SEARCH · Engineering Papers

Results for “PVD”

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.

SourceResearch connectionFrom yearThrough year

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

At least 199 records · Page 11

All sources NASA NTRS DOE OSTI

NASA NTRS2010

Fabrication and Testing of a Thin-Film Heat Flux Sensor for a Stirling Convertor

The NASA Glenn Research Center (GRC) has been testing high-efficiency free-piston Stirling convertors for potential use in radioisotope power systems since 1999. Stirling convertors are being operated for many years to demonstrate a radioisotope power system capable of providing reliable power for potential multiyear missions. Techniques used to monitor the convertors for change in performance include measurements of temperature, pressure, energy addition, and energy rejection. Micro-porous bulk insulation is used in the Stirling convertor test setup to minimize the loss of thermal energy from the electric heat source to the environment. The insulation is characterized before extended operation, enabling correlation of the net thermal energy addition to the convertor. Aging micro-porous bulk insulation changes insulation efficiency, introducing errors in the correlation for net thermal energy addition. A thin-film heat flux sensor was designed and fabricated to directly measure the net thermal energy addition to the Stirling convertor. The fabrication techniques include slipcasting and using Physical Vapor Deposition (PVD). One-micron-thick noble metal thermocouples measure temperature on the surface of an alumina ceramic disk and heat flux is calculated. Fabrication, integration, and test results of a thin-film heat flux sensor are presented.

Wilson, Scott D.↗

NASA NTRS2011

Monitoring Delamination of Thermal Barrier Coating During Interrupted High-Heat Flux Laser Testing Using Upconversion Luminescence Imaging

Upconversion luminescence imaging of thermal barrier coatings (TBCs) has been shown to successfully monitor TBC delamination progression during interrupted furnace cycling. However, furnace cycling does not adequately model engine conditions where TBC-coated components are subjected to significant heat fluxes that produce through-thickness temperature gradients that may alter both the rate and path of delamination progression. Therefore, new measurements are presented based on luminescence imaging of TBC-coated specimens subjected to interrupted high-heat-flux laser cycling exposures that much better simulate the thermal gradients present in engine conditions. The TBCs tested were deposited by electron-beam physical vapor deposition (EB-PVD) and were composed of 7wt% yttria-stabilized zirconia (7YSZ) with an integrated delamination sensing layer composed of 7YSZ co-doped with erbium and ytterbium (7YSZ:Er,Yb). The high-heat-flux exposures that produce the desired through-thickness thermal gradients were performed using a high power CO2 laser operating at a wavelength of 10.6 microns. Upconversion luminescence images revealed the debond progression produced by the cyclic high-heat-flux exposures and these results were compared to that observed for furnace cycling.

Eldridge, Jeffrey I.↗

NASA NTRS2011

Moisture-Induced TBC Spallation on Turbine Blade Samples

Delayed failure of TBCs is a widely observed laboratory phenomenon, although many of the early observations went unreported. "The weekend effect" or "DeskTop Spallation" (DTS) is characterized by initial survival of a TBC after accelerated laboratory thermal cycling, then failure by exposure to ambient humidity or water. Once initiated, failure can occur quite dramatically in less than a second. To this end, the water drop test and digital video recordings have become useful techniques in studies at NASA (Smialek, Zhu, Cuy), DECHMA (Rudolphi, Renusch, Schuetze), and CNRS Toulouse/SNECMA (Deneux, Cadoret, Hervier, Monceau). In the present study the results for a commercial turbine blade, with a standard EB-PVD 7YSZ TBC top coat and Pt-aluminide diffusion bond monitored by weight change and visual appearance. Failures were distributed widely over a 5-100 hr time range, depending on temperature. At some opportune times, failure was captured by video recording, documenting the appearance and speed of the moisture-induced spallation process. Failure interfaces exhibited alumina scale grains, decorated with Ta-rich oxide particles, and alumina inclusions as islands and streamers. The phenomenon is thus rooted in moisture-induced delayed spallation (MIDS) of the alumina scale formed on the bond coat. In that regard, many studies show the susceptibility of alumina scales to moisture, as long as high strain energy and a partially exposed interface exist. The latter conditions result from severe cyclic oxidation conditions, which produce a highly stressed and partially damaged scale. In one model, it has been proposed that moisture reacts with aluminum in the bond coat to release hydrogen atoms that 'embrittle' the interface. A negative synergistic effect with interfacial sulfur is also invoked.

Smialek, James L.↗

NASA NTRS2011

Moisture-Induced TBC Spallation on Turbine Blade Samples

Delayed failure of TBCs is a widely observed laboratory phenomenon, although many of the early observations went unreported. The weekend effect or DeskTop Spallation (DTS) is characterized by initial survival of a TBC after accelerated laboratory thermal cycling, then failure by exposure to ambient humidity or water. Once initiated, failure can occur quite dramatically in less than a second. To this end, the water drop test and digital video recordings have become useful techniques in studies at NASA (Smialek, Zhu, Cuy), DECHMA (Rudolphi, Renusch, Schuetze), and CNRS Toulouse/SNECMA (Deneux, Cadoret, Hervier, Monceau). In the present study the results for a commercial turbine blade, with a standard EB-PVD 7YSZ TBC top coat and Pt-aluminide diffusion bond coat are reported. Cut sections were intermittently oxidized at 1100, 1150, and 1200 C and monitored by weight change and visual appearance. Failures were distributed widely over a 5-100 hr time range, depending on temperature. At some opportune times, failure was captured by video recording, documenting the appearance and speed of the moisture-induced spallation process. Failure interfaces exhibited alumina scale grains, decorated with Ta-rich oxide particles, and alumina inclusions as islands and streamers. The phenomenon is thus rooted in moisture-induced delayed spallation (MIDS) of the alumina scale formed on the bond coat. In that regard, many studies show the susceptibility of alumina scales to moisture, as long as high strain energy and a partially exposed interface exist. The latter conditions result from severe cyclic oxidation conditions, which produce a highly stressed and partially damaged scale. In one model, it has been proposed that moisture reacts with aluminum in the bond coat to release hydrogen atoms that embrittle the interface. A negative synergistic effect with interfacial sulfur is also invoked.

Smialek, James↗

NASA NTRS2012

Enhanced MgF2 and LiF Over-Coated Al Mirrors for FUV Space Astronomy

We reported gains in Far-Ultraviolet (FUV) reflectivity of Al+MgF2 and Al+LiF mirrors by employing a-step process during PVD coating deposition of these materials.

Quijada, Manuel↗

NASA NTRS2009

Fabrication and Testing of a Thin-Film Heat Flux Sensor for a Stirling Convertor

The NASA Glenn Research Center (GRC) has been testing high efficiency free-piston Stirling convertors for potential use in radioisotope power systems since 1999. Stirling convertors are being operated for many years to demonstrate a radioisotope power system capable of providing reliable power for potential multi-year missions. Techniques used to monitor the convertors for change in performance include measurements of temperature, pressure, energy addition, and energy rejection. Micro-porous bulk insulation is used in the Stirling convertor test set up to minimize the loss of thermal energy from the electric heat source to the environment. The insulation is characterized before extended operation, enabling correlation of the net thermal energy addition to the convertor. Aging microporous bulk insulation changes insulation efficiency, introducing errors in the correlation for net thermal energy addition. A thin-mm heat flux sensor was designed and fabricated to directly measure the net thermal energy addition to the Stirling convertor. The fabrication techniques include slip casting and using Physical Vapor Deposition (PVD). One micron thick noble metal thermocouples measure temperature on the surface of an Alumina ceramic disc and heat flux is calculated. Fabrication, integration, and test results of a thin film heat flux sensor are presented.

Wilson, Scott D.↗

NASA NTRS2012

Development of YAG:Dy Thermographic Phosphor Coatings for Turbine Engine Applications

The selection and development of thermographic phosphor coatings were pursued to meet the objective of demonstrating luminescence-decay-based temperature measurements up to 1300C on the surface of a vane in an operating demonstrator turbine engine. To meet this objective, YAG:Dy was selected based on the desirable luminescence performance observed for YAG:Dy powder: (1) excellent temperature sensitivity and intensity at operating turbine engine temperatures, (2) an emission peak at the relatively short wavelength of 456 nm, where the interference from background blackbody radiation is fairly low, and (3) its nearly single exponential decay which makes for a simple, reliable temperature calibration. However, implementation of YAG:Dy for surface temperature measurements required application of YAG:Dy as a coating onto the surface of a superalloy component with a preexisting yttria-stabilized zirconia (YSZ) thermal barrier coating (TBC). An inherent dilemma in producing a YAG:Dy coating is that coating processing is constrained to be performed at temperatures below (less than 1200C) what is considered safe for the superalloy component, much lower than temperatures used to produce the high quality crystalline powder. Therefore, YAG:Dy coatings tend to exhibit lower luminescence performance compared to well prepared YAG:Dy powder, and the luminescence performance of the coating will depend on the method of coating deposition. In this presentation, the luminescence performance of YAG:Dy coatings prepared by the different methods of (1) application of a binder-based YAG:Dy-containing paint, (2) solution precursor plasma spray (SPPS), and (3) electron-beam physical vapor deposition (EB-PVD) and the effect of post-deposition heat treatments will be discussed.

Eldridge, J. I.↗

NASA NTRS2014

Development and Performance Evaluations of HfO2-Si and Rare Earth-Si Based Environmental Barrier Bond Coat Systems for SiC/SiC Ceramic Matrix Composites

Ceramic environmental barrier coatings (EBC) and SiCSiC ceramic matrix composites (CMCs) will play a crucial role in future aircraft propulsion systems because of their ability to significantly increase engine operating temperatures, improve component durability, reduce engine weight and cooling requirements. Advanced EBC systems for SiCSiC CMC turbine and combustor hot section components are currently being developed to meet future turbine engine emission and performance goals. One of the significant material development challenges for the high temperature CMC components is to develop prime-reliant, high strength and high temperature capable environmental barrier coating bond coat systems, since the current silicon bond coat cannot meet the advanced EBC-CMC temperature and stability requirements. In this paper, advanced NASA HfO2-Si based EBC bond coat systems for SiCSiC CMC combustor and turbine airfoil applications are investigated. The coating design approach and stability requirements are specifically emphasized, with the development and implementation focusing on Plasma Sprayed (PS) and Electron Beam-Physic Vapor Deposited (EB-PVD) coating systems and the composition optimizations. High temperature properties of the HfO2-Si based bond coat systems, including the strength, fracture toughness, creep resistance, and oxidation resistance were evaluated in the temperature range of 1200 to 1500 C. Thermal gradient heat flux low cycle fatigue and furnace cyclic oxidation durability tests were also performed at temperatures up to 1500 C. The coating strength improvements, degradation and failure modes of the environmental barrier coating bond coat systems on SiCSiC CMCs tested in simulated stress-environment interactions are briefly discussed and supported by modeling. The performance enhancements of the HfO2-Si bond coat systems with rare earth element dopants and rare earth-silicon based bond coats are also highlighted. The advanced bond coat systems, when integrated with advanced EBC top coats, showed promise to achieve 1500 C temperature capability, helping enable next generation turbine engines with significantly improved engine component temperature capability and long-term durability.

HfO2-Si bond coat↗

NASA NTRS2014

Aperture Valve for the Mars Organic Molecule Analyzer (MOMA)

NASA's participation in the multi-nation ExoMars 2018 Rover mission includes a critical astrobiology Mass Spectrometer Instrument on the Rover called the Mars Organic Molecule Analyzer (MOMA). The Aperture Valve is a critical electromechanical valve used by the Mass Spectrometer to facilitate the transfer of ions from Martian soil to the Mass Spectrometer for analysis. The MOMA Aperture Valve development program will be discussed in terms of the Initial valve design and subsequent improvements that resulted from prototype testing. The Initial Aperture Valve concept seemed promising, based on calculations and perceived merits. However, performance results of this design were disappointing, due to delamination of TiN and DLC coatings applied to the Titanium base metals, causing debris from the coatings to seize the valve. While peer reviews and design trade studies are important forums to vet a concept design, results from testing should not be underestimated.Despite the lack of development progress to meet requirements, valuable information from weakness discovered in the Initial Valve design was used to develop a second, more robust Aperture valve. Based on a check-ball design, the ETU flight valve design resulted in significantly less surface area to create the seal. Moreover, PVD coatings were eliminated in favor of hardened, nonmagnetic corrosion resistant alloys. Test results were impressive, with the valve achieving five orders of magnitude better sealing leak rate over end of life requirements. Cycle life was equally impressive, achieving 280,000 cycles without failure.

Mars↗

NASA NTRS2014

Aperture Valve for the Mars Organic Molecule Analyzer (MOMA)

NASA's participation in the multi-nation ExoMars 2018 Rover mission includes a critical astrobiology Mass Spectrometer Instrument on the Rover called the Mars Organic Molecule Analyzer (MOMA). The Aperture Valve is a critical electromechanical valve used by the Mass Spectrometer to facilitate the transfer of ions from Martian soil to the Mass Spectrometer for analysis. The MOMA Aperture Valve development program will be discussed in terms of the Initial valve design and subsequent improvements that resulted from prototype testing. The Initial Aperture Valve concept seemed promising, based on calculations and perceived merits. However, performance results of this design were disappointing, due to delamination of TiN and DLC coatings applied to the Titanium base metals, causing debris from the coatings to seize the valve. While peer reviews and design trade studies are important forums to vet a concept design, results from testing should not be underestimated. Despite the lack of development progress to meet requirements, valuable information from weakness discovered in the Initial Valve design was used to develop a second, more robust Aperture valve. Based on a check-ball design, the ETU /flight valve design resulted in significantly less surface area to create the seal. Moreover, PVD coatings were eliminated in favor of hardened, nonmagnetic corrosion resistant alloys. Test results were impressive, with the valve achieving five orders of magnitude better sealing leak rate over end of life requirements. Cycle life was equally impressive, achieving 280,000 cycles without failure.

00000↗

NASA NTRS2014

Aperture Valve for the Mars Organic Molecule Analyzer (MOMA)

NASA's participation in the multi-nation ExoMars 2018 Rover mission includes a critical astrobiology Mass Spectrometer Instrument on the Rover called the Mars Organic Molecule Analyzer (MOMA). The Aperture Valve is a critical electromechanical valve used by the Mass Spectrometer to facilitate the transfer of ions from Martian soil to the Mass Spectrometer for analysis. The MOMA Aperture Valve development program will be discussed in terms of the initial valve design and subsequent improvements that resulted from prototype testing. The initial Aperture Valve concept seemed promising, based on calculations and perceived merits. However, performance results of this design were disappointing, due to delamination of TiN and DLC coatings applied to the titanium base metals, causing debris from the coatings to seize the valve. While peer reviews and design trade studies are important forums to vet a concept design, results from testing should not be underestimated. Despite the lack of development progress to meet requirements, valuable information from weakness discovered in the initial Valve design was used to develop a second, more robust Aperture Valve. Based on a check-ball design, the ETU / flight valve design resulted in significantly less surface area to create the seal. Moreover, PVD coatings were eliminated in favor of hardened, non-magnetic corrosion resistant alloys. Test results were impressive, with the valve achieving five orders of magnitude better sealing leak rate over end of life requirements. Cycle life was equally impressive, achieving 280,000 cycles without failure.

Engler, Charles↗

NASA NTRS2015

Acoustic Emission Analysis of Damage Progression in Thermal Barrier Coatings Under Thermal Cyclic Conditions

Damage evolution of electron beam-physical vapor deposited (EBVD-PVD) ZrO2-7 wt.% Y2O3 thermal barrier coatings (TBCs) under thermal cyclic conditions was monitored using an acoustic emission (AE) technique. The coatings were heated using a laser heat flux technique that yields a high reproducibility in thermal loading. Along with AE, real-time thermal conductivity measurements were also taken using infrared thermography. Tests were performed on samples with induced stress concentrations, as well as calcium-magnesium-alumino-silicate (CMAS) exposure, for comparison of damage mechanisms and AE response to the baseline (as-produced) coating. Analysis of acoustic waveforms was used to investigate damage development by comparing when events occurred, AE event frequency, energy content and location. The test results have shown that AE accumulation correlates well with thermal conductivity changes and that AE waveform analysis could be a valuable tool for monitoring coating degradation and provide insight on specific damage mechanisms.

calcium-magnesium-alumino-silicate (CMAS)↗

NASA NTRS2015

Surface Temperature Measurements from a Stator Vane Doublet in a Turbine Engine Afterburner Flame Using a YAG:Tm Thermographic Phosphor

Luminescence-based surface temperature measurements were obtained from a YAG:Tm-coated stator vane doublet exposed to the afterburner flame of a J85 test engine at University of Tennessee Space Institute (UTSI). The objective of the testing was to demonstrate that reliable surface temperatures based on luminescence decay of a thermographic phosphor producing short-wavelength emission could be obtained from the surface of an actual engine component in a high gas velocity, highly radiative afterburner flame environment. YAG:Tm was selected as the thermographic phosphor for its blue emission at 456 nm (1D23F4 transition) and UV emission at 365 nm (1D23H6 transition) because background thermal radiation is lower at these wavelengths, which are shorter than those of many previously used thermographic phosphors. Luminescence decay measurements were acquired using a probe designed to operate in the afterburner flame environment. The probe was mounted on the sidewall of a high-pressure turbine vane doublet from a Honeywell TECH7000 turbine engine coated with a standard electron-beam physical vapor deposited (EB-PVD) 200-m-thick TBC composed of yttria-stabilized zirconia (YSZ) onto which a 25-m-thick YAG:Tm thermographic phosphor layer was deposited by solution precursor plasma spray (SPPS). Spot temperature measurements were obtained by measuring luminescence decay times at different afterburner power settings and then converting decay time to temperature via calibration curves. Temperature measurements using the decays of the 456 and 365 nm emissions are compared. While successful afterburner environment measurements were obtained to about 1300C with the 456 nm emission, successful temperature measurements using the 365 nm emission were limited to about 1100C due to interference by autofluorescence of probe optics at short decay times.

thermographic phosphor↗

NASA NTRS2016

Development Status and Performance Comparisons of Environmental Barrier Coating Systems for SiCSiC Ceramic Matrix Composites

Environmental barrier coatings (EBC) and SiCSiC ceramic matrix composites (CMCs) will play a crucial role in future aircraft turbine engine systems, because of their ability to significantly increase engine operating temperatures, reduce engine weight and cooling requirements. This paper presents current NASA EBC-CMC development emphases including: the coating composition and processing improvements, laser high heat flux-thermal gradient thermo-mechanical fatigue - environmental testing methodology development, and property evaluations for next generation EBC-CMC systems. EBCs processed with various deposition techniques including Plasma Spray, Electron Beam - Physical Vapor Deposition, and Plasma Spray Physical Vapor Deposition (PS-PVD) will be particularly discussed. The testing results and demonstrations of advanced EBCs-CMCs in complex simulated engine thermal gradient cyclic fatigue, oxidizing-steam and CMAS environments will help provide insights into the coating development strategies to meet long-term engine component durability goals.

Processing and Properties↗

NASA NTRS2017

CMAS Interactions with Advanced Environmental Barrier Coatings Deposited via Plasma Spray- Physical Vapor Deposition

Materials for advanced turbine engines are expected to have temperature capabilities in the range of 1370-1500C. At these temperatures the ingestion of sand and dust particulate can result in the formation of corrosive glass deposits referred to as CMAS. The presence of this glass can both thermomechanically and thermochemically significantly degrade protective coatings on metallic and ceramic components. Plasma Spray- Physical Vapor Deposition (PS-PVD) was used to deposit advanced environmental barrier coating (EBC) systems for investigation on their interaction with CMAS compositions. Coatings were exposed to CMAS and furnace tested in air from 1 to 50 hours at temperatures ranging from 1200-1500C. Coating composition and crystal structure were tracked with X-ray diffraction and microstructure with electron microscopy.

Coatings↗

NASA NTRS2017

Environmental Stability and Oxidation Behavior of HfO2-Si and YbGd(O) Based Environmental Barrier Coating Systems for SiCSiC Ceramic Matrix Composites

Ceramic Matrix Composites↗

NASA NTRS2017

Advanced Environmentally Resistant Lithium Fluoride Mirror Coatings for the Next Generation of Broadband Space Observatories

Recent advances in the physical vapor deposition (PVD) of protective fluoride films have raised the far-ultraviolet (FUV: 912-1600 A) reflectivity of aluminum-based mirrors closer to the theoretical limit. The greatest gains, at more than 20%, have come for lithium fluoride-protected aluminum, which has the shortest wavelength cutoff of any conventional overcoat. Despite the success of the NASA FUSE mission, the use of lithium fluoride (LiF)-based optics is rare, as LiF is hygroscopic and requires handling procedures that can drive risk. With NASA now studying two large mission concepts for astronomy, Large UV-Optical-IR Surveyor (LUVOIR) and the Habitable Exoplanet Imaging Mission (HabEx), which mandate throughput down to 1000 , the development of LiF-based coatings becomes crucial. This paper discusses steps that are being taken to qualify these new enhanced LiF-protected aluminum (eLiF) mirror coatings for flight. In addition to quantifying the hygroscopic degradation, we have developed a new method of protecting eLiF with an ultrathin (10-20 A) capping layer of a nonhygroscopic material to increase durability. We report on the performance of eLiF-based optics and assess the steps that need to be taken to qualify such coatings for LUVOIR, HabEx, and other FUV-sensitive space missions.

Fleming, Brian↗

NASA NTRS2019

Durability of YSZ Coated Ti2AlC in 1300°C Mach 0.3 Burner Rig Tests

A thermal barrier coating system survived burner rig testing at 1300°C for 500 h. A 160 µm thick YSZ coating was applied to a Ti2AlC MAX phase sample by PS-PVD and tested face-on in an atmospheric Mach 0.3 jet fuel burner, using 5-h thermal cycles. No TBC spallation or recession was observed, only a 2.4 mg/sq. cm mass gain. The modest weight gain precluded severe volatility losses under high velocity burner conditions. The coating surface exhibited colonies of (111) flourite fiber-textured columns separated by craze patterns, with no visible moisture attack. The metastable tetragonal t' YSZ phase was obtained initially, transitioning to teq and cubic YSZ, but with little detrimental monoclinic. The thickness of the alumina TGO was ~21-23 m under the heated YSZ face and ~13-15 m on the uncoated, cooler backside. The backside exhibited removal of initial transient TiO2 nodules and etching of the underlying Al2O3 scale by volatile hydroxides in high temperature, high velocity water vapor. Aerodynamic forces produced some bending of the cantilevered sample due to creep. The test indicated exceptional stability of YSZ coatings on Ti2AlC under turbine conditions.

Smialek, J.↗