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At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
NASA NTRS1989

Undercutting of defects in thin film protective coatings on polymer surfaces exposed to atomic oxygen

Protection for polymeric surfaces is needed to make them durable in the low Earth orbital environment, where oxidation by atomic oxygen is the predominant failure mechanism. Thin film coatings of oxides such as silicon dioxide are viable candidates to provide this protection, but concern has been voiced over the ability of these coatings to protect when defects are present in the coating due to surface anomalies occurring during the deposition process, handling, or micrometeoroid and debris bombardment in low Earth orbit. When a defected coating protecting a polymer substrate is exposed to atomic oxygen, the defect provides a pathway to the underlying polymer allowing oxidation and subsequent undercutting to occur. Defect undercutting was studied for sputter deposited coatings of silicon dioxide on polyimide Kapton. Preliminary results indicate that undercutting may be limited as long as the coating remains intact with the substrate. Therefore, coatings may not need to be defect free to give protection to the underlying surface.

Rutledge, Sharon K.↗
NASA NTRS1989

Failure processes within ceramic coatings at high temperatures

Plasma sprayed coatings have a complex structure which is produced by the overlaying of many molten or semi-molten particles in the diameter range of 20 to 120 microns. The failure behavior of coatings has been characterized by using acoustic emission (AE) methodology. Coatings of NiCrAlY bond coat with a zirconia-12 wt pct yttria overlay were applied to disk-shaped specimens of U-700 alloy. A waveguide of 1-mm diameter platinum was TlG welded to the specimen and allowed it to be suspended in a tubular furnace. The specimen was thermally cycled to 1150 C and the AE monitored. Analyses have been carried out with the aim of establishing parameters which are related to the crack size population. These studies have been used to postulate types of cracking mechanisms which may occur in plasma sprayed coatings during thermal cycling. It is shown that microcracking gave rise to a large amount of AE. However, this coating still survived more thermal cycles than a coating which exhibited macrocracking events.

Berndt, Christopher↗
NASA NTRS1989

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.↗
NASA NTRS1989

Diffusional aspects of the high-temperature oxidation of protective coatings

The role of diffusional transport associated with the high-temperature oxidation of coatings is examined, with special attention given to the low-pressure plasma spraying MCrAl-type overlay coatings and similar Ni-base alloys which form protective AlO3 scales. The use of diffusional analysis to predict the minimum solute concentration necessary to form and grow a solute oxide scale is illustrated. Modeling procedures designed to simulate the diffusional transport in coatings and substrates are presented to show their use in understanding coating degradation, predicting the protective life of a coating, and evaluating various coating parameters to guide coating development.

Nesbitt, J. A.↗
NASA NTRS1989

Two-layer thermal barrier coating. I - Effects of composition and temperature on oxidation behavior and failure

The effects of 21 bond and 2 ceramic coating compositions on the specific mass gain, internal crack location at failure, and life of a two-layer thermal barrier coating (TBC) were studied by cyclic testing in a furnace. MAR-M 200 + Hf alloy specimens were completely coated with bond and thermal barrier (ceramic) coatings. Both coatings were applied by air plasma spray deposition. Cyclic test data were obtained at 1110, 1160, and 1220 deg C. The data show that the specific mass gain and the TBC life are significantly affected by the composition of the bond coating and the temperature and only slightly affected by the composition of the ceramic coating.

Stecura, Stephan↗
NASA NTRS1991

Cryo-mechanical tests of Ames 24E2 IR-black coating

In addition to the ambient condition tape test, five mechanical tests of the IR-black coating, Ames 24E2, were performed at either liquid helium or liquid nitrogen temperatures. Tensile strain in the coating at liquid nitrogen temperature was measured up to values of 4E-3, both before and after the coating was cycled down to liquid helium temperature. When applied to an aluminum substrate which was then bent in liquid nitrogen, the aluminum substrate always failed (permanently deformed) well before the coating failed. Sinusoidal accelerations up to 45 Gs in liquid nitrogen and 25 Gs in liquid helium did not crack or otherwise visibly damage the coating. Both sinusoidal and random acceleration at about 90 K of a representative baffle vane structure, at frequencies from 10 to 2000 Hz and up to 15 Gs, did not damage the coating, even at the intersection of a baffle with the telescope tube. Thus on a macroscopic level, cryogenic cooling and various levels of acceleration and strain did not affect this coating. However, on a microscopic scale, some loose particles were found associated with several tests. Outgassing data are also given.

Smith, Sheldon M.↗
NASA NTRS1989

Undercutting of defects in thin film protective coatings on polymer surfaces exposed to atomic oxygen

Protection for polymeric surfaces is needed to make them durable in the low earth orbital environment. Thin film coatings of oxides such as SiO2 are viable candidates to provide this protection, but concern has been voiced over the ability of these coatings to protect when defects are present in the coating due to surface anomalies. When a defected coating protecting a polymer substrate is exposed to atomic oxygen, the defect provides a pathway to the underlying polymer allowing oxidation and subsequent undercutting to occur. Defect undercutting was studied for sputter deposited coatings of SiO2 on polyimide Kapton. Preliminary results indicate that undercutting may be limited as long as the coating remains intact with the substrate. Therefore, coatings may not need to be defect free to give protection to the underlying surface.

Rutledge, Sharon K.↗
NASA NTRS1992

Evaluation of selected thermal control coatings for long-life space structures

Graphite-reinforced resin matrix composites are being considered for spacecraft structural applications because of their light weight, high stiffness, and lower thermal expansion. Thin protective coatings with stable optical properties and the proper ratio of solar absorption (alpha sub s) to thermal emittance (epsilon) minimize orbital thermal extremes and protect these materials against space environment degradation. Sputtered coatings applied directly to graphite/epoxy composite surfaces and anodized coatings applied to thin aluminum foil were studied for use both as an atomic oxygen barrier and as thermal control coatings. Additional effort was made to develop nickel-based coatings which could be applied directly to composites. These coating systems were selected because their inherent tenacity made them potentially more reliable than commercial white paints for long-life space missions. Results indicate that anodized aluminum foil coatings are suitable for tubular and flat composite structures on large platforms in low Earth orbit. Anodized foil provides protection against some elements of the natural space environment (atomic oxygen, ultraviolet, and particulate radiation) and offers a broad range of tailored alpha sub s/epsilon. The foil is readily available and can be produced in large quantities, while the anodizing process is a routine commercial technique.

Teichman, Louis A.↗
NASA NTRS1992

Pyrolytic boron nitride coatings on ceramic yarns and fabrication of insulations

Pyrolytic boron nitride (PBN) was deposited on Nicalon NL 202 silicon carbide yarns at 1000 to 1200 C with the goal of improving the resistance of the Nicalon to deterioration in an aerodynamic environment at temperatures up to 1000 C. For continuous coating, the yarns were fed through the deposition chamber of a pilot plant sized CVD furnace at a rate of about 2 feet per minute. PBN coatings were obtained by reacting boron trichloride and ammonia gases inside the deposition chamber. Most of the PBN coatings were made at around 1080 C to minimize thermal degradation of the Nicalon. Pressures were typically below 0.1 Torr. The coated yarns were characterized by weight per unit length, tensile strength and modulus, scanning electron microscopy, and scanning Auger microscopy. The PBN coated Nicalon was woven into cloth, but was not entirely satisfactory as a high temperature sizing. Several 13 in. square pieces of Nicalon cloth were coated with PBN in a batch process in a factory sized deposition furnace. Samples of cloth made from the PBN coated Nicalon were sewn into thermal insulation panels, whose performance is being compared with that of panels made using uncoated Nicalon.

Moore, Arthur W.↗
NASA NTRS1990

Cryo-mechanical tests of Ames 24E2 IR-black coating

In addition to the ambient condition tape test, five mechanical tests of the IR-black coating, Ames 24E2, were performed at either liquid helium or liquid nitrogen teperatures. Tensile strain in the coating at liquid nitrogen temperature was measured up to values of 4E-3, both before and after the coating was cycled down to liquid helium temperature. When applied to an aluminum substrate which was then bent in liquid nitrogen, the aluminum substrate always failed (permanently deformed) well before the coating failed. Sinusoidal accelerations up to 45 Gs in liquid nitrogen and 25 Gs in liquid helium did not crack or otherwise visibly damage the coating. Both sinusoidal and random acceleration at about 90 K of a representative baffle vane structure, at frequencies from 10 to 2000 Hz and up to 15 Gs, did not damage the coating, even at the intersection of a baffle with the telescope tube. Thus on a macroscopic level, cryogenic cooling and various levels of acceleration and strain did not affect this coating. However, on a microscopic scale, some loose particles were found associated with several tests. Outgassing data are also given

Smith, Sheldon M.↗
NASA NTRS1993

Positron lifetime spectroscopy for investigation of thin polymer coatings

In the aerospace industry, applications for polymer coatings are increasing. They are now used for thermal control on aerospace structures and for protective insulating layers on optical and microelectronic components. However, the effectiveness of polymer coatings depends strongly on their microstructure and adhesion to the substrates. Currently, no technique exists to adequately monitor the quality of these coatings. We have adapted positron lifetime spectroscopy to investigate the quality of thin coatings. Results of measurements on thin (25-micron) polyurethane coatings on aluminum and steel substrates have been compared with measurements on thicker (0.2-cm) self-standing polyurethane discs. In all cases, we find positron lifetime groups centered around 560 psec, which corresponds to the presence of 0.9-A(exp 3) free-volume cells. However, the number of these free-volume cells in thin coatings is larger than in thick discs. This suggests that some of these cells may be located in the interfacial regions between the coatings and the substrates. These results and their structural implications are discussed in this report.

Singh, Jag J.↗
NASA NTRS1993

Space environmental effects on LDEF composites: A leading edge coated graphite epoxy panel

The electronics module cover for the leading edge (Row D 9) experiment M0003-8 was fabricated from T300 graphite/934 epoxy unidirectional prepreg tape in a (O(sub 2), +/- 45, O(sub 2), +/- 45, 90, 0)(sub s) layup. This 11.75 in x 16.75 in panel was covered with thermal control coatings in three of the four quadrants with the fourth quadrant uncoated. The composite panel experienced different thermal cycling extremes in each quadrant due to the different optical properties of the coatings and bare composite. The panel also experienced ultraviolet (UV) and atomic oxygen (AO) attack as well as micrometeoroid and space debris impacts. An AO reactivity of 0.99 x 10(exp -24) cm(sup 3)/atom was calculated for the bare composite based on thickness loss. The white urethane thermal control coatings (A276 and BMS 1060) prevented AO attack of the composite substrate. However, the black urethane thermal control coating (Z306) was severely eroded by AO, allowing some AO attack of the composite substrate. An interesting banding pattern on the AO eroded bare composite surface was investigated and found to match the dimensions of the graphite fiber tow widths as prepregged. Also, erosion depths were greater in the darker bands. Five micrometeoroid/space debris impacts were cross sectioned to investigate possible structural damage as well as impact/AO interactions. Local crushing and delaminations were found to some extent in all of the impacts. No signs of coating undercutting were observed despite the extensive AO erosion patterns seen in the exposed composite material at the impact sites. An extensive microcrack study was performed on the panel along with modeling of the thermal environment to estimate temperature extremes and thermal shock. The white coated composite substrate displayed almost no microcracking while the black coated and bare composite showed extensive microcracking. Significant AO erosion was seen in many of the cracks in the bare composite.

George, Pete E.↗
NASA NTRS1991

Thin coatings for protecting titanium aluminides in high-temperature oxidizing environments

Titanium aluminides have high specific strengths at high temperatures but are susceptible to environmental attack. Their use in many aerospace applications would require that they be protected with coatings that, for structural efficiency, must be thin. It is conceivable that acceptable coatings might be found in several oxide systems, and consequently, oxide coatings of many compositions were prepared from sol-gels for study. Response-surface methodology was used to refine coating compositions and factorial experiments were used to develop coating strategies. Oxygen permeability diagrams of two-layer coatings for several oxide systems, an analysis of multiple-layer coatings on rough and polished surfaces, and modeling of the oxidation weight gain are presented.

Wiedemann, K. E.↗
NASA NTRS1990

Positron lifetime spectroscopy in thin polymer coatings

Polymer coatings are finding increasing applications in aerospace industry. The effectiveness of coatings depends strongly on their microstructure and adhesion to the substrates. Currently, there is no technique for adequately monitoring the quality of the coatings. We adapted positron lifetime spectroscopy for the investigation of thin coatings. Results of measurements on 0.001-in-thick polyurethane coatings on aluminum and steel substrates and thicker (0.080-in.) self-standing polyurethane discs were compared. In all cases, we find positron lifetime groups centered around 560 ps, corresponding to the presence of 0.9 A exp 3 free volume cells. However, the number of free volume cells in thin coatings is larger, suggesting that the morphology of thin coatings is different from that of bulk polyurethane. These results and their structural implications are discussed.

Singh, Jag J.↗
NASA NTRS1993

Insoluble coatings for Stirling engine heat pipe condenser surfaces

The work done by Thermacore, Inc., Lancaster, Pennsylvania, for the Phase 1, 1992 SBIR National Aeronautics and Space Administration Contract, 'Insoluble Coatings for Stirling Engine Heat Pipe Condenser Surfaces' is described. The work was performed between January 1992 and July 1992. Stirling heat engines are being developed for electrical power generation use on manned and unmanned earth orbital and planetary missions. Dish Stirling solar systems and nuclear reactor Stirling systems are two of the most promising applications of the Stirling engine electrical power generation technology. The sources of thermal energy used to drive the Stirling engine typically are non-uniform in temperature and heat flux. Liquid metal heat pipe receivers are used as thermal transformers and isothermalizers to deliver the thermal energy at a uniform high temperature to the heat input section of the Stirling engine. The use of a heat pipe receiver greatly enhances system efficiency and potential life span. One issue that is raised during the design phase of heat pipe receivers is the potential solubility corrosion of the Stirling engine heat input section by the liquid metal working fluid. This Phase 1 effort initiated a program to evaluate and demonstrate coatings, applied to nickel based Stirling engine heater head materials, that are practically 'insoluble' in sodium, potassium, and NaK. This program initiated a study of nickel aluminide as a coating and developed and demonstrated a heat pipe test vehicle that can be used to test candidate materials and coatings. Nickel 200 and nickel aluminide coated Nickel 200 were tested for 1000 hours at 800 C at a condensation heat flux of 25 W/sq cm. Subsequent analyses of the samples showed no visible sign of solubility corrosion of either coated or uncoated samples. The analysis technique, photomicrographs at 200X, has a resolution of better than 2.5 microns (.0001 in). The results indicate that the heat pipe environment is not directly comparable to liquid metal pumped loop data, that nickel aluminide is still a leading candidate for solubility corrosion protection, and that longer duration tests are required to reach a definitive conclusion whether coatings are required at all. Should further testing be required, the test vehicle and analytical tools were developed.

Dussinger, Peter M.↗
NASA NTRS1995

A design perspective on thermal barrier coatings

This technical paper addresses the challenges for maximizing the benefit of thermal barrier coatings for turbine engine applications. The perspective is from a customer's viewpoint, a turbine airfoil designer, who is continuously challenged to increase the turbine inlet temperature capability for new products while maintaining cooling flow levels or even reducing them. This is a fundamental requirement to achieve increased engine thrust levels. Developing advanced material systems for the turbine flowpath airfoils is one approach to solve this challenge, for example, high temperature nickel based superalloys or thermal barrier coatings to insulate the metal airfoil from the hot flowpath environment. The second approach is to increase the cooling performance of the turbine airfoil, which enables increased flowpath temperatures and reduced cooling flow levels. Thermal barrier coatings have been employed in jet engine applications for almost 30 years. The initial application was on augmenter lines to provide thermal protection during afterburner operation. However, the production use of thermal barrier coating in the turbine section has only occurred in the past 15 years. The application was limited to stationary parts, and only recently incorporated on the rotating turbine blades. This lack of endorsement of thermal barrier coatings resulted from the poor initial durability of these coatings in high heat flux environments. Significant improvements have been made to enhance spallation resistance and erosion resistance which has resulted in increased reliability of these coatings in turbine applications.

Soechting, F. O.↗
NASA NTRS1995

Thermal barrier coatings issues in advanced land-based gas turbines

The Department of Energy's Advanced Turbine System (ATS) program is aimed at forecasting the development of a new generation of land-based gas turbine systems with overall efficiencies significantly beyond those of current state-of-the-art machines, as well as greatly increased times between inspection and refurbishment, improved environmental impact, and decreased cost. The proposed duty cycle of ATS turbines will require the use of different criteria in the design of the materials for the critical hot gas path components. In particular, thermal barrier coatings will be an essential feature of the hot gas path components in these machines. While such coatings are routinely used in high-performance aircraft engines and are becoming established in land-based turbines, the requirements of the ATS turbine application are sufficiently different that significant improvements in thermal barrier coating technology will be necessary. In particular, it appears that thermal barrier coatings will have to function on all airfoil sections of the first stage vanes and blades to provide the significant temperature reduction required. In contrast, such coatings applied to the blades and vances of advanced aircraft engines are intended primarily to reduce air cooling requirements and extend component lifetime; failure of those coatings can be tolerated without jeopardizing mechanical or corrosion performance. A major difference is that in ATS turbines these components will be totally reliant on thermal barrier coatings which will, therefore, need to be highly reliable even over the leading edges of first stage blades. Obviously, the ATS program provides a very challenging opportunity for TBC's, and involves some significant opportunities to extend this technology.

Parks, W. P.↗
NASA NTRS1995

A design perspective on thermal barrier coatings

This technical paper addresses the challenges for maximizing the benefit of thermal barrier coatings for turbine engine applications. The perspective is from a customer's viewpoint, a turbine airfoil designer, who is continuously challenged to increase the turbine inlet temperature capability for new products while maintaining cooling flow levels or even reducing them. This is a fundamental requirement to achieve increased engine thrust levels. Developing advanced material systems for the turbine flowpath airfoils is one approach to solve this challenge; such as high temperature nickel based superalloys or thermal barrier coatings to insulate the metal airfoils from the hot flowpath environment. The second approach is to increase the cooling performance of the turbine airfoil, which enables increased flowpath temperatures and reduced cooling flow levels. Thermal barrier coatings have been employed in jet engine applications for almost 30 years. The initial application was on augmentor liners to provide thermal protection during afterburner operation. However, the production use of thermal barrier coating in the turbine section has only occurred in the past 15 years. The application was limited to stationary parts, and only recently incorporated on the rotating turbine blades. This lack of endorsement of thermal barrier coatings resulted from the poor initial durability of these coatings in high heat flux environments. Significant improvements have been made to enhance spallation resistance and erosion resistance which has resulted in increased reliability of these coatings in turbine applications.

Soechting, Friedrich O.↗