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NASA NTRS2003

High Temperature Thermographic Phosphor Coatings Development

For many years, phosphor thermometry has been used for non-contact temperature measurements. A large number of applications have been associated with high temperatures, especially for aerospace systems where blackbody radiation backgrounds are large and in challenging environments, such as vibration, rotation, flame, or noise. These environments restrict the use of more common thermocouples or infrared thermometric techniques. In particular, temperature measurements inside jet turbines, rocket engines, or similar devices are especially amenable to phosphor techniques. Often the fluorescent materials are used as powders, either suspended in binders and applied like paint or applied as high-temperature sprays. Thin coatings that are less than 50 m thick are used on the surfaces of interest. These coatings will quickly assume the same temperature as the surface to which they are applied. The temperature dependence of fluorescent materials is a function of the base matrix atoms and a small quantity of added activator or dopant ions. Often for high temperature applications, the selected materials are refractory and include rare earth ions. Phosphors like Y3Al5O12 (YAG) doped with Eu, Dy, or Tm, Y2O3 doped with Eu, or similar rare earth compounds, will survive high temperatures and can be configured to emit light that changes rapidly in lifetime and intensity. For example, researchers at Oak Ridge National Laboratory recently observed fluorescence from YAG:Dy and YAG:Tm at temperatures above 1400 C. One of the biggest challenges is to locate a binder material that can withstand tremendous variations in temperature in an adverse aerospace environment. This poster will provide an overview into our attempt to utilize phosphors for thermometry purposes. Emphasis will be placed on the use of selected binder materials that can withstand high temperatures. This research was completed for the National Aeronautics and Space Administration's Glenn Research Center in Cleveland, Ohio.

Goedeke, Shawn↗

NASA NTRS1988

Unified constitutive model development for metal matrix composites at high temperature

Structural alloys used in high temperature applications exhibit complex thermomechanical behavior that is time dependent and hereditary. Recent attention is being focused on metal matrix composite materials for high temperature applications where they exhibit all the complexities of conventional alloys and their strong anisotropy adds further complexities. Here, a proven constitutive model for isotropic materials in which the inelastic strain rate and internal state are expressible as gradients of a dissipation potential is taken to depend on invariants that reflect local transverse isotropy. Applications illustrate the capability of the theory of representing the time dependent, hereditary, anisotropic behavior typical of these materials at high temperature.

Robinson, D. N.↗

NASA NTRS1991

Thin film thermocouples for high temperature turbine application

The objective is to develop thin film thermocouples (TFTC) for Space Shuttle Main Engine (SSME) components such as the high pressure fuel turbopump (HPFTP) blades and to test TFTC survivability and durability in the SSME environment. The purpose for developing TFTC's for SSME components is to obtain blade temperatures for computational models developed for fluid mechanics and structures. The TFTC must be able to withstand the presence of high temperature, high pressure hydrogen as well as a severe thermal transient due to a cryogenic to combustion temperature change. The TFTC's will eventually be installed and tested on SSME propulsion system components in the SSME test bed engine. The TFTC's were successfully fabricated on flat coupons of MAR-M 246 (Hf+), which is the superalloy material used for HPFTP turbine blades. The TFTC's fabricated on flat coupons survived thermal shock cycling as well as testing in a heat flux measurement facility which provided a rapid thermal transient. The same fabrication procedure was used to deposit TFTC's on HPFTP first stage rotor blades. Other results from the experiments are presented, and future testing plans are discussed.

Martin, Lisa C.↗

NASA NTRS2013

Advanced Materials and Fabrication Techniques for the Orion Attitude Control Motor

Rhenium, with its high melting temperature, excellent elevated temperature properties, and lack of a ductile-to-brittle transition temperature (DBTT), is ideally suited for the hot gas components of the ACM (Attitude Control Motor), and other high-temperature applications. However, the high cost of rhenium makes fabricating these components using conventional fabrication techniques prohibitive. Therefore, near-net-shape forming techniques were investigated for producing cost-effective rhenium and rhenium alloy components for the ACM and other propulsion applications. During this investigation, electrochemical forming (EL-Form ) techniques were evaluated for producing the hot gas components. The investigation focused on demonstrating that EL-Form processing techniques could be used to produce the ACM flow distributor. Once the EL-Form processing techniques were established, a representative rhenium flow distributor was fabricated, and samples were harvested for material properties testing at both room and elevated temperatures. As a lower cost and lighter weight alternative to an all-rhenium component, rhenium- coated graphite and carbon-carbon were also evaluated. The rhenium-coated components were thermal-cycle tested to verify that they could withstand the expected thermal loads during service. High-temperature electroforming is based on electrochemical deposition of compact layers of metals onto a mandrel of the desired shape. Mandrels used for electro-deposition of near-net shaped parts are generally fabricated from high-density graphite. The graphite mandrel is easily machined and does not react with the molten electrolyte. For near-net shape components, the inner surface of the electroformed part replicates the polished graphite mandrel. During processing, the mandrel itself becomes the cathode, and scrap or refined refractory metal is the anode. Refractory metal atoms from the anode material are ionized in the molten electrolytic solution, and are deposited onto the cathodic mandrel by electrochemical reduction. Rotation of the mandrel ensures uniform distribution of refractory material. The EL-Form process allows for manufacturing in an inert atmosphere with deposition rates from 0.0004 to 0.002 in./h (10.2 to 50.8 m/h). Thicknesses typically range from microns to greater than 0.5 in. (13 mm). The refractory component produced is fabricated, dependably, to within one micron of the desired tolerances with no shrinkage or distortion as in other refractory metal manufacture techniques. The electroforming process has been used to produce solid, nonporous deposits of rhenium, iridium, niobium, tungsten, and their alloys.

Gorti, Sridhar↗

NASA NTRS1991

Space applications of high temperature superconductivity technology

A review is presented of the present status of high temperature superconductivity (HTS) technology and related areas of potential space application. Attention is given to areas of application that include microwave communications, cryogenic systems, remote sensing, and space propulsion and power. Consideration is given to HTS phase shifters, miniaturization of microwave filters, far-IR bolometers, and magnetic refrigeration using flux compression.

Connolly, D. J.↗

NASA NTRS1990

Space applications for high temperature superconductivity - Brief review

An overview is presented of materials and devices based on high-temperature superconductivity (HTS) that could have useful space-oriented applications. Of specific interest are applications of HTS technologies to mm and microwave systems, spaceborne and planet-surface sensors, and to magnetic subsystems for robotic, rescue, and docking maneuvers. HTS technologies can be used in optoelectronics, magnetic-field detectors, antennae, transmission/delay lines, and launch/payload coils.

Krishen, Kumar↗

NASA NTRS1992

The 1992 NASA Langley Measurement Technology Conference: Measurement Technology for Aerospace Applications in High-Temperature Environments

An intensive 2-day conference to discuss the current status of measurement technology in the areas of temperature/heat flux, stress/strain, pressure, and flowfield diagnostics for high temperature aerospace applications was held at Langley Research Center, Hampton, Virginia, on April 22 and 23, 1993. Complete texts of the papers presented at the Conference are included in these proceedings.

Singh, Jag J.↗

NASA NTRS2002

Photovoltaic Power for Future NASA Missions

Recent advances in crystalline solar cell technology are reviewed. Dual-junction and triple-junction solar cells are presently available from several U. S. vendors. Commercially available triple-junction cells consisting of GaInP, GaAs, and Ge layers can produce up to 27% conversion efficiency in production lots. Technology status and performance figures of merit for currently available photovoltaic arrays are discussed. Three specific NASA mission applications are discussed in detail: Mars surface applications, high temperature solar cell applications, and integrated microelectronic power supplies for nanosatellites.

Landis, Geoffrey↗

NASA NTRS2007

Development of a HTSMA-Actuated Surge Control Rod for High-Temperature Turbomachinery Applications

In recent years, a demand for compact, lightweight, solid-state actuation systems has emerged, driven in part by the needs of the aeronautics industry. However, most actuation systems used in turbomachinery require not only elevated temperature but high-force capability. As a result, shape memory alloy (SMA) based systems have worked their way to the forefront of a short list of viable options to meet such a technological challenge. Most of the effort centered on shape memory systems to date has involved binary NiTi alloys but the working temperatures required in many aeronautics applications dictate significantly higher transformation temperatures than the binary systems can provide. Hence, a high temperature shape memory alloy (HTSMA) based on NiTiPdPt, having a transformation temperature near 300 C, was developed. Various thermo-mechanical processing schemes were utilized to further improve the dimensional stability of the alloy and it was later extruded/drawn into wire form to be more compatible with envisioned applications. Mechanical testing on the finished wire form showed reasonable work output capability with excellent dimensional stability. Subsequently, the wire form of the alloy was incorporated into a benchtop system, which was shown to provide the necessary stroke requirements of approx.0.125 inches for the targeted surge-control application. Cycle times for the actuator were limited to ~4 seconds due to control and cooling constraints but this cycle time was determined to be adequate for the surge control application targeted as the primary requirement was initial actuation of a surge control rod, which could be completed in approximately one second.

Padula, Santo, II↗

NASA NTRS2004

Actively Cooled Ceramic Matrix Composite Concepts for High Heat Flux Applications

High temperature composite heat exchangers are an enabling technology for a number of aeropropulsion applications. They offer the potential for mass reductions of greater than fifty percent over traditional metallics designs and enable vehicle and engine designs. Since they offer the ability to operate at significantly higher operating temperatures, they facilitate operation at reduced coolant flows and make possible temporary uncooled operation in temperature regimes, such as experienced during vehicle reentry, where traditional heat exchangers require coolant flow. This reduction in coolant requirements can translate into enhanced range or system payload. A brief review of the approaches, challenges and test results are presented, along with a status of recent government-funded projects.

Eckel, Andrew J.↗

NASA NTRS2002

Evaluation of Ultra-High Temperature Ceramics for Propulsion Application

Ultra-high temperature ceramic (UHTC) materials consisting of zirconium diboride or hafnium diboride plus silicon carbide offer a combination of properties that make them candidates for airframe leading edges on sharp-bodied reentry vehicles. These UHTC perform well in the environment for such applications, i.e. low pressure air. The purpose of this study was to examine three of these materials under conditions more representative of a propulsion environment, i.e. higher oxygen and total pressure. Results of stren$h and fracture toughness measurements, furnace oxidation, and thermal shock exposures are presented. The poor oxidation resistance of UHTCs is the predominant factor limiting their applicability to propulsion.

Levine, Stanley R.↗

NASA NTRS2007

Ceramic Integration Technologies for Aerospace and Energy Systems: Technical Challenges and Opportunities

Ceramic integration technology has been recognized as an enabling technology for the implementation of advanced ceramic systems in a number of high-temperature applications in aerospace, power generation, nuclear, chemical, and electronic industries. Various ceramic integration technologies (joining, brazing, attachments, repair, etc.) play a role in fabrication and manufacturing of large and complex shaped parts of various functionalities. However, the development of robust and reliable integrated systems with optimum performance requires the understanding of many thermochemical and thermomechanical factors, particularly for high temperature applications. In this presentation, various challenges and opportunities in design, fabrication, and testing of integrated similar (ceramic-ceramic) and dissimilar (ceramic-metal) material systems will be discussed. Experimental results for bonding and integration of SiC based LDI fuel injector, high conductivity C/C composite based heat rejection system, solid oxide fuel cells system, ultra high temperature ceramics for leading edges, and ceramic composites for thermostructural applications will be presented. Potential opportunities and need for the development of innovative design philosophies, approaches, and integrated system testing under simulated application conditions will also be discussed.

Singh, Mrityunjay↗

NASA NTRS1994

Potential aerospace applications of high temperature superconductors

The recent discovery of High Temperature Superconductors (HTS) with superconducting transition temperature, T(sub c), above the boiling point of liquid nitrogen has opened the door for using these materials in new and practical applications. These materials have zero resistance to electric current, have the capability of carrying large currents and as such have the potential to be used in high magnetic field applications. One of the space applications that can use superconductors is electromagnetic launch of payloads to low-earth-orbit. An electromagnetic gun-type launcher can be used in small payload systems that are launched at very high velocity, while sled-type magnetically levitated launcher can be used to launch larger payloads at smaller velocities. Both types of launchers are being studied by NASA and the aerospace industry. The use of superconductors will be essential in any of these types of launchers in order to produce the large magnetic fields required to obtain large thrust forces. Low Temperature Superconductor (LTS) technology is mature enough and can be easily integrated in such systems. As for the HTS, many leading companies are currently producing HTS coils and magnets that potentially can be mass-produced for these launchers. It seems that designing and building a small-scale electromagnetic launcher is the next logical step toward seriously considering this method for launching payloads into low-earth-orbit. A second potential application is the use of HTS to build sensitive portable devices for the use in Non Destructive Evaluation (NDE). Superconducting Quantum Interference Devices (SQUID's) are the most sensitive instruments for measuring changes in magnetic flux. By using HTS in SQUID's, one will be able to design a portable unit that uses liquid nitrogen or a cryocooler pump to explore the use of gradiometers or magnetometers to detect deep cracks or corrosion in structures. A third use is the replacement of Infra-Red (IR) sensor leads on Earth Orbit Systems (EOS) with HTS leads. IR detectors on these EOS missions are cooled to a 4.2K to improve their signal to noise ratio. They are connected to data acquisitions systems using manganin wires (low thermal conductors) to reduce the heat load on the cryogen. Replacing these wires with HTS leads will increase the lifetime of these missions by about 50 percent. This is a promising application that is ready for actual implementation on such systems. The analysis also show that an the number of IR detectors increase in larger EOS systems, substantial increase in the lifetime of each mission will be realized by using HTS leads instead of the manganin ones.

Selim, Raouf↗

NASA NTRS1997

Environmental Effects on Non-oxide Ceramics

Non-oxide ceramics such as silicon carbide (SiC) and silicon nitride (Si3N4) are promising materials for a wide range of high temperature applications. These include such diverse applications as components for heat engines, high temperature electronics, and re-entry shields for space vehicles. Table I lists a number of selected applications. Most of the emphasis here will be on SiC and Si3N4. Where appropriate, other non-oxide materials such as aluminum nitride (AlN) and boron nitride (BN) will be discussed. Proposed materials include both monolithic ceramics and composites. Composites are treated in more detail elsewhere in this volume, however, many of the oxidation/corrosion reactions discussed here can be extended to composites. In application these materials will be exposed to a wide variety of environments. Table I also lists reactive components of these environments.It is well-known that SiC and Si3N4 retain their strength to high temperatures. Thus these materials have been proposed for a variety of hot-gas-path components in combustion applications. These include heat exchanger tubes, combustor liners, and porous filters for coal combustion products. All combustion gases contain CO2, CO, H2, H2O, O2, and N2. The exact gas composition is dependent on the fuel to air ratio or equivalence ratio. (Equivalence ratio (EQ) is a fuel-to-air ratio, with total hydrocarbon content normalized to the amount of O2 and defined by EQ=1 for complete combustion to CO2 and H2O). Figure 1 is a plot of equilibrium gas composition vs. equivalence ratio. Note that as a general rule, all combustion atmospheres are about 10% water vapor and 10% CO2. The amounts of CO, H2, and O2 are highly dependent on equivalence ratio.

Jacobson, Nathan S.↗

NASA NTRS1995

Applications of Silicon Carbide for High Temperature Electronics and Sensors

Silicon carbide (SiC) is a wide bandgap material that shows great promise in high-power and high temperature electronics applications because of its high thermal conductivity and high breakdown electrical field. The excellent physical and electronic properties of SiC allows the fabrication of devices that can operate at higher temperatures and power levels than devices produced from either silicon or GaAs. Although modern electronics depends primarily upon silicon based devices, this material is not capable of handling may special requirements. Devices which operate at high speeds, at high power levels and are to be used in extreme environments at high temperatures and high radiation levels need other materials with wider bandgaps than that of silicon. Many space and terrestrial applications also have a requirement for wide bandgap materials. SiC also has great potential for high power and frequency operation due to a high saturated drift velocity. The wide bandgap allows for unique optoelectronic applications, that include blue light emitting diodes and ultraviolet photodetectors. New areas involving gas sensing and telecommunications offer significant promise. Overall, the properties of SiC make it one of the best prospects for extending the capabilities and operational regimes of the current semiconductor device technology.

Silicon Carbide↗

NASA NTRS2018

Coupled Thermomechanical Micromechanics Modeling of the Influence of Thermally Grown Oxide Layer in an Environmental Barrier Coating System

Environmental Barrier Coatings (EBCs) have emerged as a promising means of protecting critical components for high temperature applications (e.g., aircraft engines). EBCs are often used to protect an underlying material (substrate) from extreme thermal/chemical environments. However, systems that utilize EBCs are susceptible to a number of failure modes including oxidation/delamination. Environmental Barrier Coatings (EBCs) have emerged as a promising means of protecting silicon based ceramic matrix composite (CMC) components for high temperature applications (e.g., aircraft engines). EBCs are often used to protect an underlying material (substrate) such as silicon carbide from extreme thermal/chemical environments. In a typical CMC/EBC system, an EBC may or may not be adhered to an underlying substrate with a bond coat (e.g., silicon). Irrespective, systems that utilize EBCs are susceptible to a number of failure modes including oxidation/delamination, recession, chemical attack and dissolution, thermo-mechanical degradation, erosion, and foreign object damage. Current work at NASA Glenn Research Center is aimed at addressing these failure modes in EBC systems and developing robust analysis tools to aid in the design process. The Higher-Order Theory for Functionally Graded Materials (HOTFGM), a precursor to the High-Fidelity Generalized Method of Cells micromechanics approach, was developed to investigate the coupled thermo-mechanical behavior of functionally graded composites and will be used herein to assess the development and growth of a low-stiffness thermally grown oxide (TGO) layer in EBC/CMC systems without a silicon bond coat. To accomplish this a sensitivity study is conducted to examine the influence of uniformly and non-uniformly grown oxide layer on the associated driving forces leading to mechanical failure (spallation) of EBC layer when subjected to isothermal loading, recession, chemical attack and dissolution, thermomechanical degradation, erosion, and foreign object damage. Current work at NASA Glenn Research Center is aimed at addressing these failure modes in EBC systems and developing robust analysis tools to aid in the design process. The Higher-Order Theory for Functionally Graded Materials (HOTFGM), a precursor to the High-Fidelity Generalized Method of Cells micromechanics approach, was developed to investigate the coupled thermo-mechanical behavior of functionally graded composites (Aboudi et al., 1999, Composites B). For example, HOTFGM was previously used (Arnold et al, 1995, NASA CP 10178, paper 34), to assess interlaminar stresses (including free edge effects) in a substrate with a thermal barrier coating (TBC). In this study, HOTFGM micromechanics analyses will be used to assess the development and growth of a low-stiffness thermally grown oxide (TGO) layer between a silicon carbide substrate and a ytterbium disilicate EBC. In order to realistically simulate TGO growth, an evolution law will be incorporated into HOTFGM. In addition, the effect of TGO roughness will be explored consistent with previous TBC work (Pindera et al., 2000. Material Science and Engineering, A284, pp. 158-175). This model represents a first step in developing a robust analysis tool that can ultimately be used to design durable EBC systems. Additional failure modes will be considered as part of a future work.

environmental barrier coating↗

NASA NTRS2014

An Overview of High Temperature Seal Development and Testing Capabilities at the NASA Glenn Research Center

The NASA Glenn Research Center (GRC), partnering with the University of Toledo, has a long history of developing and testing seal technologies for high-temperature applications. The GRC Seals Team has conducted research and development on high-temperature seal technologies for applications including advanced propulsion systems, thermal protection systems (airframe and control surface thermal seals), high-temperature preloading technologies, and other extreme-environment seal applications. The team has supported several high-profile projects over the past 30 years and has partnered with numerous organizations, including other government entities, academic institutions, and private organizations. Some of these projects have included the National Aerospace Space Plane (NASP), Space Shuttle Space Transport System (STS), the Multi-Purpose Crew Vehicle (MPCV), and the Dream Chaser Space Transportation System, as well as several high-speed vehicle programs for other government organizations. As part of the support for these programs, NASA GRC has developed unique seal-specific test facilities that permit evaluations and screening exercises in relevant environments. The team has also embarked on developing high-temperature preloaders to help maintain seal functionality in extreme environments. This paper highlights several propulsion-related projects that the NASA GRC Seals Team has supported over the past several years and will provide an overview of existing testing capabilities

National Aerospace Plane↗

NASA NTRS1992

Metallic threaded composite fastener

A metallic threaded composite fastener, particularly suited for high temperature applications, has a body member made of high temperature resistant composite material with a ceramic coating. The body member has a head portion configured to be installed in a countersunk hole and a shank portion which is noncircular and tapered. One part of the shank may be noncircular and the other part tapered, or the two types of surface could be combined into a frustum of a noncircular cone. A split collar member made of high strength, high temperature tolerant metal alloy is split into two halves and the interior of the halves are configured to engage the shank. The exterior of the collar has a circumferential groove which receives a lock ring to secure the collar halves to the shank. In the assembled condition torque may be transmitted from the body to the split collar by the engaged noncircular portions to install and remove the fastener assembly into or from a threaded aperture and shear loads in the collar threads are transferred to the shank tapered portion as a combination of radial compression and axial tension loads. Thus, tension loads may be applied to the fastener shank without damaging the ceramic coating.

Dunn, Thomas J.↗