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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.

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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Tribological behavior of ceramic-alloy bearing contacts in molten salt lubrication for concentrating solar power

Molten salts are considered as candidate heat transfer fluids and thermal energy storage media for next generation concentrating solar power (CSP). A molten salt circulates inside the piping and heat exchanger and also functions as a lubricant for the sleeve bearings of the CSP pump. Furthermore, wear- and corrosion-resistant high-temperature bearing materials are critical for the pump efficiency and durability. This study evaluated the tribological performance of candidate bearing materials in lubrication of a molten chloride salt mixture (20% NaCl + 40% MgCl 2 + 40% KCl) at 750 °C in an inert argon gas (a simulative CSP pump environment). Six ceramic-alloy pairs were tested, zirconia and silicon nitride against Haynes 244, Hastelloy C276, and Tribaloy T900 alloy, and ranked by the friction coefficient and wear loss. Characterization of worn surfaces suggested the wear mechanism as a combination of abrasion, adhesion, and tribocorrosion. Results from this study provide fundamental insight for the development and selection of bearing materials for molten salt powered CSP pumps.

14 SOLAR ENERGY↗
DOE OSTI2022

Manufacture aluminum alloy tube from powder with a single-step extrusion via ShAPE

Mechanical performance of aluminum in terms of strength, wear and corrosion resistance, especially high-temperature strength has been shown to improve with the addition of transition metal (TM) elements of Fe, Cr, and Ti. However, these feedstock materials occur as powders. As such, the traditional fabrication process is complex and expensive because it requires multiple procedures and consumes considerable energy. This study developed Shear Assisted Processing and Extrusion (ShAPE) as a single-step process that manufactures tubes directly from Al-TM powders obtained via gas atomization. Meter-long Al-TM alloy tubes are extruded from powders with different processing conditions. The ShAPE tubes have very low porosity and the average density is 2.94 kg/cm 3 , which is equal to or higher than parts fabricated by hot extrusion and sintering. The powder-to-tube fabrication process was revealed and discussed by examining the microstructural evolution. The Vickers hardness of ShAPE tubes ranges from 110 to 140 HV through wall thickness and at different extrusion speeds. The variation in hardness was correlated with the extent of refinement of intermetallics and attributed to the shear deformation per unit extrusion length. Energy cost analysis shows that ShAPE save ~60% energy compared to the conventional sintering and extrusion processes. Results indicate ShAPE is a low-cost, high-efficiency manufacturing process for producing tubes from metallic powders.

36 MATERIALS SCIENCE↗
DOE OSTI2023

High-density SSiC 3D-printed Lattices for Compact HTHP Aero-engine Recuperators

The proposed project utilizes advanced ceramic-based 3D-printing technology to develop light, low-cost, ultra-compact, high-temperature high-pressure (HTHP) heat exchangers (HX) for the harsh oxidizing environment of aircraft gas-turbine engines. Typical 3D printing technologies (powder bed or lithographic techniques) cannot produce large high-density, monolithic ceramic material with intricate internal features and channels required for high-temperature, high-pressure recuperators. Furthermore, typical 3D printing technologies are not yet economical for large high-density components. A high-density material is required for hermeticity, high-temperature strength, and oxidation, corrosion, and wear resistance. The team has invented an extrusion-based additive manufacturing technology (referred to as robocasting) and developed processing techniques to tailor composition and rheological mix properties for rapid 3D printing of high-density alumina and SiC parts. The goal of the proposed project is to use robocasting technology to demonstrate commercializable high-density 3D-printed ceramic HX modules with high durability and quality, thereby reducing the risk of thermo-mechanical failure under extreme environments. In addition, the proposed project improves the quality of the ceramic 3D-printing process over a large printed area and HTHP operating conditions. Ceramic 3D printing technology also provides a means to create advanced topologies that are unobtainable with conventional manufacturing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2005

Oxide Ceramic Films Grown on 60 Nitinol for NASA and Department of Defense Applications

Both the NASA Glenn Research Center and the U.S. Army Research Laboratory, Development and Engineering Center (ARDEC) have worked to develop oxide ceramic films grown on 60 nitinol (60-wt% nickel and 40-wt% titanium) to decrease friction and increase wear resistance under unlubricated conditions. In general, oxide and nonoxide ceramic films have unique capabilities as mechanical-, chemical-, and thermal-barrier materials in diverse applications, including high-temperature bearings and gas bearings requiring low friction, wear resistance, and chemical stability. All oxide ceramic films grown on 60 nitinol were furnished by ARDEC, and materials and surface characterization and tribological experiments were conducted at Glenn.

Miyoshi, Kazuhisa↗
NASA NTRS2004

Cyclic Oxidation of High-Temperature Alloy Wires in Air

High-temperature alloy wires are proposed for use in seal applications for future re-useable space vehicles. These alloys offer the potential for improved wear resistance of the seals. The wires must withstand the high temperature environments the seals are subjected to as well as maintain their oxidation resistance during the heating and cooling cycles of vehicle re-entry. To model this, the wires were subjected to cyclic oxidation in stagnant air. of this layer formation is dependent on temperature. Slow growing oxides such as chromia and alumina are desirable. Once the oxide is formed it can prevent the metal from further reacting with its environment. Cyclic oxidation models the changes in temperature these wires will undergo in application. Cycling the temperature introduces thermal stresses which can cause the oxide layer to break off. Re-growth of the oxide layer consumes more metal and therefore reduces the properties and durability of the material. were used for cyclic oxidation testing. The baseline material, Haynes 188, has a Co base and is a chromia former while the other two alloys, Kanthal A1 and PM2000, both have a Fe base and are alumina formers. Haynes 188 and Kanthal A1 wires are 250 pm in diameter and PM2000 wires are 150 pm in diameter. The coiled wire has a total surface area of 3 to 5 sq cm. The wires were oxidized for 11 cycles at 1204 C, each cycle containing a 1 hour heating time and a minimum 20 minute cooling time. Weights were taken between cycles. After 11 cycles, one wire of each composition was removed for analysis. The other wire continued testing for 70 cycles. Post-test analysis includes X-Ray Diffraction (XRD), Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS) for phase identification and morphology.

Reigel, Marissa M.↗
DOE OSTI2025

Additively manufactured and cast high-temperature aluminum alloys for electric vehicle brake rotor application

Electric vehicle brake rotors demand lightweight, high thermal conductivity materials with good resistance to wear, creep, salt corrosion, and thermal fade, all of which present challenges to the traditionally used cast iron. In this work, we investigated the braking performance of recently developed high-temperature aluminum alloys in both cast and 3D printed forms, that possess excellent microstructural and mechanical stability at elevated temperatures. Three aluminum alloys, Al-6Cu-Mn-Zr, Al-9Cu-Mn-Zr, and Al-Ce-Ni-Mn-Zr and a reference cast iron were tested on a sub-scale brake tester against a commercial brake pad material over a range of sliding speeds between 2 and 15 m/s. The performance of these alloys was evaluated for wear resistance, friction behavior, temperature elevation, and surface morphological change. Although all three candidate alloys had lower wear-resistance than cast iron, Al-Ce-Ni-Mn-Zr showed a significantly reduced wear rate in comparison to the Al-Cu-Mn-Zr alloys. Moreover, Al-Ce-Ni-Mn-Zr alloy had the most consistent friction behavior at all sliding speeds and good fade resistance, as the coefficient of friction did not dramatically decrease with temperature rise but stayed within a desirable range of 0.35–0.50 instead. The superior wear resistance and braking performance of the Al-Ce-Ni-Mn-Zr alloy were attributed to its higher hardness, and high temperature yield strength and creep resistance compared with the Al-Cu-Mn-Zr alloys. In conclusion, the results suggest that the braking performance of these aluminum alloys could be further enhanced by increasing the hardness and forming a more stable transfer layer on the sliding surface.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Ab-initio predictions of phase stability, electronic structure, and optical properties of (0001)-MAX surfaces in M 2 AC (M = Cr, Zr, Hf; A = Al, Ga)

In this work, we report MAX phases' surface properties, which are essential for thin-film technology due to their excellent resistance to high-temperature oxidation, corrosion, and wear. The surface stability, electronic, and optical properties of 0001-surfaces in M 2 AC (M = Zr, Hf, Cr; A = Al, Ga) are investigated and compared with their bulk counterparts. The interplay between chemical bonding and charge distribution is discussed from electronic structure, including the Fermi surfaces. Four possible (0001)-terminated surfaces are considered by breaking M - C and M-A bonds in which cleavage energy of M - C is higher than M-A. The Cr–Al bond in Cr 2 AlC is stronger than other M-A bonds. The charge density of valance A-p electrons redistributes in the surface area, distinct from that of the bulk. The A- and M(C)-terminated (0001)-surfaces are the most stable and energetically favorable terminations due to lower surface energies. The optical properties of the most stable (0001)-surfaces were also investigated to understand the dielectric and photoconductive behavior in the (0001)-terminated surfaces of M 2 AC.

36 MATERIALS SCIENCE↗
NASA NTRS1988

Continuous fiber ceramic matrix composites for heat engine components

High strength at elevated temperatures, low density, resistance to wear, and abundance of nonstrategic raw materials make structural ceramics attractive for advanced heat engine applications. Unfortunately, ceramics have a low fracture toughness and fail catastrophically because of overload, impact, and contact stresses. Ceramic matrix composites provide the means to achieve improved fracture toughness while retaining desirable characteristics, such as high strength and low density. Materials scientists and engineers are trying to develop the ideal fibers and matrices to achieve the optimum ceramic matrix composite properties. A need exists for the development of failure models for the design of ceramic matrix composite heat engine components. Phenomenological failure models are currently the most frequently used in industry, but they are deterministic and do not adequately describe ceramic matrix composite behavior. Semi-empirical models were proposed, which relate the failure of notched composite laminates to the stress a characteristic distance away from the notch. Shear lag models describe composite failure modes at the micromechanics level. The enhanced matrix cracking stress occurs at the same applied stress level predicted by the two models of steady state cracking. Finally, statistical models take into consideration the distribution in composite failure strength. The intent is to develop these models into computer algorithms for the failure analysis of ceramic matrix composites under monotonically increasing loads. The algorithms will be included in a postprocessor to general purpose finite element programs.

Tripp, David E.↗
NASA NTRS1989

Tribological properties of PM212: A high-temperature, self-lubricating, powder metallurgy composite

This paper describes a research program to develop and evaluate a new high temperature, self-lubricating powder metallurgy composite, PM212. PM212 has the same composition as the plasma-sprayed coating, PS212, which contains 70 wt percent metal-bonded chromium carbide, 15 wt percent silver and 15 wt percent barium fluoride/calcium fluoride eutectic. The carbide acts as a wear resistant matrix and the silver and fluorides act as low and high temperature lubricants, respectively. The material is prepared by sequential cold press, cold isostatic pressing and sintering techniques. In this study, hemispherically tipped wear pins of PM212 were prepared and slid against superalloy disks at temperatures from 25 to 850 C in air in a pin-on-disk tribometer. Friction coefficients range from 0.29 to 0.38 and the wear of both the composite pins and superalloy disks was moderate to low in the 10(exp -5) to 10(exp -6) cubic mm/N-m range. Preliminary tests indicate that the material has a compressive strength of at least 130 MPa over the entire temperature range of 25 to 900 C. This material has promise for use as seal inserts, bushings, small inside diameter parts and other applications where plasma-sprayed coatings are impractical or too costly.

Dellacorte, Christopher↗
NASA NTRS1990

Tribological properties of PM212 - A high temperature, self-lubricating, powder metallurgy composite

This paper describes a research program to develop and evaluate a new high temperature, self-lubricating powder metallurgy composite, PM212. PM212 has the same composition as the plasma-sprayed coating, PS212, which contains 70 wt percent metal-bonded chromium carbide, 15 wt percent silver and 15 wt percent barium fluoride/calcium fluoride eutectic. The carbide acts as a wear resistant matrix and the silver and fluorides act as low and high temperature lubricants, respectively. The material is prepared by sequential cold press, cold isostatic pressing and sintering techniques. In this study, hemispherically tipped wear pins of PM212 were prepared and slid against superalloy disks at temperatures from 25 to 850 C in air in a pin-on-disk tribometer. Friction coefficients range from 0.29 to 0.38 and the wear of both the composite pins and superalloy disks was moderate to low in the 10(exp -5) to 10(exp -6) cubic mm/N-m range. Preliminary tests indicate that the material has a compressive strength of at least 130 MPa over the entire temperature range of 25 to 900 C. This material has promise for use as seal inserts, bushings, small inside diameter parts and other applications where plasma-sprayed coatings are impractical or too costly.

Dellacorte, Christopher↗
NASA NTRS2003

Industry Needs Fulfilled by Patented NASA PS300 Solid Lubricant Technology

In 1999, the NASA Glenn Research Center was awarded a patent (#5866518) for a new high-temperature solid lubricant coating material, PS300. A combination of wear-resistant metals and ceramics with solid lubricant additives, PS300 reduces friction and wear in sliding contacts from below ambient to over 650 C. This lubricant is an outgrowth of over three decades of high-temperature tribological research and was specifically developed as a shaft lubricant to protect foil air bearings used in Oil-Free turbomachinery, like gas turbines. Foil bearings are lubricated by air at high speeds but experience sliding and wear during initial startup and shut down when a lubricating film of air has not yet developed. PS300 shaft coatings have successfully lubricated foil bearings for over 100 000 cycles without wearing out.

DellaCorte, Christopher↗
NASA NTRS1982

A commentary on solid lubricants and wear resistant solids for use in extreme environments

The need for high temperature tribological coatings and self-lubricating materials in advanced technology is discussed. A qualitative model for the mechanism of solid lubrication is proposed. The model is based upon microscopic observations of the dynamics of third-body solids in lubricated contacts. In this model, the rheology of plastic flow is suggested as a more general criterion for predicting the lubricating potential of a solid material than, for example, a specific crystal structure. Some examples of layer-lattice and nonlayer-lattice solids that lubricate by virtue of their extreme plasticity, film coherence, and adhesion to the lubricated metal are described. Circumstantial evidence for the model is presented for low shear-strength solids at room temperature and for solids such as calcium fluoride that become lubricative only when their brittle-to-ductile transition temperature is exceeded. Some materials considerations in the selection of hard-coat materials for wear control are also presented.

Sliney, H. E.↗
NASA NTRS1990

The experimental evaluation and application of high-temperature solid lubricants

A research program is described which developes an understanding of high-temperature solid lubrication and experimental techniques through the development of a composite lubricant coating system. The knowledge gained through this research was then applied to a specific engineering challenge, the tribology of a sliding seal for hypersonic flight vehicles. The solid lubricant coating is a chromium carbide based composite combined with silver, which acts as a low temperature lubricant, and barium fluoride/calcium fluoride eutectic, which acts as a high-temperature lubricant. This composite coating provides good wear resistance and low friction for sliding contacts from room temperature to over 900 C in reducing or oxidative environments. The specific research on this coating included a composition screening using a foil gas bearing test rig and the use of thin silver films to reduce initial wear using a pin-on-disk test rig. The chemical stability of the materials used was also addressed. This research indicated that soft metallic films and materials which become soft at elevated temperatures are potentially good lubricants. The general results from the experiments with the model solid lubricant coating were then applied to a sliding seal design concept. This seal design requires that a braided ceramic fabric slide against a variety of metal counterface materials at temperatures from 25 to 850 C in an oxidative environment. A pin-on-disk tribometer was used to evaluate the tribological properties of these materials and to develop lubrication techniques. The results indicate that these seal materials must be lubricated to prevent wear and reduce friction. Thin films of silver, gold and calcium fluoride provided lubrication to the sliding materials.

Dellacorte, Christopher↗
NASA NTRS1997

Micromechanical Modeling Efforts for Advanced Composites

Over the past two decades, NASA Lewis Research Center's in-house efforts in analytical modeling for advanced composites have yielded several computational predictive tools. These are, in general, based on simplified micromechanics equations. During the last 3 years, our efforts have been directed primarily toward developing prediction tools for high temperature ceramic matrix composite (CMC's) materials. These materials are being considered for High Speed Research program applications, specifically for combustor liners. In comparison to conventional materials, CMC's offer several advantages: high specific stiffness and strength, and higher toughness and nonbrittle failure in comparison to monolithic ceramics, as well as environmental stability and wear resistance for both roomtemperature and elevated-temperature applications. Under the sponsorship of the High Temperature Engine Materials Program (HITEMP), CMC analytical modeling has resulted in the computational tool Ceramic Matrix Composites Analyzer (CEMCAN).

Source record↗
NASA NTRS2000

Erosion Coatings for High-Temperature Polymer Composites: A Collaborative Project With Allison Advanced Development Company

The advantages of replacing metals in aircraft turbine engines with high-temperature polymer matrix composites (PMC's) include weight savings accompanied by strength improvements, reduced part count, and lower manufacturing costs. Successfully integrating high-temperature PMC's into turbine engines requires several long-term characteristics. Resistance to surface erosion is one rarely reported property of PMC's in engine applications because PMC's are generally softer than metals and their erosion resistance suffers. Airflow rates in stationary turbine engine components typically exceed 2.3 kg/sec at elevated temperatures and pressures. In engine applications, as shown in the following photos, the survivability of PMC components is clearly a concern, especially when engine and component life-cycle requirements become longer. Although very few publications regarding the performance of erosion coatings on PMC's are available particularly in high-temperature applications the use of erosion-resistant coatings to significantly reduce wear on metallic substrates is well documented. In this study initiated by the NASA Glenn Research Center at Lewis Field, a low-cost (less than $140/kg) graphite-fiber-reinforced T650 35/PMR 15 sheet-molding compound was investigated with various coatings. This sheet-molding compound has been compression molded into many structurally complicated components, such as shrouds for gas turbine inlet housings and gearboxes. Erosion coatings developed for PMC s in this study consisted of a two-layered system: a bondcoat sprayed onto a cleaned PMC surface, followed by an erosion-resistant, hard topcoat sprayed onto the bondcoat as shown in following photomicrograph. Six erosion coating systems were evaluated for their ability to withstand harsh thermal cycles, erosion resistance (ASTM G76 83 "Standard Practice for Conducting Erosion Tests by Solid Particle Impingement Using Gas Jets") using Al2O3, and adhesion to the graphite fiber polyimide composite (ASTM D 4541 95 "Pull Off Strength of Coatings"). Glenn and Allison Advanced Development Company collaborated to optimize erosion coatings for gas turbine fan and compressor applications. All the coating systems survived aggressive thermal cycling without spalling. During erosion tests (see the final photo), the most promising coating systems tested had Cr3C2-NiCr and WC-Co as the hard topcoats. In all cases, these coating systems performed significantly better than that with a TiN hard topcoat. When material depth (thickness) loss is considered, the Cr3C2-NiCr and WC-Co coating systems provided, on average, an erosion resistance 8.5 times greater than that for the uncoated PMR 15/T650 35 composite. Similarly, Cr3C2-NiCr and WC-Co coating systems adhered to the PMC substrate during tensile tests significantly better than systems containing a TiN topcoat. Differences in topcoats of Cr3C2-NiCr and WC-Co were determined by considering issues such as cost and environmental impact. The preferred erosion-resistant coating system for PMR 15/T650 35 has WC-Co as the hard topcoat. This system provides the following benefits in comparison to the coating system with Cr3C2-NiCr topcoat: lower powder material cost (15 to 20 percent), environmentally friendly materials (Cr3C2-NiCr is hazardous), and higher deposition yield (10 to 15 percent), which results in less waste.

Sutter, James K.↗
NASA NTRS1988

Sputtered silver films to improve chromium carbide based solid lubricant coatings for use to 900 C

Thin silver films, 250 to 3500 A thick, were sputtered onto PS200, a plasma sprayed, chromium carbide based solid lubricant coating, to reduce run-in wear and improve tribological properties. The coating contains bonded chromium carbide as the wear resistant base stock with silver and barium fluoride/calcium fluoride eutectic added as low and high temperature lubricants respectively. Potential applications for the PS200 coating are cylinder wall/piston ring lubrication for Stirling engines and foil bearing journal lubrication. In this preliminary program, the silver film overlay thickness was optimized based on tests using a pin-on-disk tribometer. The friction and wear studies were performed in a helium atmosphere at temperatures from 25 to 760 C with a sliding velocity of 2.7 m/s under a 4.9 N load. Films between 1000 and 1500 A provide the best lubrication of the counterface material. The films enrich the sliding surface with lubricant and reduce the initial abrasiveness of the as ground, plasma-sprayed coating surface, thus reducing wear.

Dellacorte, Christopher↗
NASA NTRS1988

Sputtered silver films to improve chromium carbide based solid lubricant coatings for use to 900 C

Thin silver films, 250 to 3500 A thick, were sputtered onto PS200, a plasma sprayed, chromium carbide based solid lubricant coating, to reduce run-in wear and improve tribological properties. The coating contains bonded chromium carbide as the wear resistant base stock with silver and barium fluoride/calcium fluoride eutectic added as low and high temperature lubricants, respectively. Potential applications for the PS200 coating are cylinder wall/piston ring lubrication for Stirling engines and foil bearing journal lubrication. In this preliminary program, the silver film overlay thickness was optimized based on tests using a pin-on-disk tribometer. The friction and wear studies were performed in a helium atmosphere at temperatures from 25 to 760 C with a sliding velocity of 2.7 m/s under a 4.9 N load. Films between 1000 and 1500 A provide the best lubrication of the counterface material. The films enrich the sliding surface with lubricant and reduce the initial abrasiveness of the as ground, plasma-sprayed coating surface, thus reducing wear.

Dellacorte, Christopher↗