SEARCH · Engineering Papers

Results for “zirconia”

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 343 records · Page 19

All sources NASA NTRS DOE OSTI

NASA NTRS1988

Vacuum application of thermal barrier plasma coatings

Coatings are presently applied to Space Shuttle Main Engine (SSME) turbine blades for protection against the harsh environment realized in the engine during lift off-to-orbit. High performance nickel, chromium, aluminum, and yttrium (NiCrAlY) alloy coatings, which are applied by atmospheric plasma spraying, crack and spall off because of the severe thermal shock experienced during start-up and shut-down of the engine. Ceramic coatings of yttria stabilized zirconia (ZrO2-Y2O3) were applied initially as a thermal barrier over coating to the NiCrAlY but were removed because of even greater spalling. Utilizing a vacuum plasma spraying process, bond coatings of NiCrAlY were applied in a low pressure atmosphere of argon/helium, producing significantly improved coating-to-blade bonding. The improved coatings showed no spalling after 40 MSFC burner rig thermal shock cycles, cycling between 1700 and -423 F. The current atmospheric plasma NiCrAlY coatings spalled during 25 test cycles. Subsequently, a process was developed for applying a durable thermal barrier coating of ZrO2-Y2O3 to the turbine blades of first stage high-pressure fuel turbopumps utilizing the vacuum plasma process. The improved thermal barrier coating has successfully passed 40 burner rig thermal shock cycles without spalling. Hot firing in an SSME turbine engine is scheduled for the blades. Tooling was installed in preparation for vacuum plasma spray coating other SSME hardware, e.g., the titanium main fuel valve housing (MFVH) and the fuel turbopump nozzle/stator.

Holmes, R. R.↗

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 NTRS1990

The electrochemical generation of useful chemical species from lunar materials

Electrochemical cells have been fabricated for the simultaneous generation of oxygen and lithium from a Li2O-containing molten salt (Li2O-LiCl-LiF). The cell utilizes an oxygen vacancy conducting solid electrolyte, yttria-stabilized zirconia (YSZ), to effect separation between oxygen evolving and lithium reduction half-cell reactions. The cell, which operates at 700-850 C, possesses rapid electrode kinetics at the lithium-alloy electrode with exchange current density values being greater than 60 mA/sq cm. When used in the electrolytic mode, lithium produced at the negative electrode would be continuously removed from the cell for later use (under lunar conditions) as an easily storable reducing agent for the chemical refining of lunar ores. Because of the high reversibility of this electrochemical system, it has also formed the basis for the lithium-oxygen secondary battery system which possesses the highest theoretical energy density yet investigated.

Tsai, Kan J.↗

NASA NTRS1990

Electrochemical measurements and thermodynamic calculations of redox equilibria in pallasite meteorites - Implications for the eucrite parent body

The intrinsic oxygen fugacity (IOF) of olivine separates from the Salta, Springwater, and Eagle Station pallasites was measured between 850 and 1150 C using oxygen-specific solid zirconia electrolytes at 100,000 Pa. Thermodynamic calculations of redox equilibria involving equalibrium pallasite assemblages are in good agreement with the experimental results and provide a lower limit to pallasite redox stability; others involving disequilibrium assemblages, suggest that pallasites experienced localized, late-stage oxidation and reduction effects. Consideration of the redox buffer metal-olivine-orthopyroxene utilizing calculated Eucrite Parent Body (EPB) mantle phase compositions indicates that small redox gradients may have existed in the EPB. Such gradients may have produced strong compositional variation within the EPB. In addition, there is apparently significant redox heterogeneity in the source area of Eagle Station Trio pallasites and Bocaiuva iron meteorites.

Righter, Kevin↗

NASA NTRS1990

Ion beam sputtering of in situ superconducting Y-Ba-Cu-O films

Oriented superconducting YBa2Cu3O7 thin films were deposited on yttria stabilized zirconia and SrTiO3 substrates by ion-beam sputtering of a nonstoichiometric oxide target. The films exhibited zero-resistance critical temperatures as high as 83.5 K without post-deposition anneals. Both the deposition rate and the c-lattice parameter data displayed two distinct regimes of dependence on the beam power of the ion source. Low-power sputtering yielded films with large c-dimensions and low Tc. Higher-power sputtering produced a continuous decrease in the c-lattice parameter and increase in critical temperature. Films having the smaller c-lattice parameters were Cu rich. The Cu content of films deposited at beam voltages of 800 V and above increased with increasing beam power.

Klein, J. D.↗

NASA NTRS1991

Making Three-Layer Solid Electrolyte/Electrode Sandwiches

Tape-casting-and-sintering process joins two ceramic materials having widely different sintering temperatures into integral sandwich structure. Layers retain their identities, without migration of constituents. Used to make three-layer structure composed of outer porous layers of strontium-doped lanthanum manganite and inner dense layer of yttria-stabilized zirconia. Structures used to make electrolytic and fuels cells with solid electrolytes for use at high temperatures. Other potential applications include oxygen pumps and oxygen sensors.

Schroeder, James E.↗

NASA NTRS1991

Stacking Oxygen-Separation Cells

Simplified configuration and procedure developed for assembly of stacks of solid-electrolyte cells separating oxygen from air electrochemically. Reduces number of components and thus reduces probability of such failures as gas leaks, breakdown of sensitive parts, and electrical open or short circuits. Previous, more complicated version of cell described in "Improved Zirconia Oxygen-Separation Cell" (NPO-16161).

Schroeder, James E.↗

NASA NTRS1990

Metallic seal for thermal barrier coating systems

The invention is particularly concerned with sealing thermal barrier coating systems of the type in use and being contemplated for use in diesel and other internal combustion engines. The invention also would find application in moderately high temperature regions of gas turbine engines and any other application employing a thermal barrier coating at moderate temperatures. Ni-35Cr-6Al-1Y, Ni-35Cr-6Al-1Yb, or other metallic alloy denoted as MCrAlx is applied over a zirconia-based thermal barrier overlayer. The close-out layer is glass-bead preened to densify its surface. This seals and protects the thermal barrier coating system.

Miller, Robert A.↗

NASA NTRS1991

Thermal analysis, optimization and design of a Martian oxygen production plant

The objective is to optimally design the thermal components of a system that uses carbon dioxide (CO2) from the Martian atmosphere to produce oxygen (O2) for spacecraft propulsion and/or life-support. Carbon dioxide is thermally decomposed into carbon monoxide (CO) and O2 followed by the electrochemical separation of O2. The design of the overall system and its various individual components depends on, among other things, the fraction of the stoichiometric yield of O2 that can be realized in the system and the temperature of operation of the electrochemical separation membrane. The analysis indicates that a substantial reduction could be obtained in the mass and power requirements of the system if the unreacted CO2 were to be recycled. The concepts of an optimum temperature of the zirconia cell and impracticality of plant operation at low cell efficiencies are also discussed. The design of the thermal equipment is such that the mass and power requirements of the individual components and of the overall system are optimized.

Iyer, Venkatesh A.↗

NASA NTRS1991

Issues on the production and electrochemical separation of oxygen from carbon dioxide

There is considerable interest in in-situ propellant manufacturing on the moon and Mars. One of the concepts of oxygen production that is being actively pursued is the processing of atmospheric carbon dioxide on Mars to produce oxygen by means of thermal decomposition and electrochemical separation. The key component of such a production facility is the electrochemical separation cell that filters out the oxygen from the gas mixture of carbon dioxide, carbon monoxide, and oxygen. Efficient design of the separation cell and the selection of electrolyte and electrode materials of superior performance for the cell would translate to significant reduction in the power requirement and the mass of the production facility. The objective is to develop the technology required to produce the cells in-house and test various electrolyte and electrode materials systematically until the optimal combination is found. An effective technique was developed for the fabrication of disk shaped cells. Zirconia and Ceria cells were made in-house. Complete modules of the electrochemical cell and housings were designed, fabricated, and tested.

Kaloupis, P.↗

NASA NTRS1991

Crystallization and characterization of Y2O3-SiO2 glasses

Glasses in the yttria-silica system with 20 to 40 mol pct Y2O3 were subjected to recrystallization studies after melting at 1900 to 2100 C in W crucibles in 1 and 50 atm N2. The TEM and XRD results obtained indicate the presence of the delta, gamma, gamma prime, and beta-Y2Si2O7 crystalline phases, depending on melting and quenching conditions. Heat treatment in air at 1100 to 1600 C increased the amount of crystallization, and led to the formation of Y2SiO5, cristabalite, and polymorphs of Y2Si2O7. Also investigated were the effects of 5 and 10 wt pct zirconia additions.

Drummond, Charles H., III↗

NASA NTRS1990

PdCr based high temperature static strain gage

The program at NASA Lewis Research Center to develop a high temperature static strain gage system for the hypersonic vehicle and turbine engine research has emphasized a palladium-13 wt pct chromium (PdCr) alloy. Gages made from this alloy are being developed in both fine wire and thin film form. The wire gage system had platinum wire as a temperature compensator and was coated with a special alumina and zirconia mixture overcoat. This PdCr compensated wire gage responded linearly to the imposed strain to at least 1000 microstrain. The apparent strain varied within 300 microstrain from room temperature to 800 C with a reproducibility within 50 microstrain between thermal cycles to 800 C. The sputtered thin film PdCr strain gage, whose size was 8 x 8 mm and 10 microns thick, has demonstrated the possibility of extending the use of the PdCr strain gage to a temperature of approximately 1000 C.

Lei, Jih-Fen↗

NASA NTRS1991

Ceramic thermal barrier coatings for commercial gas turbine engines

The paper provides an overview of the short history, current status, and future prospects of ceramic thermal barrier coatings for gas turbine engines. Particular attention is given to plasma-sprayed and electron beam-physical vapor deposited yttria-stabilized (7 wt pct Y2O3) zirconia systems. Recent advances include improvements in the spallation life of thermal barrier coatings, improved bond coat composition and spraying techniques, and improved component design. The discussion also covers field experience, life prediction modeling, and future directions in ceramic coatings in relation to gas turbine engine design.

Meier, Susan Manning↗

NASA NTRS1991

YBa2Cu3O(7-delta)/Au/Nb sandwich geometry SNS weak links on c-axis oriented YBa2Cu3O(7-delta)

Sandwich geometry superconductor/normal metal/superconductor structures have been fabricated on LaAlO3 and cubic zirconia with laser-ablated, c-axis-oriented YBa2Cu3O(7-delta) base electrodes, 100-600 A of Au, and Nb counter electrodes, all formed in situ without breaking vacuum. Junctions range in size from 5 to 50 micron on a side. Four probe I-V measurements at 4.2 K show RnA products as low as 6 x 10 to the -9th sq cm and critical current densities up to 5.2 kA/sq cm. AC Josephson steps were observed with the application of 10-GHz radiation. The temperature dependence of Jc and the observation of the AC Josephson effect suggest that true supercurrents are present and that they do indeed represent the characteristics of the YBa2Cu3O(7-delta)/Au/Nb structure. The best results were obtained when the devices were annealed at about 450 C in O2 for 30 min after Au deposition.

Foote, M. C.↗

NASA NTRS1991

Propellant production on Mars - Single cell oxygen production test bed

A study focusing on oxygen production using resources indigenous to Mars is presented. A bank of solid zirconia electrolytic cells that will electrochemically separate oxygen from a high temperature stream of carbon dioxide is at the center of the oxygen production system. The experimental data are discussed with attention given to the cell operating temperature, the carbon dioxide flow rate, and the voltage applied across the cell.

Colvin, James↗

NASA NTRS1991

A resistance strain gage with repeatable apparent strain to 800 C

Experimental PdCr temperature-compensated resistance static-strain gages are described. The gages are developed in both fine-wire and thin-film forms. It is found that a PdCr wire strain gage coated with a flame-sprayed mixture of alumina and 4 wt pct zirconia demonstrates the smallest variation in and the best repeatability of apparent strain among the existing gages used at temperatures up to 800 C. Results of preliminary tests indicate uncompensated uncoated thin-film gages have potential usefulness at temperatures up to 1000 C.

Lei, J.-F.↗

NASA NTRS1990

A resistance strain gage with repeatable and cancellable apparent strain for use to 1500 F

A temperature compensated static strain gauge, which is fabricated from Pd13Cr alloy and a Pt compensator, is being developed and has been tested over a temperature range to 1500 F at NASA-Lewis. The PdCr compensated strain gage has significantly lower apparent strain to 500 F than other high temperature strain gages. The PdCr compensated gage is protected from oxidation by a flame-sprayed alumina-4 wt pct zirconia overcoating. Test Results to 1500 F indicate apparent strain variations of less than 250 micro-epsilon and reproducibility between thermal cycles within 50 micro-epsilon. The apparent strain of the coated PdCr compensated gage can be predicted and cancelled due to its reproducibility and low value.

Lei, Jih-Fen↗