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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Development of Additive Manufacturing for Ceramic Matrix Composite Vanes

This report discusses the development of additive manufacturing for polymer-derived ceramic materials to create novel cooled gas turbine airfoils made from ceramics. Gas turbine engines have extremely high temperatures in the hot section of the engine that exceed the melting point of nickel superalloy materials that the engine is made from. Advanced cooling technologies have been developed over decades for metallic parts. Ceramic materials have higher temperature capabilities than superalloys, but are difficult to shape in the complex designs used in modern turbines. Several thrusts were investigated during the project, including development of higher material strength resins, improvement of ultraviolet (UV) photopolymerization and post-processing techniques to increase survivability of ceramic parts, thermomechanical modeling of novel ceramic airfoil designs for higher cooling effectiveness, and experimental validation of the modeling and manufacturing in a turbine vane test facility at nondimensional conditions that are relevant to modern gas turbines. Some major findings of the work include a significant increase in ceramic survivability during pyrolysis (a high temperature process that converts the organic material to a ceramic) by adjusting the composition ratios of the resins, as well as a tolulene soak after printing to remove unreacted polymer material. Thermomechanical optimization of the internal cooling structure indicated that a high density pin fin array would enable an 80% increase in overall cooling effectiveness relative to a baseline geometry, which was later verified during experimental testing in a high speed linear cascade. Ceramic vanes were tested at Mach numbers of up to 0.9 which is relevant to modern gas turbines. High temperature capability of the ceramic vanes was not tested in this work.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Novel High Temperature Carbide and Boride Ceramics for Direct Power Extraction Electrode Applications. Final report

The current project aims to develop new carbide and boride ceramic materials that incorporate different metal elements (e.g., (Hf 1-x Zr x )B 2 , also called ceramic solid solutions) and understand the fundamental composition-processing-structure-property relationships for such materials. Specifically, nano powders and related nano-composites for selected mixed metal carbide and boride materials are synthesized from nano-scale mixed precursors obtained from solution-based processing via heat treatment in inert atmosphere. The obtained fine powders were then consolidated into dense ceramics via a novel flash sintering process. The mechanical properties and thermal oxidation resistance for the obtained materials were evaluated for these materials. It was found that different synthesis routes produced powders with somewhat different characteristics in terms of composition and microstructure, which then led to different properties for the final ceramics. The synthesis and processing methods demonstrated in this study might be adopted for developing other similar high temperature ceramics, while the mixed metal or solid solution ceramic materials obtained from this study might be used as hot electrodes for direction power extraction and other energy-related applications.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2019

Method and apparatus for fabricating ceramic and metal components via additive manufacturing with uniform layered radiation drying

A freeform extrusion fabrication process for producing three-dimensional ceramic, metal and functionally gradient composite objects, including the steps of filling a plurality of paste sources with a respective plurality of aqueous paste compositions, operationally connecting respective syringes containing respective aqueous paste compositions to a mixing chamber, moving a first aqueous paste composition from a first respective paste source into the mixing chamber, moving a second aqueous paste composition from a second respective paste source into the mixing chamber, mixing the first and second aqueous paste compositions to define a first admixture having a first admixture composition, extruding the first admixture onto a surface to define an extruded layer having a first admixture composition, surrounding the sides of the extruded layer with an oil bath, radiatively drying the extruded layer.

Leu, Ming C.↗
DOE OSTI2015

Fractographical characterization of hot pressed and pressureless sintered AlN-doped ZrB{sub 2}–SiC composites

In this paper, ZrB{sub 2}–SiC composites doped with 0–5 wt.% AlN were prepared by a low pressure hot pressing as well as a pressureless sintering methods at 1900 °C for 2 h. The influence of aluminum nitride addition on the sinterability and microstructure development of such ceramic composites was studied by a fractographical approach. The results revealed that only 1 wt.% AlN can aid the densification process of the hot pressed ceramic composite via the liquid phase sintering mechanism due to the formation of nano-scale metakaolinite spinel layers. In the pressureless sintering method, adding more AlN can increase the formation of gaseous products which raised the amount of porosities in the final microstructure. The formation of nano-graphite phase in the hot pressing process, the formation of Al{sub 2}OC in the pressureless sintering process, and the formation of BN in the both processes were disclosed by X-ray diffraction, SEM and TEM analyses. - Highlights: • The effect of AlN addition on densification of ZrB{sub 2}–SiC composites was studied. • AlN promotes the densification in hot pressed samples by liquid phase formation. • A fully dense composite was obtained by adding 1 wt.% AlN in hot pressing process. • In pressureless sintering, more AlN content intensifies the formation of porosities.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Magnetorheological materials, method for making, and applications thereof

A magnetorheological material comprises a magnetic particle and a ceramic material, wherein the magnetorheological material is in a dried form and further wherein a portion of the ceramic material is in the form of a nanocrystalline coating over the entire exterior surface of the magnetic particle and another portion of the ceramic material is in the form of a free nanocrystal. A magnetorheological material comprises a magnetic particle having a ceramic material coating over an external surface thereof as a result of a coating process, and a free nanocrystal of the ceramic material in the form of a residual by-product of the coating process. A sol-gel process for making a magnetorheological product comprises providing a sol of a desired ceramic coating material; combining a desired quantity of carbonyl iron (CI) particles with the sol to coat the CI particles with the ceramic coating material; creating a resulting quantity of nanocrystalline ceramic material-coated CI particles and a quantity of free nanocrystals of the ceramic material; and, drying the resulting quantity of coated CI particles and free nanocrystals to a moisture content equal to or less than 2 wt %.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A semi-empirical power-law model for the dip-coating of a substrate into a particle-containing, non-Newtonian, complex fluid system

The apparent viscosity of a particle suspension of ZrSi 2 particles, polyhydromethylsiloxane (PHMS) preceramic polymer and n-Octane solvent, used to process polymer-derived ceramic composite coatings, is shown by viscometric experiments to be shear-thinning. The suspension is dip-coated onto substrates and the measured entrained coating thickness, h 0 , is observed to be a power-law function of U, the substrate extraction speed, as h 0 = 0.5051U 0.5 . The experimentally observed semi-empirical model is directly compared to the results of a variety of theoretically derived Landau-Levich scaling laws and other models that have similar liquids and that include other effects. None of these cases predicts the scaling observed in these experiments. A correction factor is introduced to quantify the difference between the semi-empirical model with existing theoretical models. Possible explanations for the observed scaling behavior are presented.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Modeling MTS pyrolysis and SiC deposition kinetics using principal component analysis and neural networks

Accurate chemical kinetics modeling is crucial for improving the efficiency of chemical processing and synthesis of ceramic matrix composites. Detailed kinetic models are computationally expensive due to the large number of transported chemical species, while the simplified physics-based models, such as single-step global mechanisms, are efficient but often overlook key chemical intermediates and pathways. Recent deep learning approaches promise accurate and cost-effective models. Yet, they require additional closures for the transported nonlinear latent variables, complicating integration with existing solvers. In this work, we develop a hybrid linear—nonlinear reduced model for silicon carbide deposition from methyltrichlorosilane precursor by combining principal component analysis (PCA) and autoencoder (AE) neural network (NN) approaches. PCA is used to identify a smaller set of linear transport variables, enabling direct reuse of conventional transport solvers. NNs then reconstruct the full chemical state from these reduced variables. We demonstrate the method on a chemical vapor deposition reactor—comprising a gas-phase pyrolysis plug flow reactor and a heterogeneous surface reactor—over a wide range of temperatures, pressures, and residence times. Our PCA–AE model achieves high accuracy with only five transported scalars, achieving an eightfold cost reduction compared to detailed mechanisms, in both a priori (using data from the test set only) and a posteriori (coupled with a differential equation solver). In conclusion, notable errors arise primarily near training domain boundaries and for long residence times, indicating the need for domain shift indicators and better long-horizon predictions in future reduced chemistry model development.

autoencoder neural networks↗
DOE OSTI2022

Relaxor ferroelectric polymer exhibits ultrahigh electromechanical coupling at low electric field

Electromechanical (EM) coupling—the conversion of energy between electric and mechanical forms—in ferroelectrics has been used for a broad range of applications. Ferroelectric polymers have weak EM coupling that severely limits their usefulness for applications. Here, we introduced a small amount of fluorinated alkyne (FA) monomers (<2 mol %) in relaxor ferroelectric poly(vinylidene fluoride-trifluoroethylene-chlorofluoroethylene) (PVDF-TrFE-CFE) terpolymer that markedly enhances the polarization change with strong EM coupling while suppressing other polarization changes that do not contribute to it. Under a low–dc bias field of 40 megavolts per meter, the relaxor tetrapolymer has an EM coupling factor (k 33 ) of 88% and a piezoelectric coefficient (d 33 ) >1000 picometers per volt. These values make this solution-processed polymer competitive with ceramic oxide piezoelectrics, with the potential for use in distinct applications.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Development of a Thermal Spray, Redox Stable, Ceramic Anode for Metal Supported SOFC

In this program, GE global research and GE fuel cells in Malta conducted thermal spray optimization experiments, initially focusing on a well-established ceramic anode formulation, lanthanum strontium titanate combined with gadolinium doped ceria. Powder engineering work was conducted both internally and with vendors to develop repeatable, stable, and flowable thermal spray feedstocks. Agglomerate sintering was conducted in the last phase of the project, building on earlier program work, and was used to increase run stability during the longer scaled up runs for the 410 cm 2 cells. Further powder engineering would be needed to fully design a powder ready for full scale manufacturing. During preliminary work on the LST-GDC electrodes, GE demonstrated 100 cm 2 stacks enduring multiple redox cycles with limited impact. Another key finding on the project was the identification of process conditions for two component ceramic anode thermal spray without the formation of phase impurities which were present in all early work on the program. GE global research and West Virginia University screened a large number of ceramic anode formulations, focused on identifying materials with ideal materials properties for use in SOFC anodes. In addition, synthetic scaling research was conducted to increase powder synthesis batch size several orders of magnitude during the course of project work. West Virginia University was able to show button cells using two component ceramic anodes which produced > 890 mW/cm 2 and even a single component SOFC button demonstrating > 1 W/cm 2 performance. These button cell tests show the great potential of these redox stable materials. Down-selected ceramic anode formulations were combined with the optimized thermal spray process methods to first demonstrate multiple groups of 100 cm 2 SOFC stacks able to achieve the power density goals for the project. GE research also quickly investigated the performance of a subset of these formulations on long term degradation tests and assessed their performance on simulated natural gas reformate. In the final phase of the program, scaling activities were employed to translate from the 100cm2 process up to 410 cm 2 . Two large format 10-cell stack tests were completed, and one of these stacks produced 0.987 kW which is one of the highest power demonstrations of ceramic anode, metal support, SOFC technology known to GE. These ceramic anode stacks had been produced with all other materials in the stack held constant, demonstrating the flexibility of the thermal spray process in scaling to very large electrode size.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2026

Screening and qualification methodology for SiC end plug processing methods

Deployment of SiC-ceramic-based fuel cladding for light water reactors requires a hermetic end plug–to–cladding joint that can withstand neutron irradiation during normal operation and maintain integrity during design-basis accidents. Reactor experiments have shown that some SiC composite tubes with SiC end plugs can retain hermeticity after irradiation. However, achieving consistent joint performance under irradiation remains a key challenge. Resolving this issue is essential to enable integral irradiation testing and to demonstrate fuel integrity under commercial-reactor irradiation conditions. This report aims to: (1) provide guidance for designing radiation-tolerant end plug joints for SiC cladding; (2) demonstrate experimental methods to detect processing defects that are unstable under neutron irradiation at light-water-reactor-relevant temperatures and doses; and (3) outline a step-by-step approach for designing and conducting reactor experiments to screen joining methods. The resulting data will be used to improve joint processing and to define critical defect types and sizes that must be detected and eliminated through non-destructive evaluation for quality assurance. Based on prior irradiation experiments at the High Flux Isotope Reactor, differential swelling among the cladding, bonding layer, and end plug was identified as an underlying mechanism for irradiation-induced joint degradation. Accordingly, this effect must be considered in the design of radiation-tolerant joining techniques. In this work, miniature SiC end plug joint specimens irradiated during the previous project were analyzed using X-ray computed tomography to characterize the joint microstructure. Digital volume correlation of the tomography data quantified radiation-induced microstructural changes and enabled evaluation of defect-related risks. Finally, ongoing neutron irradiation efforts using larger specimen volumes are presented. These efforts aim to statistically assess joint performance and to build a microstructure–performance (e.g., leak-tightness) dataset to inform processing improvements and quality control.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Fractal nature structure reconstruction method in designing microstructure properties

Highlights: • Structure and material’s properties, within the material’s consolidation triad: Synthesis – Structure – Properties. • The grain prediction methods is based on the measurements of the solid Euclidean geometric fractal characteristics. • The intergranular contacts inside the BaTiO3 -ceramic are responsible for intergranular capacities. • The inner complex geometry of intergrain contacts imposes fractal correction factor for permeability. - Abstract: In the process of predicting materials properties, it is necessary to predict microstructures. This is important for ceramic materials, for the purpose of miniaturization and for a higher level of integration. Although the method of material structure reconstruction is for the first time used on BaTiO{sub 3}-ceramics by these authors, it can also be used for silicate, refractory and other ceramics, and, for any powder-based material. The reconstruction is based on the grain perimeter fractal analysis and the Richardson method. The main contribution of this paper is establishing the relationship between the electronic properties of BaTiO{sub 3}-ceramics and its microstructural fractal nature. Similar relations can be used for any ceramics or even any materials. The samples consolidation includes both powder pressing (cold sintering phase) and sintering in a furnace (hot sintering phase). The fractal nature characterization has a very important role from the powder phase up to the final microstructure, through which structures it directly impacts electro-physical and other ceramics properties. Thereby, the new possibilities in the microstructure characterization applications are directly introduced to an engineering system, providing the new solutions related to computer aided support. This creates new industrial production and application possibilities, especially in the process of ceramics material consolidation, now based on microstructural properties, which is providing a basis for “fractal electronics’’ development.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Additive Manufacturing of a Steel–Ceramic Multi-Material by Selective Laser Melting

Most techniques employed for powder bed additive manufacturing (AM) only can handle a single material. However, additional functionality of the structures built, e.g., local insulation, is desirable for more sophisticated applications. In the present work, a multi-material process allowing for realization of a ceramic coating on a steel substrate and a novel sandwich system are introduced. Both were manufactured by selective laser melting (SLM). As a first step, the microstructure of a bulk zirconia–alumina ceramic, directly manufactured by SLM, was examined and its tensile strength determined. Afterwards, the ceramic was manufactured directly on the as-built surface of a tool steel processed by SLM. For this compound, the adhesive strength was determined. Finally, an open porous structure, made of the same tool steel, was built on top of the ceramic layer. The results clearly prove that the SLM process can be used for direct manufacturing of a multi-material sandwich structure made from metal and ceramic, providing an important step towards complex structures functionalized for electric insulation.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Novel, Ceramic Membrane System For Hydrogen Separation

Separation of hydrogen from coal gas represents one of the most promising ways to produce alternative sources of fuel. Ceramatec, teamed with CoorsTek and Sandia National Laboratories has developed materials technology for a pressure driven, high temperature proton-electron mixed conducting membrane system to remove hydrogen from the syngas. This system separates high purity hydrogen and isolates high pressure CO 2 as the retentate, which is amenable to low cost capture and transport to storage sites. The team demonstrated a highly efficient, pressure-driven hydrogen separation membrane to generate high purity hydrogen from syngas using a novel ceramic-ceramic composite membrane. Recognizing the benefits and limitations of present membrane systems, the all-ceramic system has been developed to address the key technical challenges related to materials performance under actual operating conditions, while retaining the advantages of thermal and process compatibility offered by the ceramic membranes. The feasibility of the concept has already been demonstrated at Ceramatec. This project developed advanced materials composition for potential integration with water gas shift rectors to maximize the hydrogen production.

08 HYDROGEN↗
DOE OSTI2013

Radioactive Demonstration Of Mineralized Waste Forms Made From Hanford Low Activity Waste (Tank Farm Blend) By Fluidized Bed Steam Reformation (FBSR)

The U.S. Department of Energy’s Office of River Protection (ORP) is responsible for the retrieval, treatment, immobilization, and disposal of Hanford’s tank waste. A key aspect of the River Protection Project (RPP) cleanup mission is to construct and operate the Hanford Tank Waste Treatment and Immobilization Plant (WTP). The WTP will separate the tank waste into high-level and low-activity waste (LAW) fractions, both of which will subsequently be vitrified. The projected throughput capacity of the WTP LAW Vitrification Facility is insufficient to complete the RPP mission in the time frame required by the Hanford Federal Facility Agreement and Consent Order, also known as the Tri-Party Agreement (TPA), i.e. December 31, 2047. Supplemental Treatment is likely to be required both to meet the TPA treatment requirements as well as to more cost effectively complete the tank waste treatment mission. The Supplemental Treatment chosen will immobilize that portion of the retrieved LAW that is not sent to the WTP’s LAW Vitrification facility into a solidified waste form. The solidified waste will then be disposed on the Hanford site in the Integrated Disposal Facility (IDF). Fluidized Bed Steam Reforming (FBSR) offers a moderate temperature (700-750°C) continuous method by which LAW can be processed irrespective of whether the waste contain organics, nitrates, sulfates/sulfides, chlorides, fluorides, volatile radionuclides or other aqueous components. The FBSR technology can process these wastes into a crystalline ceramic (mineral) waste form. The mineral waste form that is produced by co-processing waste with kaolin clay in an FBSR process has been shown to be comparable to LAW glass, i.e. leaches Tc-99, Re and Na at <2g/m 2 during ASTM C1285 (Product Consistency) durability testing. Monolithing of the granular FBSR product was investigated to prevent dispersion during transport or burial/storage. Monolithing in an inorganic geopolymer binder, which is amorphous, macro-encapsulates the granules, and the monoliths pass ANSI/ANS 16.1 and ASTM C1308 durability testing with Re achieving a Leach Index (LI) of 9 (the Hanford Integrated Disposal Facility, IDF, criteria for Tc-99) after a few days and Na achieving an LI of >6 (the Hanford IDF criteria for Na) in the first few hours. The granular and monolithic waste forms also pass the EPA Toxicity Characteristic Leaching Procedure (TCLP) for all Resource Conservation and Recovery Act (RCRA) components at the Universal Treatment Standards (UTS). Two identical Benchscale Steam Reformers (BSR) were designed and constructed at SRNL, one to treat non-radioactive simulants and the other to treat actual radioactive wastes. The results from the non-radioactive BSR were used to determine the parameters needed to operate the radioactive BSR in order to confirm the findings of non-radioactive FBSR pilot scale and engineering scale tests and to qualify an FBSR LAW waste form for applications at Hanford. Radioactive testing commenced using SRS LAW from Tank 50 chemically trimmed to look like Hanford’s blended LAW known as the Rassat simulant as this simulant composition had been tested in the non-radioactive BSR, the non-radioactive pilot scale FBSR at the Science Applications International Corporation-Science and Technology Applications Research (SAIC-STAR) facility in Idaho Falls, ID and in the TTT Engineering Scale Technology Demonstration (ESTD) at Hazen Research Inc. (HRI) in Denver, CO. This provided a “tie back” between radioactive BSR testing and non-radioactive BSR, pilot scale, and engineering scale testing. Approximately six hundred grams of non-radioactive and radioactive BSR product were made for extensive testing and comparison to the non-radioactive pilot scale tests performed in 2004 at SAIC-STAR and the engineering scale test performed in 2008 at HRI with the Rassat simulant. The same mineral phases and off-gas species were found in the radioactive and non-radioactive testing. The granular ESTD and BSR products (radioactive and non-radioactive) were analyzed for total constituents and durability tested as a granular waste form. A subset of the granular material was stabilized in a clay based geopolymer matrix at 42% and 65% FBSR loadings and durability tested as a monolith waste form. The 65 wt% FBSR loaded monolith made with clay (radioactive) was more durable than the 67-68 wt% FBSR loaded monoliths made from fly ash (non-radioactive) based on short term PCT testing. Long term, 90 to 107 day, ASTM C1308 testing (similar to ANSI/ANS 16.1 testing) was only performed on two fly ash geopolymer monoliths at 67-68 wt% FBSR loading and three clay geopolymer monoliths at 42 wt% FBSR loading. More clay geopolymers need to be made and tested at longer times at higher FBSR loadings for comparison to the fly ash monoliths. Monoliths made with metakaolin (heat treated) clay are of a more constant composition and are very reactive as the heat treated clay is amorphous and alkali activated. The monoliths made with fly ash are subject to the inherent compositional variation found in fly ash as it is a waste product from burning coal and it contains unreactive components such as mullite. However, both the fly ash and the clay based monoliths perform well in long term ASTM C1308 testing.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Fabrication and characterization of 3D printing induced orthotropic functional ceramics

The orthotropic functional properties of additively manufactured ceramics due to the fabrication process was characterized in this study. Spherical, environmentally benign barium titanate (BaTiO 3 ) powders were fabricated using binder jetting 3D printing. Dielectric and piezoelectric properties of these ceramics were characterized as a function of the printing orientation. The dielectric constant of the samples tested normal to the printing layers was observed to be 20% higher than those tested in the parallel fashion. Similarly, the piezoelectric response was found to be over 35% in the normal orientation. With these results, it was shown that the electroding orientation has a direct influence on the functional properties of additively manufactured ceramics. Overall, with less than 37% of the theoretical density, the average piezoelectric coefficient for the perpendicularly tested ceramics was found to be 152.7 pC N -1 , which is 80% of the theoretical value. Finally, the high piezoelectric response obtained with such low densities can lead to the development of more mass efficient, and cost-effective sensing and energy harvesting devices, as well as structures that can be tuned to respond based on the direction of the loads applied.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructural and basic mechanical characteristics of ZA27 alloy-based nanocomposites synthesized by mechanical milling and compocasting

Particulate nanocomposites with the base of ZA27 alloy were synthesized using an innovative route, which includes mechanical milling and compocasting. Scrap from the matrix alloy and ceramic nanoreinforcements were mechanically milled using the ball-milling technique, which led to the formation of composite microparticles. The use of these particles in the compocasting process provided better wettability of ceramic nanoreinforcements in the semi-solid metal matrix, which resulted in a relatively good dispersion of the nanoreinforcements in nanocomposite castings. The presence of nanoreinforcements led to the grain refinement in the matrix of nanocomposites. The mechanical properties of the synthesized nanocomposites are improved and compared with the properties of the metal matrix. The observed increase in the hardness of nanocomposites with Al2O3 nanoreinforcements (20–30 nm) was 6.5% to 10.8%, while the yield strength of these nanocomposites has increased by 12.2% to 23.2%. The hardness and compressive yield strength of the nanocomposites with Al2O3 nanoparticles (100 nm) increased by 1.7% to 8.0% and 2.3% to 8.3%, respectively. The increase in hardness of the nanocomposites with SiC nanoparticles (50 nm) was 11.5% to 20.6%, while the increase in the yield strength was 15.6% to 24.5%. The greatest contribution to the overall strengthening in the synthesized nanocomposites is the result of increased dislocation density due to the difference in coefficients of thermal expansion for the matrix alloy and nanoreinforcements. © The Author(s) 2018.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

Effect of sintering temperature on adhesion of spray-on piezoelectric transducers

Conventionally sol-gel spray-on transducers require a high-temperature (> 700 ◦C) sintering process; however, this process can affect the microstructure of the substrate material. For mechanical elbows and valves utilized for fluid transport in the energy sector, the components are designed to have a specific microstructure, and deviations from these specifications can create weak points in the system. For this reason it is important to investigate how the temperature of the deposition process affects the substrate. This paper investigates the effect of high-temperature and low-temperature (< 150 ◦C) processing conditions on the surface composition of the substrate. Furthermore, the resultant transducers from high- and low-temperature fabrication processes are compared to determine if a low-temperature processing method is feasible. For these studies a sol-gel spray-on process is employed to deposit piezoelectric ceramics onto a stainless-steel 316L substrate. Energy-dispersive X-ray spectroscopy is utilized to determine the composition of the substrate surface before and after transducer deposition. Results indicate that the high-temperature processing conditions may alter the surface composition of the metal due to a diffusion of the metal into the ceramic, which results in a metal surface that is bonded to the ceramic. Furthermore, it is shown that low-temperature processing of spray-on transducers is a viable method for transducer fabrication where the resultant transducers meet the industry minimum requirement of 30 dB signalto-noise ratio. In parallel simulation calculations, finite-element method (FEM) studies were performed to model the adhesive strength of the low-temperature processed transducer to the substrate surface. Comparisons between the simulations and experiments suggest that the bond strength is much greater than the commercial gel bonds and closer to hardened epoxy glue bonds. These results indicate that spray-on transducers fabricated under lowtemperature processing conditions are a viable solution for leave-in-place monitoring of structures.

M. Sinding, Kyle↗