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At least 181 records · Page 10

Summary of NASA research on thermal-barrier coatings

This paper summarizes the work conducted at the NASA Lewis Research Center to evolve and evaluate a two-layer, thermal-barrier coating system. 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 investigations evaluated the reflective and insulative capability, microstructure, and durability of several coating materials on flat metal specimens, a combustor liner, and turbine vanes and blades. In addition, the effect on the aerodynamic performance of a coated turbine vane was measured. The tests were conducted in furnaces, cascades, hot-gas rigs, an engine combustor, and a research turbojet engine. Included also are summaries of current research related to the coating and potential applications for the coating.

Stepka, F. S.↗

The Effect of Compositional Tailoring on the Thermal Expansion and Tribological Properties of PS300: A Solid Lubricant Composite Coating

This paper describes a research program in which the goal is to alter the thermal expansion coefficient of a composite solid lubricant coating, PS300, by compositional tailoring. PS300 is a plasma sprayed coating consisting of chrome oxide, silver and barium fluoride/calcium fluoride eutectic in NiCr binder. By adjusting the composition, the thermal expansion coefficient can be altered, and hence chosen, to more closely match a selected substrate preventing coating spallation at extreme temperatures. Thermal expansion coefficients (CTE) for a variety of compositions were measured from 25 to 800 C using a commercial dilatometer. The CTE's ranged from 7.0 to 13 x lO(exp -6)/deg C depending on the binder content. Subsequent tribological testing of a modified composition indicated that friction and wear properties were relatively insensitive to compositional tailoring.

DellaCorte, C.↗

An LED Approach for Measuring the Photocatalytic Breakdown of Crystal Violet Dye

A simple technique to assess the reactivity of photocatalytic coatings sprayed onto transmissive glass surfaces was developed. This new method uses ultraviolet (UV) gallium nitride (GaN) light-emitting diodes (LEDs) to drive a photocatalytic reaction (the photocatalytic breakdown of a UV-resistant dye applied to a surface coated with the semiconductor titanium dioxide); and then a combination of a stabilized white light LED and a spectrometer to track the dye degradation as a function of time. Simple, standardized evaluation techniques that assess photocatalytic materials over a variety of environmental conditions, including illumination level, are not generally available and are greatly needed prior to in situ application of photocatalytic technologies. To date, much research pertaining to this aspect of photocatalysis has been limited and has focused primarily on laboratory experiments using mercury lamps. Mercury lamp illumination levels are difficult to control over large ranges and are temporally modulated by line power, limiting their use in helping to understand and predict how photocatalytic materials will behave in natural environmental settings and conditions. The methodology described here, using steady-state LEDs and time series spectroradiometric techniques, is a novel approach to explore the effect of UV light on the photocatalytic degradation of a UV resistant dye (crystal violet). GaN UV LED arrays, centered around 365 nm with an adjustable DC power supply, are used to create a small, spatially uniform light field where the steady state light level can be varied over three to four orders of magnitude. For this study, a set of glass microscope slides was custom coated with a thinly sprayed layer of photocatalytic titanium dioxide. Crystal violet was then applied to these titanium-dioxide coated slides and to uncoated control slides. The slides were then illuminated at various light levels from the dye side of the slide by the UV LED array. To monitor dye degradation on the slides over time, a temperature-stabilized white light LED was used to illuminate the opposite side of the slides. As the dye degraded, the amount of light from the white light LED transmitted through the slide was monitored with a spectrometer and subsequently analyzed to determine and compare the rate of dye degradation for photocatalytically coated versus uncoated slide surfaces. The long-term stability of the spectrometer/white light LED combination, which required only a single reference spectra to be taken for a time series sequence of several hours, enabled accurate measurements of transmitted light over time. Time series transmission curves were generated and results demonstrated that over time the transmission increased much more rapidly on the coated slides than on the control slides. This experimental configuration and methodology for photocatalytic activity measurement minimizes many external variable effects and allows low light level studies to be performed. This study also compares the advantages of this novel LED light source design to traditional mercury lamp systems and non-LED lamp approaches that have conventionally been used. The methodology and experimental design research summarized in this abstract is partly funded by the Department of Homeland Security, Science and Technology Directorate, and by the NASA Stennis Space Center Innovative Partnerships Program.

Ryan, Robert E.↗

Thermal and stress analysis of thermal barrier coatings

An analysis has been performed that predicts the thermomechanical behavior of thermal barrier coated specimens. The analysis predicts the behavior during both plasma spray coating application and burner rig testing conditions simulating engine operation. The analysis was accomplished through utilization of one-dimensional through thickness and two-dimensional finite element calculations. The results of these calculations showed that specimens with a substrate control temperature between 300 F and 600 F would be optimum. Controlling substrate temperature was found to have a more dominant effect on the mechanical strains than the ceramic or substrate thicknesses. The predicted stresses and mechanical strains at the bond-coating interface are large enough to cause cracks in this region where post-test observations have determined coating failures originate.

Cassenti, B. N.↗

Thermal Gradient Cyclic Behavior of a Thermal/Environmental Barrier Coating System on SiC/SiC Ceramic Matrix Composites

Thermal barrier and environmental barrier coatings (TBCs and EBCs) will play a crucial role in future advanced gas turbine engines because of their ability to significantly extend the temperature capability of the ceramic matrix composite (CMC) engine components in harsh combustion environments. In order to develop high performance, robust coating systems for effective thermal and environmental protection of the engine components, appropriate test approaches for evaluating the critical coating properties must be established. In this paper, a laser high-heat-flux, thermal gradient approach for testing the coatings will be described. Thermal cyclic behavior of plasma-sprayed coating systems, consisting of ZrO2-8wt%Y2O3 thermal barrier and NASA Enabling Propulsion Materials (EPM) Program developed mullite+BSAS/Si type environmental barrier coatings on SiC/SiC ceramic matrix composites, was investigated under thermal gradients using the laser heat-flux rig in conjunction with the furnace thermal cyclic tests in water-vapor environments. The coating sintering and interface damage were assessed by monitoring the real-time thermal conductivity changes during the laser heat-flux tests and by examining the microstructural changes after the tests. The coating failure mechanisms are discussed based on the cyclic test results and are correlated to the sintering, creep, and thermal stress behavior under simulated engine temperature and heat flux conditions.

Zhu, Dongming↗

Instrumented adhesion tests on plasma sprayed thermal barrier coatings

The failure mechanisms of plasma-sprayed two-layer coatings consisting of an NiCrAlY or NiCrAlZr bond coat with an yttria-stabilized zirconia overlay are presently examined by tensile adhesion tests. It has been found that adhesive failure within the bond coat exhibits greater failure strain than the cohesive failure of the ceramic overlay, supporting the view of the intermediate coatings being highly compliant. The absolute extension exhibited by failures occurring only through the ceramic coating is greater than that of adhesive failure, since the ceramic coating is much thicker than the bond coat.

Berndt, Christopher C.↗

High-Temperature Solid Lubricant Coating

NASA PS400 is a solid lubricant coating invented for high-temperature tribological applications. This plasma-sprayed coating is a variant of the previously patented PS304 coating, and has been formulated to provide higher density, smoother surface finish, and better dimensional stability. This innovation is a new composite material that provides a means to reduce friction and wear in mechanical components. PS400 is a blend of a nickel-molybdenum binder, chrome oxide hardener, silver lubricant, and barium fluoride/calcium fluoride eutectic lubricant that can either be sprayed or deposited by other means, such as powder metallurgy. The resulting composite material is then finished by grinding and polishing to produce a smooth, self-lubricating surface.

DellaCorte, Christopher↗

Exploratory screening tests of several alloys and coatings for automobile thermal reactors

A total of 23 materials (including uncoated ferritic and austenitic iron-base alloys, uncoated nickel and cobalt-base superalloys, and several different coatings on AISI 304 stainless steel) were screened as test coupons on a rack in an automobile thermal reactor. Test exposures were generally 51 hours including 142 thermal cycles of 10 minutes at 1010 + or - 30 C test coupon temperature and 7-minutes cool-down to about 510 C. Materials that exhibited corrosion resistance better than that of Hastelloy X include: a ferritic iron alloy with 6 weight percent aluminum; three nickel-base superalloys; two diffused-aluminum coatings on AISI 304; and a Ni-Cr slurry-sprayed coating on AISI 304. Preliminary comparison is made on the performance of the directly impinged coupons and a reactor core of the same material.

Oldrieve, R. E.↗

Assessment of variations in thermal cycle life data of thermal barrier coated rods

An analysis of thermal cycle life data for 22 thermal barrier coated (TBC) specimens was conducted. The Zr02-8Y203/NiCrAlY plasma spray coated Rene 41 rods were tested in a Mach 0.3 Jet A/air burner flame. All specimens were subjected to the same coating and subsequent test procedures in an effort to control three parametric groups; material properties, geometry and heat flux. Statistically, the data sample space had a mean of 1330 cycles with a standard deviation of 520 cycles. The data were described by normal or log-normal distributions, but other models could also apply; the sample size must be increased to clearly delineate a statistical failure model. The statistical methods were also applied to adhesive/cohesive strength data for 20 TBC discs of the same composition, with similar results. The sample space had a mean of 9 MPa with a standard deviation of 4.2 MPa.

Hendricks, R. C.↗

Effect of Air Plasma Sprayed Flash Bond Coatings on Furnace Cycle Lifetime of Disks and Rods

Air plasma sprayed (APS) flash coatings on high velocity oxygen fuel (HVOF) bond coatings are well known to extend the lifetime of thermal barrier coatings (TBCs). Recent work compared flash coatings of NiCoCrAlY and NiCoCrAlYHfSi applied to both rods and disk substrates of alloy 247. For rod specimens, 100 h cycles were used at 1100 °C in wet air. Both flash coatings significantly improved the lifetime compared to HVOF-only and vacuum plasma spray (VPS)-only MCrAlY bond coatings with no statistical difference between the two flash coatings. For disk specimens tested in 1 h cycles at 1100 °C in wet air, the NiCoCrAlY flash coating significantly outperformed an HVOF-only NiCoCrAlYHfSi bond coating and a NiCoCrAlYHfSi flash coating. The flash coatings formed a mixed oxide-metal zone that appeared to inhibit crack formation and therefore extend lifetime. In addition to the flash coating increasing the bond coating roughness, the underlying HVOF layer acted as a source of Al for this intermixed zone and prevented the oxide from penetrating deeper into the bond coating. Here, the lower Y+Hf content in the Y-only flash coating appeared to minimize oxidation in the flash layer, thereby increasing the benefit compared to a NiCoCrAlYHfSi flash coating.

42 ENGINEERING↗

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.↗

Coatings for high-temperature bearings and seals

Criteria are discussed for predicting the probable lubricating ability of candidate solid materials from a consideration of their basic chemical and physical properties. The properties considered to be important in the model are thermochemical potential, adhesion, low hardness, plasticity, yield strength in shear, and brittle-to-ductile transition characteristics. A review of the selection and tribological testing of materials, which were selected for use in self-lubricating composite coatings by employing this model, is given. Two series of plasma-sprayed coatings with good tribological properties over a wide temperature spectrum are described. The PS 100 series of coatings contain oxidatively stable solid lubricants in a nichrome matrix. The PS 200 series contains the same solid lubricants in a very wear resistant metal-bonded chromium carbide matrix. Examples are given of applications of these coatings in high speed shaft seals, sliding contact bearings, and Stirling engine cylinder liners.

Sliney, Harold E.↗

Factors Influencing Residual Stresses in Yttria Stabilized Zirconia Thermal Barrier Coatings

To improve gas turbine and diesel engine performance using thermal barrier coatings (TBC's) requires an understanding of the factors that influence the in-service behavior of thermal barrier coatings. One of the many factors related to coating performance is the state of stress in the coating. The total stress state is composed of the stresses due to the in-service loading history and the residual stresses. Residual stresses have been shown to affect TBC life, the bond strength of thermal spray coatings, and the fatigue life of tungsten carbide coatings. Residual stresses are first introduced in TBC's by the spraying process due to elevated temperatures during processing and the difference in coefficients of thermal expansion of the top coat, bond coat, and substrate. Later, the residual stresses can be changed by the in-service temperature history due to a number of time and temperature dependent mechanisms, such as oxidation, creep, and sintering. Silica content has also been shown to affect sintering and the cyclic life of thermal barrier coatings. Thus, it is important to understand how the spraying process, the in-service thermal cycles, and the silica content can create and alter residual stresses in thermal barrier coatings.

McGrann, Roy T. R.↗

Evaluation of present thermal barrier coatings for potential service in electric utility gas turbines

The resistance of present-day thermal barrier coatings to combustion gases found in electric utility turbines was assessed. The plasma sprayed coatings, both duplex and graded types, were primarily zirconia-based, although a calcium silicate was also evaluated. Both atmospheric burner rig tests and high pressure tests (135 psig) showed that several present-day thermal barrier coatings have a high potential for service in gas turbines burning the relatively clean GT No. 2 fuel. However, coating improvements are needed for use in turbines burning lower grade fuel such as residual oil. The duplex ZrO2.8Y2O3/NiCrA1Y coating was ranked highest and selected for near-term field testing, with Ca2SiO4/NiCrA1Y ranked second. Graded coatings show potential for corrosive turbine operating conditions and warrant further development. The coating degradation mechanisms for each coating system subjected to the various environmental conditions are also described.

Bratton, R. J.↗

NASA PS400: A New Temperature Solid Lubricant Coating for High Temperature Wear Applications

A new solid lubricant coating, NASA PS400, has been developed for high temperature tribological applications. This plasma sprayed coating is a variant of the patented PS304 coating and has been formulated to provide higher density, smoother surface finish and better dimensional stability than PS304. PS400 is comprised of a nickel-molybdenum binder that provides strength, creep resistance and extreme oxidative and dimensional stability. Chromium oxide, silver and barium-calcium fluoride eutectic are added to the binder to form PS400.Tribological properties were evaluated with a pin-on-disk test rig in sliding contact to 650 C. Coating material samples were exposed to air, argon and vacuum at 760 C followed by cross section microscopic analysis to assess microstructure stability. Oil-Free microturbine engine hot section foil bearing tests were undertaken to assess PS400 s suitability for hot foil gas bearing applications. The preliminary results indicate that PS400 exhibits tribological characteristics comparable to the PS304 coating but with enhanced creep resistance and dimensional stability suitable for demanding, dynamic applications.

DellaCorte, C.↗

MXene/graphene oxide nanocomposites for friction and wear reduction of rough steel surfaces

Development of solid lubricant materials that render reliable performance in ambient conditions, are amenable to industrial size and design complexities, and work on engineered surfaces is reported. These coatings are composed of Ti 3 C 2 T x -Graphene Oxide blends, spray-coated onto bearing steel surfaces. The tribological assessment was carried out in ambient environmental conditions and high contact pressures in a ball-on-disc experimental set-up. The evaluation yielded that the use of Ti 3 C 2 T x -Graphene-Oxide coatings led to substantial reduction in friction down to 0.065 (at 1 GPa contact pressure and 100 mm/s) in comparison to the uncoated of single-component-coated surfaces, surpassing the state-of-the-art. The coatings also provided excellent protection against wear loss of the substrate and counter-face. The results were explained based on the observations from Raman spectroscopy, scanning electron microscopy, transmission electron microscopy, and nanoindentation measurements. In operando formation of a dense, hard and stiff, dangling-bond-saturated tribolayer was observed to be the reason for the sustained lubricity even at high test loads and sliding speeds. This report presents the holistic exploration and correlation of structure-property-processing pertaining to the advancement of solid lubrication science.

36 MATERIALS SCIENCE↗

Molecular Adsorber Coating

A document discusses a zeolite-based sprayable molecular adsorber coating that has been developed to alleviate the size and weight issues of current ceramic puck-based technology, while providing a configuration that more projects can use to protect against degradation from outgassed materials within a spacecraft, particularly contamination-sensitive instruments. This coating system demonstrates five times the adsorption capacity of previously developed adsorber coating slurries. The molecular adsorber formulation was developed and refined, and a procedure for spray application was developed. Samples were spray-coated and tested for capacity, thermal optical/radiative properties, coating adhesion, and thermal cycling. Work performed during this study indicates that the molecular adsorber formulation can be applied to aluminum, stainless steel, or other metal substrates that can accept silicate-based coatings. The coating can also function as a thermal- control coating. This adsorber will dramatically reduce the mass and volume restrictions, and is less expensive than the currently used molecular adsorber puck design.

Straka, Sharon↗