Search NASA⌕ Search

SEARCH · Search NASA

Results for “abradable coating material”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

An experimental investigation of interfacial temperatures in blade-seal material rubbing of aircraft compressors

Results are presented for the rubbing of rotating (100 m/s) titanium blade specimens, with different plasma-sprayed tip coating, against an abradable porous seal material at two different incursion rates. In general, there was a good correspondence between the average transverse force of rubbing and the seal specimen surface temperature. Instantaneous seal surface temperature measurement showed a significant temperature jump before and after each rubbing with a high rate of cooling during each revolution and a high overall temperature level. Numerical predictions of both blade and seal temperature agreed well for the bare blade tip experiments but were consistently high for the coated blades. This suggests that the thermal properties of the coatings may significantly affect the temperatures and hence the wear characteristics of the system.

Emery, A. F.↗

Abradable dual-density ceramic turbine seal system

A plasma sprayed dual density ceramic abradable seal system for direct application to the HPT seal shroud of small gas turbine engines. The system concept is based on the thermal barrier coating and depends upon an additional layer of modified density ceramic material adjacent to the gas flow path to provide the desired abradability. This is achieved by codeposition of inert fillers with yttria stabilized zirconia (YSZ) to interrupt the continuity of the zirconia struture. The investigation of a variety of candidate fillers, with hardness values as low as 2 on Moh's scale, led to the conclusion that solid filler materials in combination with a YSZ matrix, regardless of their hardness values, have a propensity for compacting rather than shearing as originally expected. The observed compaction is accompanied by high energy dissipation in the rub interaction, usually resulting in the adhesive transfer of blade material to the stationary seal member. Two YSZ based coating systems which incorported hollow alumino silicate spheres as density reducing agents were surveyed over the entire range of compositions from 100 percent filler to 100 percent YSZ. Abradability and erosion characteristics were determined, hardness and permeability characterized, and engine experience acquired with several system configurations.

Clingman, D. L.↗

Continued development of abradable gas path seals

Major program objectives were the continued development of NiCrAlY feltmetal and honeycomb systems for knife edge seal applications in the 1144 to 1366 K temperature range, and to initiate abradable seal material evaluation for blade tip seal applications in the 1366 to 1589 K temperature range. Larger fiber size, higher density feltmetal showed greatly improved erosion resistance with a slight reduction in abradability compared to the baseline feltmetal. Pack aluminide coating of the honeycomb extended the oxidation resistance and slightly improved the abradability of this material. Evaluation through selected abradability, erosion and oxidation testing, and pertinent metallography led to selection of a plasma sprayed yttria stabilized zirconia (ZrO2)/CoCrAlY layered system as the system with the most potential to meet the 1589 K requirement for blade tip seals. This system demonstrated structural integrity, erosion resistance, and some degree of abradability.

Shiembob, L. T.↗

Photoelectron emission analysis of surface elements of the International Sun Earth Explorer

The photoemission was measured of engineering materials (aluminum; copper, plain; copper, abraded; copper-beryllium; magnesium; silver; In2O3 on silica; reflective coating on silica; teflon; kapton; and Pyre ML) associated with the International Sun Earth Explorer (ISEE) Satellite. The procedures used are described, including the experimental equipment; results of the program, the conclusions reached, and areas for further work are presented. Data regarding the measured yield of the 11 materials whose surface emission was determined is included in the form of plots of photoelectric yield versus incident light wavelength.

Spencer, W. T.↗

Abradable compressor and turbine seals, volume 2

The applications and advantages of abradable coatings as gas path seals in a general aviation turbofan engine were investigated. Abradable materials were evaluated for the high pressure radial compressor and the axial high and low pressure turbine shrouds.

Sundberg, D. V.↗

Developing Materials and Coating Technologies for Mitigation of Lunar Dust Adhesion and Abrasion

Lunar regolith was first identified as a major issue during the Apollo missions. There are three characteristics of lunar regolith that cause issues: small size, rough surface topology, and particle charge. The lack of a magnetosphere allows solar wind to bombard the lunar surface which results in the regolith becoming charged. These charged particles will adhere to most surfaces and degrade thermal control systems. The lack of atmosphere and surface liquids on the lunar surface results in the regolith’s small particle size, abrasive topology, and chemical reactivity. When the dust adheres to a surface, or the lunar lander exhaust kicks up dust regolith, it can impair instrument or thermal control system function, abrade optical surfaces, diminish range of motion, and mechanically degrade soft-goods such as gloves and astronaut suits. All of these examples were experienced during the Apollo missions. The objective of this study was to select and evaluate abrasion-resistant ceramic materials for application on the lunar landing equipment.

materials↗

Science and Science-Enabling Activities of the SHERLOC and WATSON Imaging Systems in Jezero Crater, Mars

During its first year of operation, the Perseverance rover explored the cratered and fractured floor of Jezero crater on Mars. Here, we report the use of the Scanning Habitability Environments with Raman and Luminescence for Organics and Chemicals (SHERLOC) imaging system that includes two high-resolution cameras, the Autofocus and Contextual Imager (ACI) and Wide Angle Topographic Sensor for Operations and eNgineering (WATSON). ACI is a fixed focus gray scale imager with a resolution of 10.1 μm/pixel whereas WATSON is a variable field of view, variable focus imager capable of resolution down to 14 μm/pixel. WATSON is a reflight of the MArs Hand Lens Imager (MAHLI) imager and has similar capabilities. During first-time activities, WATSON was used to support both science and engineering operations related to sample and abrasion patch assessment and sample collection and caching. WATSON also documented the deployment of the Ingenuity helicopter. The Crater Floor Campaign identified two primary rock units, the Máaz formation and the Séítah formation, which have been interpreted as lava flows and an olivine cumulate, respectively. Interpretation of rock textures with WATSON and ACI images was limited to abraded surfaces because unmodified outcrop surfaces (herein termed “natural surfaces”) show high degrees of dust covering, wind abrasion, and coating by secondary mineral products. WATSON and ACI images support the hypothesis that the material of both the Máaz and Séítah formations consists of largely aqueously altered mafic materials with varying igneous origins.

WATSON↗

Turbomachinery Clearance Control

Controlling interface clearances is the most cost effective method of enhancing turbomachinery performance. Seals control turbomachinery leakages, coolant flows and contribute to overall system rotordynamic stability. In many instances, sealing interfaces and coatings are sacrificial, like lubricants, giving up their integrity for the benefit of the component. They are subjected to abrasion, erosion, oxidation, incursive rubs, foreign object damage (FOD) and deposits as well as extremes in thermal, mechanical, aerodynamic and impact loadings. Tribological pairing of materials control how well and how long these interfaces will be effective in controlling flow. A variety of seal types and materials are required to satisfy turbomachinery sealing demands. These seals must be properly designed to maintain the interface clearances. In some cases, this will mean machining adjacent surfaces, yet in many other applications, coatings are employed for optimum performance. Many seals are coating composites fabricated on superstructures or substrates that are coated with sacrificial materials which can be refurbished either in situ or by removal, stripping, recoating and replacing until substrate life is exceeded. For blade and knife tip sealing an important class of materials known as abradables permit blade or knife rubbing without significant damage or wear to the rotating element while maintaining an effective sealing interface. Most such tip interfaces are passive, yet some, as for the high-pressure turbine (HPT) case or shroud, are actively controlled. This work presents an overview of turbomachinery sealing. Areas covered include: characteristics of gas and steam turbine sealing applications and environments, benefits of sealing, types of standard static and dynamics seals, advanced seal designs, as well as life and limitations issues.

Chupp, Raymond E.↗

Abradable compressor and turbine seals, volume 1

The application and advantages of abradable coatings as gas-path seals in a general aviation turbine engine were evaluated for use on the high-pressure compressor, the high-pressure turbine, and the low-pressure turbine shrouds. Topics covered include: (1) the initial selection of candidate materials for interim full-scale engine testing; (2) interim engine testing of the initially selected materials and additional candidate materials; (3) the design of the component required to adapt the hardware to permit full-scale engine testing of the most promising materials; (4) finalization of the fabrication methods used in the manufacture of engine test hardware; and (5) the manufacture of the hardware necessary to support the final full-scale engine tests.

Sundberg, D. V.↗

Evaluation of transfer films of Salox M on 440C for HPOTP bearing cage applications, task 119

The objective of the task was to evaluate the suitability of a bronze-filled polytetra fluoroethylene (Salox M) as the cage material in Space Shuttle Main Engine (SSME) high pressure oxygen turbo pump (HPOTP) bearings. The role of the cage pocket material will be to provide a transferred lubricating interface at the ball-race contact region. A series of experiments was conducted which involved block-on-ring tests (the block was the polytetrafluoroethylene (PTFE) -filled material and the ring was through-hardened 440C steel) and high speed traction tests of two 440C disks with one disk rubbed with a PTFE block to generate a transfer film. Measurements included post test visual observations of the condition of the 440C, wear rate measurements of the blocks, and traction measurements between the disks. It was observed that both Salox M and glass-filled PTFE (Armalon) transferred PTFE to 440C at cryogenic temperatures. Bronze is also transferred to uncoated 440C from the Salox M. At room temperature no PTFE transfer was observed in the high speed disk tests due to severe frictional heating, although bronze transfer still occurred with the bronze-PTFE Salox M material. Since the bearing will operate at cryogenic temperature, transfer films are very probable. Salox M wore slightly, although probably tolerably, more than glass-filled PTFE against 440C. However, Salox M is clearly less abrasive to 440C than is the glass-filled material. When the surface layer of PTFE is depleted from the glass-filled material, the glass fibers tend to seriously abrade the steel. This problem does not occur with Salox M. The surface roughness studies indicate that smooth balls are quite reasonable for transfer films. No significant difference in wear rates of the candidate cage materials was observed when the 440C surface finish was increased from 0.025 micron to 0.1 micron cla. At higher levels of roughness, the wear rate increased. Two surface coatings (MoS2 and TiN) were tested. The surface coatings tended to reduce the Salox M wear rate and reduce bronze transfer. PTFE transfer at cryogenic temperatures still occurred with the surface coatings. Two cage design concepts are presented utilizing Salox M material. One design involves a metal-reinforced Salox M cage, while the second design uses Salox M inserts in a metal structure.

Barber, S. A.↗

Friction and wear of sintered fiber-metal abradable seal materials

Three abradable gas path seal material systems based on a sintered NiCrAlY fibermetal structure were evaluated under a range of wear conditions representative of those likely to be encountered in various knife-edge seal (labyrinth or shrouded turbine) applications. Conditions leading to undesirable wear of the rotating knife were identified and a model was proposed based on thermal effects arising under different rub conditions. It was found, and predicted by the model, that low incursion (plunge) rates tended to promote smearing of the low density sintered material with consequent wear to the knife-edge. Tradeoffs benefits between baseline 19 percent dense material, a similar material of increased density, and a self lubricating coating applied to the 19 percent material were identified based on relative rub tolerance and erosion resistance.

Bill, R. C.↗

Friction and wear of sintered fibermetal abradable seal materials

Three abradable gas-path seal-material systems based on a sintered NiCrAlY fiber metal structure were evaluated under a range of wear conditions representative of those likely to be encountered in various knife-edge seal (labyrinth or shrouded turbine) applications. Conditions leading to undesirable wear of the rotating knife were identified, and a model proposed based on thermal effects arising under different rub conditions. It was found, and predicted by the model, that low incursion (plunge) rates tended to promote smearing of the low-density sintered material with consequent wear to the knife edge. Tradeoff benefits between baseline 19 percent dense material, a similar material of increased density, and a self-lubricating coating applied to the 19 percent dense material were identified on the basis of relative rub tolerance and erosion resistance.

Bill, R. C.↗

High Energy Cutting and Stripping Utilizing Liquid Nitrogen

The Aerospace Industry has endeavored for decades to develop hybrid materials that withstand the rigors of mechanized flight both within our atmosphere and beyond. The development of these high performance materials has led to the need for environmentally friendly technologies for material re-work and removal. The NitroJet(TM) is a fluid jet technology that represents an evolution of the widely used, large-scale water jet fluid jet technology. It involves the amalgamation of fluid jet technology and cryogenics technology to create a new capability that is applicable where water jet or abrasive jet (water jet plus entrained abrasive) are not suitable or acceptable because of technical constraints such as process or materials compatibility, environmental concerns and aesthetic or legal requirements. The NitroJet(TM) uses ultra high-pressure nitrogen to cut materials, strip numerous types of coatings such as paint or powder coating, clean surfaces and profile metals. Liquid nitrogen (LN2) is used as the feed stream and is pressurized in two stages. The first stage pressurizes sub cooled LN2 to an intermediate pressure of between 15,000 and 20,000 psi at which point the temperature of the LN2 is about -250 F. The discharge from this stage is then introduced as feed to a dual intensifier system, which boosts the pressure from 15,000 - 20,000 psi up to the maximum operating pressure of 55,000 psi. A temperature of about -220 F is achieved at which point the nitrogen is supercritical. In this condition the nitrogen cuts, strips and abrades much like ultra high-pressure water would but without any residual liquid to collect, remove or be contaminated. Once the nitrogen has performed its function it harmlessly flashes back into the atmosphere as pure nitrogen gas. The system uses heat exchangers to control and modify the temperature of the various intake and discharge nitrogen streams. Since the system is hydraulically operated, discharge pressures can be easily varied over a very wide range providing considerable flexibility for various operations. The NitroJet(TM) is an advance on the nitrogen fluid jet technology initially developed at the Idaho National Engineering Laboratory in Idaho Falls, Idaho. NitroCision(R) first introduced the NitroJet(TM) into a commercial setting in 2003 and there has been considerable interest from many diverse sectors of government and industry since then. While the current system is an industrial system with the size and mass normally associated with industrial applications, a smaller system that is much more compact is being contemplated for those applications that do not need the full capabilities of the larger system. The NitroJet(TM) can be deployed as a fixed or mobile system with multiple end effectors capable of cutting, stripping, cleaning, and surface profiling either in robotic or manual applications.

Hume, Howard↗

An Overview of LO-DuSST (Lunar Occupancy Dust Surface Separation Technologies) Objectives

Of the myriad of issues facing lunar exploration and maintaining an extended lunar presence, lunar dust is possibly the most pervasive. These jagged, chemically reactive, electrostatically charged, sometimes magnetic particles can impact every aspect of a lunar surface mission ranging from abrading extra-vehicular activity (EVA) suits to disrupting lunar vehicle thermal management systems to impeding efficacy of excavation equipment to impacting lunar inhabitant health. NASA’s Lunar Occupancy Dust Surface Separation Technologies (LO-DuSST) task, as a part of the broader Lunar Surface Innovation Initiative (LSII) project, seeks to implement synergistic active and passive lunar dust management and mitigation technologies for an array of applications. One such application is protection of power generation capabilities via solar panel arrays. Plasma dust lofting coupled with a piezoelectric-driven vibration technology will be demonstrated on solar panel surfaces contaminated with lunar dust simulant. Intrinsically low adhesion coatings will be applied to these surfaces to enhance dust removal. Electrostatic repulsion in confined geometries and materials to manage high velocity lunar dust wear will also be investigated. Collectively, these active and passive mitigation technologies will facilitate lunar surface operations including occupancy logistics, landing pad operations, power generation, and transportation. Initial results regarding lunar simulant-contaminated solar panel performance experiments, dust lofting using an electron beam, surface interactions of high velocity lunar dust arising from lunar lander plume-surface interactions, and lunar dust simulant-material interaction experiments will be discussed.

Lunar dust↗

Bio-inspired Surface Structures to Mitigate Interfacial Particle Adhesion and Erosion - A Review

Lunar dust known as regolith is a huge challenge for lunar exploration missions. Formed over millennia by a complex process involving impacts of meteoroids and micrometeoroids on the lunar surface, lunar dust is porous, highly abrasive with sharp jagged edges, chemically reactive, electrostatically charged and sometimes magnetic. The chemical composition and thickness of the dust layer also varies in different regions of the lunar surface. From samples obtained by previous lunar missions, the average particle size is below 100 microns. This dust has the tendency to strongly adhere to any exposed surfaces, and often degrades the material functionality to eventually cause failure. Any material on the lunar surface is also subject to harsh temperature cycles ranging from -178 ̊C to + 123 ̊C and extreme ultraviolet radiation. While on the lunar surface, different classes of materials would be required for different applications. Advanced materials have been and will be used throughout the lunar lander, habitat, and mission equipment. Examples include: polymeric materials for astronaut protective clothing; metals and ceramics for the lunar lander legs and habitats, and excavating equipment; and semiconductors for solar panels and on-board electronics. In all these applications, the surfaces of the materials are expected or understood to be exposed to the extreme lunar environment condition that includes the regolith dust. During the Apollo missions, the dust clung to and abraded the astronaut’s suits, degraded seals, optics, clogged sensors and reduced performance of thermal radiators. The lunar dust adheres to the surface by various mechanisms, which include electrostatic and Coulombic interactions, Van-der-Waals forces, magnetic forces, mechanical interlocking, chemical bonding and donor-acceptor interactions. There are three primary strategies for developing technologies to minimize the lunar dust adhesion: active, passive and a combination of active and passive. In the active approach, an external energy is needed to prevent or remove particles from collecting on the surface. Mechanically powered brushes and electrodynamic dust screens are two examples. In the passive approach, no external power is needed, and the material surface properties are able to mitigate dust adhesion. A well-known example of this strategy is the low work function coatings for non-stick surfaces. In most cases a combination of active and passive methods might be needed to optimally manage the lunar regolith. The passive method is significantly more attractive as it does not require any external power or an additional control subsystem. These approaches optimize the mission payload and reduce risk. Surface modification to minimize the dust adhesion is thus very important to lunar missions. Here, naturally evolved surface structures might provide guidance for solutions. There are several factors that have to be considered for minimizing particle adhesion to a surface. These include the substrate material properties, surface topography, chemistry, and the characteristics of the adhering particles. When engineering a surface, the substrate material chosen would be dependent on the needs of the application. Tailoring the surface microstructure or chemistry opens up more possibilities for its optimal utilization

Lunar Dust↗

The Mars Environmental Compatibility Assessment MECA Abrasion Tool

The Mars Environmental Compatibility Assessment (MECA) experiment, an instrument suite to be flown on Mars Surveyor 2001, will include a tool for doing simple mineralogical scratch and streak tests on particles from the Martian regolith. The Abrasion Tool will be applied to particles that adhere to highly polished substrates of various hardnesses. Granular soil components will be subjected to a compressive force of about 3 N using a leaf spring. The spring will be applied with a paraffin actuator capable of a 0.76 mm throw to achieve a maximum displacement of about 7.5 mm at the tip of the tool. The pressure per grain will be dependent on the grain size, the number of grains that adhere to the substrate and the number of grains in compression. The pressure per particle is expected to be on the order of 100 MPa - 1 GPa. The MECA sample wheel containing the substrates will be rotated after the particles are placed in compression to produce scratches or pits. A primary goal of the Abrasion Tool is to identify quartz (Mohs' hardness = 7) using substrates of varying hardnesses. Quartz is considered hazardous to future human explorers of Mars because it can cause silicosis of the lungs if it is of respirable size. It is also hazardous to machinery, structures, and space suits because of its ability to abrade and scratch surfaces. Since large quantities of minerals harder than quartz are not expected, any scratches produced on polished quartz substrates might be reasonably attributed to quartz particles, although there may be minerals such as impact metamorphic diamond in the soils. Careful calibration of the tool will be necessary to ensure that grains are not overloaded; for example, a steel ball pressed into glass will produce a Hertzian fracture, even though it is softer than glass. Other minerals, such as magnetite (Mohs'hardness = 6.5) have been shown to scratch glass ceramics such as Zerodur (Mohs' hardness = 6.5). Thus, minerals can be differentiated: note that regardless of the mineral species, if any particle is harder than 6.5 it will certainly be an interesting discovery for both planetary geology and human exploration concerns. The scratches will be identified using the 6X optical microscope and profiled with the atomic force microscope included in the MECA instrument suite. Analysis of the scratch morphology will yield evidence concerning the shape of the particle responsible for producing each scratch. For example, angular grains should leave vertical cracks with microconchoidal lateral chipping, while rounded grains might leave chattermarks, or nested partial Hertzian cracks. Particle shape can thus be inferred from these indentation modes, as well as material hardness. In addition, particle size information may also be available if pits caused by rolling particles can be identified. Converse to scratching, the minerals may be crushed at their contact points, and be smeared onto the target substrates to leave what geologists refer to as "streaks". These are coldwelded trails of mineral material that have structure and color indicative of mineral composition. The AFM will determine the morphology of these streaks, while the microscope will ascertain the color. On the harder substrates, we might expect streaking to dominate; on the softer substrates, scratching may dominate. Progressions of material interactions across the substrate selection will be a valuable source of data for mineral discrimination. It should also be noted that many minerals have coatings (such as iron oxides), and these will have to be differentiated from the host mineral grains; laboratory tests will establish the effects of such coatings on the scratch results. Finally, we note that the microscope will provide corroborative data regarding likely mineral species by grain shapes, fracture patterns, surface textures, colr, and UV fluorescence reactions.

Kuhlman, K. R.↗

The Mars Environmental Compatibility Assessment (MECA) Abrasion Tool

The Mars Environmental Compatibility Assessment (MECA) experiment, an instrument suite to be flown on Mars Surveyor 2001, will include a tool for doing simple mineralogical scratch and streak tests on particles from the Martian regolith. The Abrasion Tool will be applied to particles that adhere themselves to highly polished substrates of various hardnesses. Granular soil components will be subjected to a compressive force of about 3 N using a leaf spring. The spring will be applied with a paraffin actuator capable of a 0.76 mm throw to achieve a maximum displacement of about 7.5 mm at the tip of the tool. The pressure per grain will be dependent on the grain size, the number of grains that adhere to the substrate and the number of grains in compression. The pressure per particle is expected to be on the order of 100 MPa - 1 GPa. The MECA sample wheel containing the substrates will be rotated after the particles are placed in compression to produce scratches or pits. A primary goal of the Abrasion Tool is to identify quartz (Mohs' hardness = 7) using substrates of varying hardnesses. Quartz is considered hazardous to future human explorers of Mars because it can cause silicosis of the lungs if it is of respirable size. It is also hazardous to machinery, structures, and space suits because of its ability to abrade and scratch surfaces. Since large quantities of minerals harder than quartz are not expected, any scratches produced on polished quartz substrates might be reasonably attributed to quartz particles, although there may be minerals such as impact metamorphic diamond in the soils. Careful calibration of the tool will be necessary to ensure that grains are not overloaded; for example, a steel ball pressed into glass will produce a Hertzian fracture, even though it is softer than glass. Other minerals, such as magnetite (Mohs' hardness = 6.5) have been shown to scratch glass ceramics such as Zerodur (Mohs' hardness = 6.5). Thus, minerals can be differentiated: note that regardless of the mineral species, if any particle is harder than 6.5 it will certainly be an interesting discovery for both planetary geology and human exploration concerns. The scratches will be identified using the 6X optical microscope and profiled with the atomic force microscope included in the MECA instrument suite. Analysis of the scratch morphology will yield evidence concerning the shape of the particle responsible for producing each scratch. For example, angular grains should leave vertical cracks with microconchoidal lateral chipping, while rounded grains might leave chatter marks, or nested partial Hertzian cracks. Particle shape can thus be inferred from these indentation modes, as well as material hardness. In addition, particle size information may also be available if pits caused by rolling particles can be identified. Converse to scratching, the minerals may be crushed at their contact points, and be smeared onto the target substrates to leave what geologists refer to as "streaks". These are cold-welded trails of mineral material that have structure and color indicative of mineral composition. The AFM will determine the morphology of these streaks, while the microscope will ascertain the color. On the harder substrates, we might expect streaking to dominate; on the softer substrates, scratching may dominate. Progressions of material interactions across the substrate selection will be a valuable source of data for mineral discrimination. It should also be noted that many minerals have coatings (such as iron oxides), and these will have to be differentiated from the host mineral grains; laboratory tests will establish the effects of such coatings on the scratch results. Finally, we note that the microscope will provide corroborative data regarding likely mineral species by grain shapes, fracture patterns, surface textures, color, and UV fluorescence reactions. Additional information is contained in the original extended abstract.

Kuhlman, K. R.↗