectance measurements. Section 3 applies emissivity measurements to the study of layered surfaces consisting of desert varnish coatings on granite and granodiorite rock suites. Two linear models are developed: the first assumes linear mixing of independent emission from the substrate and varnish (checkerboard model); the second models tansmission through an absorbing/emitting medium. Regardless of whether the varnish is or is not relatively transparant and strongly absorptive, the spectral effect of varnish increases linearly with varnish thickness, indicating that thick patches of varnish dominate the spectral properties. As a result, medium varnish thickness can be determined from spectral measurements. In addition, the composition of a substrate can be estimated through varnish layers up to 40-50 micrometers in median thickness, and the composition of the varnish material can be determined if the substrate material is known. The varnishes studied are composed primarily of clay materials, consistent with previous studies of varnish composition.

Christensen, Philip R.↗
NASA NTRS1999

The Successful Transfer of Space Derived Convergent Spray Technology(TM): An Application for Industrial Roof Coatings and Interstate Bridge Repair

Although the levels of volatile organic compound (VOC) emissions from industrial roof coatings and paint operations have been reduced in recent years, the roof coating partnership was an effort to further reduce VOC emission levels and to also demonstrate the use of reclaimed automobile tire rubber as a filler material in roof coating systems. Different materials and coatings were evaluated and tested before the final selection was used to coat the roofs of two small buildings at NASA's MSFC (Marshall Space Flight Center) during fiscal year 1997. The primary objective of the Bridge repair partnership was to strategically leverage public and private sector funds for the purpose of developing a bridge repair process that was cheaper, better, and faster than conventional methods. It was also, imperative that this process be environmentally friendly and capable of performing under extreme conditions for a period of not less than 2 years.

McMillan, Vernotto↗
NASA NTRS1993

Positron lifetime spectroscopy for investigation of thin polymer coatings

In the aerospace industry, applications for polymer coatings are increasing. They are now used for thermal control on aerospace structures and for protective insulating layers on optical and microelectronic components. However, the effectiveness of polymer coatings depends strongly on their microstructure and adhesion to the substrates. Currently, no technique exists to adequately monitor the quality of these coatings. We have adapted positron lifetime spectroscopy to investigate the quality of thin coatings. Results of measurements on thin (25-micron) polyurethane coatings on aluminum and steel substrates have been compared with measurements on thicker (0.2-cm) self-standing polyurethane discs. In all cases, we find positron lifetime groups centered around 560 psec, which corresponds to the presence of 0.9-A(exp 3) free-volume cells. However, the number of these free-volume cells in thin coatings is larger than in thick discs. This suggests that some of these cells may be located in the interfacial regions between the coatings and the substrates. These results and their structural implications are discussed in this report.

Singh, Jag J.↗
NASA NTRS2008

Joint Test Plan for Gas Dynamic Spray Technology Demonstration

Air Force Space Command (AFSPC) and NASA have similar missions, facilities, and structures located in similar harsh environments. Both are responsible for a number of facilities/structures with metallic structural and non-structural components in highly and moderately corrosive environments. Regardless of the corrosivity of the environment, all metals require periodic maintenance activity to guard against the insidious effects of corrosion and thus ensure that structures meet or exceed design or performance life. The standard practice for protecting metallic substrates in atmospheric environments is the use of an applied coating system. Current coating systems used across AFSPC and NASA contain volatile organic compounds (VOCs) and hazardous air pollutants (HAPs). These coatings are subject to environmental regulations at the Federal and State levels that limit their usage. In addition, these coatings often cannot withstand the high temperatures and exhaust that may be experienced by AFSPC and NASA structures. In response to these concerns, AFSPC and NASA have approved the use of thermal spray coatings (TSCs). Thermal spray coatings are extremely durable and environmentally friendly coating alternatives, but utilize large cumbersome equipment for application that make the coatings difficult and time consuming to repair. Other concerns include difficulties coating complex geometries and the cost of equipment, training, and materials. Gas Dynamic Spray (GDS) technology (also known as Cold Spray) will be evaluated as a smaller, more maneuverable repair method as well as for areas where thermal spray techniques are not as effective. The technology can result in reduced maintenance and thus reduced hazardous materials/wastes associated with current processes. Thermal spray and GDS coatings also have no VOCs and are environmentally preferable coatings. To achieve a condition suitable for the application of a coating system, including GDS coatings, the substrate must undergo some type of surface preparation and/or depainting operation to ensure adhesion of the new coating system. The GDS unit selected for demonstration has a powder feeding system that can be used for surface preparation or coating application. The surface preparation feature will also be examined. The primary objective of this effort is to demonstrate GDS technology as a repair method for TSCs. The project will also determine the optimal GDS coating thickness for acceptable performance. Successful completion of this project will result in approval of GDS technology as a repair method for TSCs at AFSPC and NASA installations and will improve corrosion protection at critical systems, facilitate easier maintenance activity, extend maintenance cycles, eliminate flight hardware contamination, and reduce the amount of hazardous waste generated.

Lewis, Pattie↗
NASA NTRS2001

Elastomers that Endure

Through assistance from NASA's Kennedy Space Center, Dow Corning developed a strong, heat-protecting coating with applications in a variety of fields. Previously, NASA used silicate coatings that simply failed to adequately protect, which resulted in the frequent recoating of the damaged areas. The enormous expense of this repeat procedure led Kennedy's Materials Science Laboratory to investigate the possibilities of ablative-type coatings. The investigations resulted in the creation of a silicone ablative material known as the Dow Corning 3-6376 Fast Cure Elastomer. The new product, which does not require a primer coating, is a 100 percent silicone material. It is currently used in the automotive and aerospace industries and serves as an exceptional coating for engine compartment firewalls. Dow Corning's Fast Cure Elastomer has also proved to be an effective sealant. Moreover, it reduces the turnaround time for reuse of the launch structure because of fewer refurbishing operations. This means that NASA is not held up due to repairs when it comes time to launch another Shuttle. To date, the Agency has launched dozens of successful missions without the need for recoating.

Source record↗
NASA NTRS1996

Low Temperature Unbalanced Magnetron Deposition of Hard, Wear-Resistant Coatings for Liquid-Film Bearing Applications

The original program for evaluating the tribological properties several different hard coatings for liquid film bearing applications was curtailed when the time for the program was reduced from 3 years to 1. Of the several different coatings originally planned for evaluation, we decided to concentrate on one coating, carbon nitride. At BIRL, we have been instrumental in the development of reactively sputtered carbon nitride coatings, and we have found that it is a very interesting new material with very good tribological properties. In this program, we found that the reactively sputtered carbon nitride does not bond well directly to hardened 440C stainless steel; but if an interlayer of titanium nitride is added between the carbon nitride and the 440C, the adhesion of the dual coating combination is very good. Statistically designed experiments were run with the dual layer combination, and 3 variables were chosen for the Box-Benken design, which were the titanium nitride interlayer thickness, the nitrogen partial pressure during the reactive sputtering of the carbon nitride, and the carbon nitride substrate bias voltage. Two responses were studied from these three variables; the adhesion of the dual coating combination to the 440C substrate and the friction coefficient of the carbon nitride in dry sliding contact with 52100 steel in air. The best adhesion came with the thickness interlayer thickness studied, which was 4 micrometers, and the lowest coefficient of friction was 0.1, which was achieved when the bias voltage was in the range of -80 to - 120 V and the nitrogen partial pressure was 3 mTorr.

Sproul, William D.↗
NASA NTRS2005

Very Tough, Erosion-Resistant Turbine Airfoil Thermal Barrier Coatings Developed

Ceramic thermal barrier coatings (TBCs) are receiving increased attention for advanced gas turbine engine applications. These coatings are considered to be technologically important because of their ability to further increase engine operating temperatures and reduce cooling requirements, thus achieving higher engine efficiency, lower emissions, and increased performance goals. To take full advantage of the capabilities of these coatings, researchers need to use an aggressive design approach whenever possible--one that allows greater temperature reductions through the coating systems and less cooling air to the components. Advanced TBCs that have significantly lower thermal conductivity and better thermal stability than current coatings have been developed for future ultra-efficient, low-emission engine systems. Multicomponent-doped, defect-clustered TBCs have been shown to offer the low conductivity and high stability required for future high-temperature engine applications.

Zhu, Dong-Ming↗
NASA NTRS1989

Atomic oxygen resistant protective coatings for the Hubble Space Telescope solar array in low earth orbit

The Hubble Space Telescope back-up solar array (BSFR-ATOX) was designed with atomic oxygen resistant materials to replace the original high efficiency cell (HEC) array. Pending qualification of the BSFR-ATOX array, protective coatings for application to the existing HEC array were evaluated. Three polysiloxane-type coating materials, SWS V-10, DC-100, and CV-1144 were evaluated with respect to atomic oxygen resistance, outgassing, contamination potential, stability under UV irradiation, electron-proton irradiation, thermal cycling, and long-term storage after application. Atomic oxygen testing included characterization of the atomic oxygen plasma using comparison of Kapton reaction to existing flight data, residual gas analysis, and temperature measurements. Results from these tests show DC-100 as a greater contamination concern if used in the vicinity of sensitive optical surfaces, i.e., solar cell cover glasses. The SWS V-10 and CV-1144 coatings met all acceptance criteria.

Burns, H. D.↗
NASA NTRS2000

Assessment of Thermal Control and Protective Coatings

This final report is concerned with the tasks performed during the contract period which included spacecraft coating development, testing, and applications. Five marker coatings consisting of a bright yellow handrail coating, protective overcoat for ceramic coatings, and specialized primers for composites (or polymer) surfaces were developed and commercialized by AZ Technology during this program. Most of the coatings have passed space environmental stability requirements via ground tests and/or flight verification. Marker coatings and protective overcoats were successfully flown on the Passive Optical Sample Assembly (POSA) and the Optical Properties Monitor (OPM) experiments flown on the Russian space station MIR. To date, most of the coatings developed and/or modified during this program have been utilized on the International Space Station and other spacecraft. For ISS, AZ Technology manufactured the 'UNITY' emblem now being flown on the NASA UNITY node (Node 1) that is docked to the Russian Zarya (FGB) utilizing the colored marker coatings (white, blue, red) developed by AZ Technology. The UNITY emblem included the US American flag, the Unity logo, and NASA logo on a white background, applied to a Beta cloth substrate.

Mell, Richard J.↗
NASA NTRS2005

Improved Small-Particle Powders for Plasma Spraying

Improved small-particle powders and powder-processing conditions have been developed for use in plasma spray deposition of thermal-barrier and environmental barrier coatings. Heretofore, plasma-sprayed coatings have typically ranged in thickness from 125 to 1,800 micrometers. As explained below, the improved powders make it possible to ensure complete coverage of substrates at unprecedently small thicknesses of the order of 25 micrometers. Plasma spraying involves feeding a powder into a hot, high-velocity plasma jet. The individual powder particles melt in the plasma jet as they are propelled towards a substrate, upon which they splat to build up a coating. In some cases, multiple coating layers are required. The size range of the powder particles necessarily dictates the minimum thickness of a coating layer needed to obtain uniform or complete coverage. Heretofore, powder particle sizes have typically ranged from 40 to 70 micrometers; as a result, the minimum thickness of a coating layer for complete coverage has been about 75 micrometers. In some applications, thinner coatings or thinner coating layers are desirable. In principle, one can reduce the minimum complete-coverage thickness of a layer by using smaller powder particles. However, until now, when powder particle sizes have been reduced, the powders have exhibited a tendency to cake, clogging powder feeder mechanisms and feed lines. Hence, the main problem is one of synthesizing smaller-particle powders having desirable flow properties. The problem is solved by use of a process that begins with a spray-drying subprocess to produce spherical powder particles having diameters of less than 30 micrometers. (Spherical-particle powders have the best flow properties.) The powder is then passed several times through a commercial sifter with a mesh to separate particles having diameters less than 15 micrometers. The resulting fine, flowable powder is passed through a commercial fluidized bed powder feeder into a plasma spray jet.

Nguyen, QuynhGiao, N.↗
NASA NTRS1996

Metal-Coated Optical Fibers for High Temperature Applications

A DC magnetron sputtering system has been used to actively coat optical fibers with hermetic metal coatings during the fiber draw process. Thin films of Inconel 625 have been deposited on optical fibers and annealed in air at 2000 F. Scanning electron microscopy and Auger electron microscopy have been used to investigate the morphology and composition of the films prior to and following thermal cycling. Issues to be addressed include film adhesion, other coating materials, and a discussion of additional applications for this novel technology.

Zeakes, Jason↗
NASA NTRS1995

Convergent spray process for environmentally friendly coatings

Conventional spray application processes have poor transfer efficiencies, resulting in an exorbitant loss in materials, solvents, and time. Also, with ever tightening Environmental Protection Agency (EPA) regulations and Occupational Safety and Health Administration requirements, the low transfer efficiencies have a significant impact on the quantities of materials and solvents that are released into the environment. High solids spray processes are also limited by material viscosities, thus requiring many passes over the surface to achieve a thickness in the 0.125 -inch range. This results in high application costs and a negative impact on the environment. Until recently, requirements for a 100 percent solid sprayable, environmentally friendly, lightweight thermal protection system that can be applied in a thick (greater than 0.125 inch) single-pass operation exceeded the capability of existing systems. Such coatings must be applied by hand lay-up techniques, especially for thermal and/or fire protection systems. The current formulation of these coatings has presented many problems such as worker safety, environmental hazards, waste, high cost, and application constraints. A system which can apply coatings without using hazardous materials would alleviate many of these problems. Potential applications include the aerospace thermal protective specialty coatings, chemical and petroleum industries that require fire-protection coatings that resist impact, chemicals, and weather. These markets can be penetrated by offering customized coatings applied by automated processes that are environmentally friendly.

Scarpa, Jack↗