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At least 217 records · Page 12

Advanced thermal barrier system bond coatings for use on nickel-, cobalt- and iron-base alloy substrates

New and improved Ni-, Co-, and Fe-base bond coatings have been identified for the ZrO2-Y2O3 thermal barrier coatings to be used on Ni-, Co-, and Fe-base alloy substrates. These bond coatings were evaluated in a cyclic furnace between 1120 and 1175 C. It was found that MCrAlYb (where M = Ni, Co, or Fe) bond coating thermal barrier systems have significantly longer lives than MCrAlY bond coating thermal barrier systems. The longest life was obtained with the FeCrAlYb thermal barrier system followed by NiCrAlYb and CoCrAlYb thermal barrier systems in that order.

Stecura, S.↗

Thermal barrier coating life prediction model development

The objective of this program is to develop an integrated life prediction model accounting for all potential life-limiting Thermal Barrier Coating (TBC) degradation and failure modes including spallation resulting from cyclic thermal stress, oxidative degradation, hot corrosion, erosion, and foreign object damage (FOD). The mechanisms and relative importance of the various degradation and failure modes will be determined, and the methodology to predict predominant mode failure life in turbine airfoil application will be developed and verified. An empirically based correlative model relating coating life to parametrically expressed driving forces such as temperature and stress will be employed. The two-layer TBC system being investigated, designated PWA264, currently is in commercial aircraft revenue service. It consists of an inner low pressure chamber plasma-sprayed NiCoCrAlY metallic bond coat underlayer (4 to 6 mils) and an outer air plasma-sprayed 7 w/o Y2O3-ZrO2 (8 to 12 mils) ceramic top layer.

Demasi, J.↗

Thermal barrier coating life prediction model

This is the first report of the first phase of a 3-year program. Its objectives are to determine the predominant modes of degradation of a plasma sprayed thermal barrier coating system, then to develop and verify life prediction models accounting for these degradation modes. The first task (Task I) is to determine the major failure mechanisms. Presently, bond coat oxidation and bond coat creep are being evaluated as potential TBC failure mechanisms. The baseline TBC system consists of an air plasma sprayed ZrO2-Y2O3 top coat, a low pressure plasma sprayed NiCrAlY bond coat, and a Rene'80 substrate. Pre-exposures in air and argon combined with thermal cycle tests in air and argon are being utilized to evaluate bond coat oxidation as a failure mechanism. Unexpectedly, the specimens pre-exposed in argon failed before the specimens pre-exposed in air in subsequent thermal cycles testing in air. Four bond coats with different creep strengths are being utilized to evaluate the effect of bond coat creep on TBC degradation. These bond coats received an aluminide overcoat prior to application of the top coat to reduce the differences in bond coat oxidation behavior. Thermal cycle testing has been initiated. Methods have been selected for measuring tensile strength, Poisson's ratio, dynamic modulus and coefficient of thermal expansion both of the bond coat and top coat layers.

Hillery, R. V.↗

A high-temperature heat sensitive element

This invention concerns the high-temperature heat sensitive element which is stable at high temperatures. A solid solution of the main component MgO-Al2O3-Cr2O3-Fe2O3 which contains spinel crystal structure is mixed with the secondary component ZrO2 at the mol ratio of 100 : 0.1 to 5.0 and sintered to prepare a high-temperature heat sensitive element.

Oguro, M.↗

Nickel-hydrogen separator development

The separator technology is a critical element in the nickel-hydrogen (Ni-H2) systems. Previous research and development work carried out at NASA Lewis Research Center has determined that separators made from zirconium oxide (ZrO2) and potassium titanate (PKT) fibers will function satisfactorily in Ni-H2 cells without exhibiting the problems associated with the asbestos separators. A program has been established to transfer the separator technology into a commercial production line. A detailed plan of this program will be presented and the preliminary results will be discussed.

Gonzalez-Sanabria, O. D.↗

Slip casting and extruding shapes of rhemium with metal oxide additives. Part 2: Development of grain stabilized rhenium parts for resistojets

The adaptation of the powdered particle process used for pure metal oxides to the coprocessing of rhenium oxides suitable to produce pure miniature resistojet hardware has been successful. Both slip casting and extrusion processes were used. The metal oxide ZrO2 was stabilized into the cubic phase with Y2O3, for use as a potentially grain stabilizing additive to rhenium. Straight meter long tubing in two sizes are reported. Tubing suitable for resistojet ohmic heater use of fully fired dimensions of nominally 3.8 mm o.d. x 2.2 mm i.d.. and 1.26 mm o.d. x .45 mm i.d. with 0, 0.5, 1.0 and 5.0% zirconia additives were produced for further study. Photomicrographs of these are discussed. The addition of the metal oxide zirconia to rhenium resulted in more dense and less porous parts. The additions of phase stabilized zirconia most likely act as a sintering aid. Tubes of varying diameter were slip cast which were representative of miniature pressure cases.

Barr, Francis A.↗

Thermal barrier coating life prediction model development

This report describes work performed to determine the predominat modes of degradation of a plasma sprayed thermal barrier coating system and to develop and verify life prediction models accounting for these degradation modes. The primary TBC system consisted of a low pressure plasma sprayed NiCrAlY bond coat, an air plasma sprayed ZrO2-Y2O3 top coat, and a Rene' 80 substrate. The work was divided into 3 technical tasks. The primary failure mode to be addressed was loss of the zirconia layer through spalling. Experiments showed that oxidation of the bond coat is a significant contributor to coating failure. It was evident from the test results that the species of oxide scale initially formed on the bond coat plays a role in coating degradation and failure. It was also shown that elevated temperature creep of the bond coat plays a role in coating failure. An empirical model was developed for predicting the test life of specimens with selected coating, specimen, and test condition variations. In the second task, a coating life prediction model was developed based on the data from Task 1 experiments, results from thermomechanical experiments performed as part of Task 2, and finite element analyses of the TBC system during thermal cycles. The third and final task attempted to verify the validity of the model developed in Task 2. This was done by using the model to predict the test lives of several coating variations and specimen geometries, then comparing these predicted lives to experimentally determined test lives. It was found that the model correctly predicts trends, but that additional refinement is needed to accurately predict coating life.

Hillery, R. V.↗

The effect of oxidation on the high heat flux behavior of a thermal barrier coating

The effect of oxidation on the high heat flux behavior of a thermal barrier coating was evaluated by cyclically exposing preoxidized specimens to a 3000 C nitrogen plasma. The thermal barrier coatings consisted of a 0.025 cm layer of air-plasma-sprayed ZrO2-7 percent Y2O3 and a 0.012 cm layer of low pressure-plasma-sprayed NiCoCrAlY applied over 0.13 cm diameter B1900+Hf cylindrical substrates. A gradient of 800 C is produced across the ceramic layer in each 0.5 second exposure. This is much more severe than the gradient encountered on a gas turbine engine. Prior to exposure, the specimens were preoxidized at 1200 C for time from 0 to 20 hours. These coatings were found to be tolerant to the high heat flux plasma flame for all but the most severe preoxidations. However, life degraded rapidly for preoxidation times in excess of 15 hours at 1200 C. A log-log plot of cycles-to-failure vs estimated oxidative weight gain yield a straight or nearly straight line, and this line could be rationalized using an oxidation-based model that was developed previously for low heat flux applications.

Miller, Robert A.↗

Destabilization of yttria-stabilized zirconia induced by molten sodium vanadate-sodium sulfate melts

The extent of surface destabilization of ZrO2 - 8 wt percent Y2O3 ceramic disks was determined after exposure to molten salt mixtures of sodium sulfate containing up to 15 mole percent sodium metavanadate (NaVO3) at 1173 K. The ceramic surface was observed to transform from the cubic/tetragonal to monoclinic phase, concurrent with chemical changes in the molten salt layer in contact with the ceramic. Significant attack rates were observed in both pure sulfate and metavanadate sulfate melts. The rate of attack was found to be quite sensitive to the mole fraction of vanadate in the molten salt solution and the partial pressure of sulfur trioxide in equilibrium with the salt melt. The observed parabolic rate of attack is interpreted to be caused by a reaction controlled by diffusion in the salt that penetrates into the porous layer formed by the destabilization. The parabolic rate constant in mixed sodium metavanadate - sodium sulfate melts was found to be proportional to the SO3 partial pressure and the square of the metavanadate concentration. In-situ Raman spectroscopic measurements allowed simultaneous observations of the ceramic phases and salt chemistry during the attack process.

Nagelberg, A. S.↗

Thermal barrier coatings for the space shuttle main engine turbine blades

The Space Shuttle Main Engine (SSME) turbopump turbine blades experience extremely severe thermal shocks during start-up and shut-down. For instance, the high pressure fuel turbopump turbine which burns liquid hydrogen operates at approximately 1500 F, but is shut down fuel rich with turbine blades quenced in liquid hydrogen. This thermal shock is a major contributor to blade cracking. The same thermal shock cause the protective ZrO2 thermal barrier coatings to spall or flake off, leaving only the NiCrAlY bond coating which provides only a minimum thermal protection. The turbine blades are therefore life limited to about 3000 sec for want of a good thermal barrier. A suitable thermal barrier coating (TBC) is being developed for the SSME turbine blades. Various TBCs developed for the gas turbine engines were tested in a specially built turbine blade tester. This tester subjects the coated blades to thermal and pressure cycles similar to those during actual operation of the turbine. The coatings were applied using a plasma spraying techniques both under atmospheric conditions and in vacuum. Results are presented. In general vacuum plasma sprayed coatings performed much better than those sprayed under atmospheric conditions. A 50 to 50 blend of Cr2O3 and NiCrAlY, vacuum plasma sprayed on SSME turbopump turbine blades appear to provide significant improvements in coating durability and thermal protection.

Bhat, B. N.↗

Sequentially evaporated thin Y-Ba-Co-O superconducting films on microwave substrates

The development of high T sub c superconducting thin films on various microwave substrates is of major interest in space electronic systems. Thin films of YBa2Cu3O(7-Delta) were formed on SrTiO3, MgO, ZrO2 coated Al2O3, and LaAlO3 substrates by multi-layer sequential evaporation and subsequent annealing in oxygen. The technique allows controlled deposition of Cu, BaF2 and Y layers, as well as the ZrO buffer layers, to achieve reproducibility for microwave circuit fabrication. The three layer structure of Cu/BaF2/Y is repeated a minimum of four times. The films were annealed in an ambient of oxygen bubbled through water at temperatures between 850 C and 900 C followed by slow cooling (-2 C/minute) to 450 C, a low temperature anneal, and slow cooling to room temperature. Annealing times ranged from 15 minutes to 5 hrs. at high temperature and 0 to 6 hr. at 450 C. Silver contacts for four probe electrical measurements were formed by evaporation followed with an anneal at 500 C. The films were characterized by resistance-temperature measurements, energy dispersive X-ray spectroscopy, X-ray diffraction, and scanning electron microscopy. Critical transition temperatures ranged from 30 K to 87 K as a function of the substrate, composition of the film, thicknesses of the layers, and annealing conditions. Microwave ring resonator circuits were also patterned on these MgO and LaAlO3 substrates.

Valco, G. J.↗

Millimeter wave transmission studies of YBa2Cu3O7-delta thin films in the 26.5 to 40.0 GHz frequency range

Millimeter wave transmission measurements through YBa2Cu3O(7-delta) thin films on MgO, ZrO2 and LaAlO3 substrates, are reported. The films (approx. 1 micron) were deposited by sequential evaporation and laser ablation techniques. Transition temperatures T sub c, ranging from 89.7 K for the Laser Ablated film on LaAlO3 to approximately 72 K for the sequentially evaporated film on MgO, were obtained. The values of the real and imaginary parts of the complex conductivity, sigma 1 and sigma 2, are obtained from the transmission data, assuming a two fluid model. The BCS approach is used to calculate values for an effective energy gap from the obtained values of sigma sub 1. A range of gap values from 2 DELTA o/K sub B T sub c = 4.19 to 4.35 was obtained. The magnetic penetration depth is evaluated from the deduced values of sigma 2. These results are discussed together with the frequency dependence of the normalized transmission amplitude, P/P sub c, below and above T sub c.

Miranda, F. A.↗

Preparation of high T(c) Tl-Ba-Ca-Cu-O thin films by pulsed laser evaporation and Tl2O3 vapor processing

Tl-Ba-Ca-Cu-O superconducting thin films with zero-resistance temperatures up to 115 K have been prepared using a Tl2O3 vapor process on Ba-Ca-Cu-O precursor thin films. The Ba-Ca-Cu-O thin films were made by laser deposition on Y-stabilized ZrO2 substrates. This technique minimizes problems caused by the toxicity of Tl2O3, and its subsequent decomposition to the volatile and toxic Tl2O upon heating. Therefore, it may have practical application in the fabrication of high T(c) Tl-Ba-Ca-Cu-O superconducting thin-film devices.

Johs, B.↗

Continuous electron stimulated desorption using a ZrO2/Ag permeation membrane

During the development of an atomic oxygen beam generator for laboratory simulation of the atmospheric conditions in low earth orbit, a new technique for performing electron stimulated desorption (ESD) in a continuous manner has been developed. In this technique, oxygen permeates through an Ag membrane at elevated temperature thereby providing a continuous supply of oxygen atoms to the 1000-A ZrO2 coating at the vacuum interface. ESD then results in a large peak of neutral O2 molecules which ultimately decay into steady-state desorption. The ESD signal is linear with respect to primary beam flux (0.035 O2 molecules per electron at a primary beam energy of 1 keV) but nonlinear with respect to primary beam energy.

Outlaw, R. A.↗

Friction and wear of oxide-ceramic sliding against IN-718 nickel base alloy at 25 to 800 C in atmospheric air

The friction and wear of oxide-ceramics sliding against the nickel base alloy IN-718 at 25 to 800 C were measured. The oxide materials tested were mullite (3Al2O3.2SiO2); lithium aluminum silicate (LiAlSi(x)O(y)); polycrystalline monolithic alpha alumina (alpha-Al2O3); single crystal alpha-Al2O3 (sapphire); zirconia (ZrO2); and silicon carbide (SiC) whisker-reinforced Al2O3 composites. At 25 C the mullite and zirconia had the lowest friction and the polycrystalline monolithic alumina had the lowest wear. At 800 C the Al2O3-8 vol/percent SiC whisker composite had the lowest friction and the Al2O3-25 vol/percent SiC composite had the lowest wear. The friction of the Al2O3-SiC whisker composites increased with increased whisker content while the wear decreased. In general, the wear-resistance of the ceramics improve with their hardness.

Sliney, Harold E.↗

Thermodynamic analysis of chemical stability of ceramic materials in hydrogen-containing atmospheres at high temperatures

The chemical stability of several ceramic materials in hydrogen-containing environments was analyzed with thermodynamic considerations in mind. Equilibrium calculations were made as a function of temperature, moisture content, and total system pressure. The following ceramic materials were considered in this study: SiC, Si3N4, SiO2, Al2O3, mullite, ZrO2, Y2O3, CaO, MgO, BeO, TiB2, TiC, HfC, and ZrC. On the basis of purely thermodynamic arguments, upper temperature limits are suggested for each material for long-term use in H2-containing atmospheres.

Misra, Ajay K.↗

TBCs for better engine efficiency

State-of-the-art thermal barrier coatings (TBCs) developed for aircraft engines can achieve both hot-section component operating temperature reductions and superior oxidation resistance. Such TBCs typically consist of two layers: a metallic, often NiCrAlY 'bond' inner layer in contact with the superalloy structural component, and an outer, insulating ceramic layer. A ceramic frequently used in this role due to its high durability is plasma-sprayed ZrO2, partially stabilized with 6-8 wt pct Y2O3. TBCs can also be useful in nonaircraft gas turbines, which frequently use highly contaminated fuels.

Brindley, William J.↗

Cold plasma processing of local planetary ores for oxygen and metallurgically important metals

The utilization of a cold or nonequilibrium plasma in chlorination processing is discussed. Titanium dioxide (TiO2) was successfully chlorinated at temperatures between 700 and 900 C without the aid of carbon. In addition to these initial experiments, a technique was developed for determining the temperature of a specimen in a plasma. Development of that technique has required evaluating the emissivity of TiO2, ZrO2, and FeOTiO2 and analyzing the specimen temperature in a plasma as a function of both power absorbed by the plasma and the pressure of the plasma. The mass spectrometer was also calibrated with TiCl4 and CCl4 vapor.

Lynch, D. C.↗