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Plasma polymerization technique is used to apply thin, adherent, hydrophobic coatings from chlorotrifluoroethylene monomer. Apparently much of the chlorine contained in original monomer is lost during polymerization, and characteristic C-Cl absorption in infrared region is essentially absent.
Polymer matrix composites (PMCs) are increasingly used in aerospace and automotive applications because of their light weight and high strength-to-weight ratio relative to metals. However, a major drawback of PMCs is poor abrasion resistance, which restricts their use, especially at high temperatures. Simply applying a hard coating on PMCs to improve abrasion and erosion resistance is not effective since coating durability is short lived (ref. 1). Generally, PMCs have higher coefficients of thermal expansion than metallic or ceramic coatings have, and coating adhesion suffers because of poor interfacial adhesion strength. One technique commonly used to improve coating adhesion or durability is the use of bond coats that are interleaved between a coating and a substrate with vastly different coefficients of thermal expansion. An example of this remedy is the use of bondcoats for ceramic thermal barrier coatings on metallic turbine components (ref. 2). Prior collaborative research between the NASA Glenn Research Center and the Allison Advanced Development Company (AADC) demonstrated that bond coats sandwiched between PMCs and high-quality plasma-sprayed, erosion-resistant coatings substantially improved the erosion resistance of PMCs (ref. 3). One unresolved problem in this earlier collaboration was that there was no easy, accurate way to measure the coating erosion wear scar. Coating wear was determined by both profilometry and optical microscopy. Both techniques are time consuming. Wear measurement by optical microscopy requires sample destruction and does not provide a comprehensive measure of the entire wear volume. An even more subtle, yet critical, problem is that these erosion coatings contain two or more materials with different densities. Therefore, simply measuring specimen mass loss before and after erosion will not provide an accurate gauge for coating and/or substrate volume loss. By using a noncontact technique called scanning optical interferometry, which was recently developed at Glenn, researchers can accurately determine the wear performance of erosion-coated PMCs while preserving the sample. An example of this interferometry technique is shown in the preceding figure for an erosion-coated inlet guide vane from a Rolls Royce AE3007 regional gas turbine jet engine. Erosion was conducted with coated and uncoated PMC vanes, with the abrasive material moving at a velocity of 229 m/s at impingement angles of 20 and 90 degrees. The coatings for PMCs remarkably reduced the erosion volume loss by a factor of approximately 10. Currently, several erosion coatings for PMCs are being compared and downselected for engine testing at Rolls Royce.
Cu/Ti coatings have been applied by sputter deposition to fused quartz housings to serve as the electrodes and lands of electrostatically supported gyroscopes. Niobium-coated fused quartz gyro rotors have been successfully suspended and spun up in those housings. The Cu/Ti bilayer coating and alternative multilayer coatings (Cu/Mo, Mo/Cu/Ti and Mo/Cu/Mo) with 2-micron thickness produced by sputter deposition on flat, fused quartz substrates have been examined with scanning electron microscopy, X-ray diffraction, X-ray photoelectron spectroscopy, and four-point resistivity measurement techniques. The multilayer coatings with a molybdenum bonding layer appear to produce smoother surfaces than those with a titanium bonding layer. All multilayer coatings survived thermal cycling to 77 K without adhesion failure.
Results are presented of a comprehensive search of the literature available, much of which has been generated by the research centers of NASA and its contractors, on plating and coating methods and techniques. Methods covered included: (1) electroplating from aqueous solutions; (2) electroplating from nonaqueous solutions; (3) electroplating from fused-salt baths; (4) electroforming; (5) electroless plating, immersion plating, and mirroring; (6) electroplating from gaseous plasmas; and (7) anodized films and conversion coatings.
Advances in materials, coatings, turbine cooling technology, structural and design concepts, and component-life prediction of helicopter gas-turbine-engine components are presented. Stationary parts including the inlet particle separator, the front frame, rotor tip seals, vanes and combustors and rotating components - compressor blades, disks, and turbine blades - are discussed. Advanced composite materials are considered for the front frame and compressor blades, prealloyed powder superalloys will increase strength and reduce costs of disks, the oxide dispersion strengthened alloys will have 100C higher use temperature in combustors and vanes than conventional superalloys, ceramics will provide the highest use temperature of 1400C for stator vanes and 1370C for turbine blades, and directionally solidified eutectics will afford up to 50C temperature advantage at turbine blade operating conditions. Coatings for surface protection at higher surface temperatures and design trends in turbine cooling technology are discussed. New analytical methods of life prediction such as strain gage partitioning for high temperature prediction, fatigue life, computerized prediction of oxidation resistance, and advanced techniques for estimating coating life are described.
The complexity of many of the components being coated today using the thermal spray process makes the trial and error approach traditionally followed in depositing a uniform coating inadequate, thereby necessitating a more analytical approach to developing robotic trajectories. A two dimensional finite difference simulation model has been developed to predict the thickness of coatings deposited using the thermal spray process. The model couples robotic and component trajectories and thermal spraying parameters to predict coating thickness. Simulations and experimental verification were performed on a rotating disk to evaluate the predictive capabilities of the approach.
Simple and convenient technique has been found for extending transmittance measurement capability of conventional magnesium oxide coated integrating sphere system at low (near ultraviolet) wavelengths. Technique can be used to determine effect of contaminants on window materials and can also be used for measurements on thermal control coatings and telescope mirrors.
Techniques appropriate to boards containing CMOS circuits detailed. Document presents procedure for applying thin conformal coating to such electronic assemblies as printed-circuit boards and wire-wrapped boards. Coating is from 1 to 7 mils (25 to 178 micrometers) thick and composed of room-temperature-vulcanizing (RTV) silicone. Specifies materials, equipment, spraying method, and quality requirements. Takes into account special needs of circuits made with complementary metal-oxide/semiconductor (CMOS) devices on circuit boards. Special attention given to preventing damage by electrostatic discharge, to which CMOS circuits especially sensitive.
A variety of techniques is available to apply protective coatings to oxidation susceptible spacecraft components, and each has associated advantages and disadvantages. Film applications by means of chemical vapor deposition (CVD) has the advantage of being able to be applied conformally to objects of irregular shape. For this reason, a study was made of the oxygen plasma durability of thin film (less than 5000 A) silicon dioxide coatings applied by CVD. In these experiments, such coatings were applied to silver mirrors, which are strongly subject to oxidation, and which are proposed for use on the space station solar dynamic power system. Results indicate that such coatings can provide adequate protection without affecting the reflectance of the mirror. Scanning electron micrographs indicated that oxidation of the silver layer did occur at stress crack locations, but this did not affect the measured solar reflectances. Oxidation of the silver did not proceed beyond the immediate location of the crack. Such stress cracks did not occur in thinner silica flims, and hence such films would be desirable for this application.
A variety of techniques is available to apply protective coatings to oxidation susceptible spacecraft components, and each has associated advantages and disadvantages. Film applications by means of chemical vapor deposition (CVD) has the advantage of being able to be applied conformally to objects of irregular shape. For this reason, a study was made of the oxygen plasma durability of thin film (less than 5000 A) silicon dioxide coatings applied by CVD. In these experiments, such coatings were applied to silver mirrors, which are strongly subject to oxidation, and which are proposed for use on the space station solar dynamic power system. Results indicate that such coatings can provide adequate protection without affecting the reflectance of the mirror. Scanning electron micrographs indicated that oxidation of the silver layer did occur at stress crack locations, but this did not affect the measured solar reflectances. Oxidation of the silver did not proceed beyond the immediate location of the crack. Such stress cracks did not occur in thinner silica films, and hence such films would be desirable for this application.
During the Apollo Program, General Magnaplate Corporation developed process techniques for bonding dry lubricant coatings to space metals. The coatings were not susceptible to outgassing and offered enhanced surface hardness and superior resistance to corrosion and wear. This development was necessary because conventional lubrication processes were inadequate for lightweight materials used in Apollo components. General Magnaplate built on the original technology and became a leader in development of high performance metallurgical surface enhancement coatings - "synergistic" coatings, - which are used in applications from pizza making to laser manufacture. Each of the coatings is designed to protect a specific metal or group of metals to solve problems encountered under operating conditions.
An investigation was conducted to determine the technology readiness of lithium-doped silicon solar cells with respect to use in space programs. A pilot line fabrication program was established, in which the pilot line cells were evaluated after being exposed to environments ordinarily imposed on nonlithium-doped silicon solar cells. Results indicate that further process improvements are required, particularly with respect to the P/N junction diffusion and the electrical contacting technique (including solder coating). It is concluded that lithium-doped cells can be fabricated to exhibit (1) high efficiencies, (2) uniform cell-to-cell recovery characteristics after exposure to 1-MeV electrons; and (3) good stability in most environments investigated (the only exception being the thermal shock environment).
Thermal fatigue and oxidation data were obtained on 61 specimens, representing 15 discrete alloy compositions or fabricating techniques and three coating systems. Conventionally fabricated alloys included V57, MM 200, Rene 77, Rene 125, MM 246, MM 509, IN-738, IN-792 + Hf, and MM 200 + Hf. The directionally solidified alloys were MM 200, MM 200 single crystal, MM 200 bicrystal, cellular gamma/gamma' - delta) and lamellar gamma/gamma' - delta. The coatings systems included NiCrAlY on IN-738, In-792 + Hf, MM 200 DS, MM 200 DS single crystal, and cellular gamma/gamma' - delta and NiCrAlY/Pt on lamellar gamma/gamma' - delta. Crack initiation survival rates were recorded for all alloys, with and without coatings. All uncoated alloys, except MM 509, exhibited significant oxidation weight loss in 75,000 to 15,000 cycles. MM 509 specimens had weight losses only slightly higher than coated specimens through 7,500 cycles. All coated specimens had low weight loss.
Silicon-growth technique, based on coating ceramic substrates with thin layer of molten silicon solidifies to form polycrystalline film, modified to produce solar-cell quality silicon sheet.
Coating thickness not critical. Polytetrafluoroethylene antireflection overcoat reduces specular reflectance of opaque baffle coating by factor of nearly 2 at millimeter and infrared wavelengths. Easily applied by spraying Teflon(TM) Wet Lubricant (or equivalent) on opague coated surface. Though technique makes it difficult to control thickness of overcoat, experimental and theoretical studies indicate thickness has little effect because antireflective property based on creating graded-index absorber.
The Mission to Planet Earth enlists the use of a geostationary platform to support Earth science monitoring instruments. The strongback for a proposed geostationary platform is a deployable box truss that supports two large diameter passive microwave radiometer (PMR) and several other science instruments. A study was performed to estimate the north-south and east-west pointing errors at the mounting locations of the two PMRs due to on-orbit thermal distortions of the main truss. The baseline configuration indicated that the east-west pointing error greatly exceeded the required limits. Primary origins of the pointing errors were identified, and methods for their reduction were discussed. Thermal performance enhancements to the truss structure were modeled and analyzed, including state-of-the-art surface coatings and insulation techniques. Comparisons of the thermal enhancements to the baseline were performed. Results demonstrated that using a thermal enclosure insulating technique reduced external heat fluxes, and distributed those heat fluxes more evenly throughout the structure, sufficiently reducing the pointing error to satisfy pointing accuracy requirements for the PMR's.
NASA has begun to study candidate vehicles for manned access to space in support of the Space Station or other future missions requiring on-demand transportation of people to and from earth orbit. One such system, which would be used to complement the present Shuttle or an upgraded version, is the Personnel Launch System (PLS), which is envisioned as a reusable priority vehicle to place people and small payloads into orbit using an experimental launch vehicle. The design of the PLS is based on a Space Station crew changeout requirement whereby eight passengers and two crew members are flown to the station and a like number are returned within a 72 hour mission duration. Experimental and computational aerothermodynamic heating studies have been conducted using a new two-color thermographic technique that involved coating the model with a phosphor that radiates at varying color intensities as a function of temperature when illuminated with UV light. A full-scale model, the HL-20, has been produced and will be used for man-machine research. Three launch vehicle concepts are being considered, a Titan IV, the Advanced Launch System, and a Shuttle equipped with liquid rocket boosters.
In this presentation, the premise that Space Station Freedom has great utility as an engineering experiment station will be explored. There are several modes in which it can be used for this purpose. The most obvious are space qualification, process development, in space satellite repair, and materials engineering. The range of engineering experiments which can be done at Space Station Freedom run the gamut from small process oriented experiments to full exploratory development models. A sampling of typical engineering experiments are discussed in this session. First and foremost, Space Station Freedom is an elaborate experiment itself, which, if properly instrumented, will provide engineering guidelines for even larger structures which must surely be built if humankind is truly 'outward bound.' Secondly, there is the test, evaluation and space qualification of advanced electric thruster concepts, advanced power technology and protective coatings which must of necessity be tested in the vacuum of space. The current approach to testing these technologies is to do exhaustive laboratory simulation followed by shuttle or unmanned flights. Third, the advanced development models of life support systems intended for future space stations, manned mars missions, and lunar colonies can be tested for operation in a low gravity environment. Fourth, it will be necessary to develop new protective coatings, establish construction techniques, evaluate new materials to be used in the upgrading and repair of Space Station Freedom. Finally, the industrial sector, if it is ever to build facilities for the production of commercial products, must have all the engineering aspects of the process evaluated in space prior to a commitment to such a facility.