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At least 379 records · Page 21

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NASA NTRS1985

Mechanisms of thermal barrier coating degradation and failure

The objectives and initial results of a Thermal Barrier Coating (TBC) Life Prediction Model Development Program are described. The goals of this program are to: identify and understand TBC failure modes; generate quantitative TBC life data; and develop and verify a TBC life prediction model. The coating being studied is a two layer thermal barrier system incorporating a nominal ten mil outer layer of seven percent yttria partially stabilized zirconia plasma deposited over an inner layer of highly oxidation resistant low pressure plasma sprayed NiCrAlY bond coating. This coating currently is in flight service on turbine vane platforms in the JT-9D and PW2037 engines and is bill-of- material on turbine vane airfoils in the advanced PW4000 and IAE V2500 engines. Effort currently is in progress on the first task, which involves the identification and understanding of TBC failures. Five modes of coating damage were considered: thermomechanical ceramic failure; oxidative bond coat failure; hot corrosion; foreign object damage (FOD); and erosion.

Demasi, J. T.↗

NASA NTRS1986

Plasma sprayed Fe(76)Nd(16)B(8) permanent magnets

Thin coatings (0.16 mm) and thick coatings (0.50 mm) of Fe(76)Nd(16)B(8) were deposited on stainless-steel substrates by low pressure plasma spraying. Microscopic examination of the coatings in a light microscope revealed excessive porosity, but good bonding to the substrate. Fracture cross sections examined in a scanning electron microscope showed the grains to be equiaxed and approximately 1 micron or less in diameter in the as-sprayed condition. The intrinsic coercivities of the as-sprayed coatings varied from 5.8 to 10.9 kOe. The effects of postspray heat treatments on the intrinsic coercivity are also given.

Overfelt, R. A.↗

NASA NTRS1985

Fabrication of strain-isolated ceramic coated combustor components

The use of strain-isolated ceramic coated material to produce an AGT1500 combustor scroll-shaped transition duct which requires no air for film cooling is investigated. The scroll receives the exhaust of the can-style combustor liner and turns it into the annular inlet of the high pressure gas producer turbine nozzle. Strain-isolation of plasma sprayed thermal barrier coating is achieved by placing a compliant pad between the structural base metal and the ceramic coating. The compliant pad is brazed to the metal structure. In order to achieve a good braze bond, the strain-isolating compliant pad and base metal must be closely matched in shape and tightly fixtured for joining. The complex geometry of the AGT1500 scroll makes it impractical to attack pads to the supporting structure in its finished shape. Instead the pads are brazed to flat stock and post-formed into scroll sections. While test samples were successfully post-formed, plasma sprayed, and subjected to cyclic heating, the forming of full scale parts by normal methods resulted in tearing of the Hastelloy-X base metal because of embrittlement by the braze material. Several solutions were explored which finally resulted in the successful forming of full scale scroll parts.

Rutter, S.↗

NASA NTRSDate not supplied

Wear-Resistance Investigations on Ceramic Coatings for Lunar Dust Mitigation

Lunar dust has posed a major challenge to exploration efforts due to abrasion and impact. This work focuses on fundamental studies on ceramic coatings as candidates for enhanced resistance to impact and wear. As a first step, standard and modified approaches to the method of abrasion testing were explored for options to incorporate lunar regolith as wear media, the effects of which were presented for AL6061-T6 control samples. Following this, wear results for air plasma-sprayed (APS) alumina coatings were investigated due to their superior strength and surface hardness. In addition, APS 8 wt % yttria-stabilized zirconia (8YSZ) coatings were studied for their strength and martensitic transformation toughness. Measurements were made by assessing the mass loss, with a standard scale at various intervals. In addition, surface roughness was measured with a profilometer and features identified with a high-resolution microscope. The findings demonstrated that wear media has a distinct effect on the abrasion. The alumina coatings demonstrated improved wear over 8YSZ. However, the tailorability of 8YSZ makes it an attractive option to continue to modify as a wear-resistant coating to protect against lunar dust abrasion. The results of these measurements provide insight into the wear behavior of future directions in candidate ceramic coatings for the harsh lunar environment.

ceramic coatings↗

NASA NTRSDate not supplied

Wear-Resistance Investigations on Ceramic Coatings for Lunar Dust Mitigation

ceramic coatings↗

NASA NTRS2003

NASA Glenn/AADC-Rolls Royce Collaborated to Measure Erosion Resistance on Coated Polymer Matrix Composites

Polymer matrix composites (PMCs) are increasingly used in aerospace and automotive applications because of their light weight and high strength-to-weight ratio relative to metals. However, a major drawback of PMCs is poor abrasion resistance, which restricts their use, especially at high temperatures. Simply applying a hard coating on PMCs to improve abrasion and erosion resistance is not effective since coating durability is short lived (ref. 1). Generally, PMCs have higher coefficients of thermal expansion than metallic or ceramic coatings have, and coating adhesion suffers because of poor interfacial adhesion strength. One technique commonly used to improve coating adhesion or durability is the use of bond coats that are interleaved between a coating and a substrate with vastly different coefficients of thermal expansion. An example of this remedy is the use of bondcoats for ceramic thermal barrier coatings on metallic turbine components (ref. 2). Prior collaborative research between the NASA Glenn Research Center and the Allison Advanced Development Company (AADC) demonstrated that bond coats sandwiched between PMCs and high-quality plasma-sprayed, erosion-resistant coatings substantially improved the erosion resistance of PMCs (ref. 3). One unresolved problem in this earlier collaboration was that there was no easy, accurate way to measure the coating erosion wear scar. Coating wear was determined by both profilometry and optical microscopy. Both techniques are time consuming. Wear measurement by optical microscopy requires sample destruction and does not provide a comprehensive measure of the entire wear volume. An even more subtle, yet critical, problem is that these erosion coatings contain two or more materials with different densities. Therefore, simply measuring specimen mass loss before and after erosion will not provide an accurate gauge for coating and/or substrate volume loss. By using a noncontact technique called scanning optical interferometry, which was recently developed at Glenn, researchers can accurately determine the wear performance of erosion-coated PMCs while preserving the sample. An example of this interferometry technique is shown in the preceding figure for an erosion-coated inlet guide vane from a Rolls Royce AE3007 regional gas turbine jet engine. Erosion was conducted with coated and uncoated PMC vanes, with the abrasive material moving at a velocity of 229 m/s at impingement angles of 20 and 90 degrees. The coatings for PMCs remarkably reduced the erosion volume loss by a factor of approximately 10. Currently, several erosion coatings for PMCs are being compared and downselected for engine testing at Rolls Royce.

Miyoshi, Kazuhisa↗

NASA NTRSDate not supplied

Exploring the Effect of EBC Composition on CMAS Wetting Behavior

Rare-earth disilicate (REDS) materials are existing materials used in environmental barrier coating (EBC) for the protection of structural materials in the hot-section of turbine engines. REDS interactions with molten calcium-magnesium-aluminosilicate (CMAS) debris are of interest to understand molten CMAS attack and improve CMAS mitigation strategies. This work assesses the effect of REDS composition on CMAS wetting by investigating wetting angle, spreading, and reactivity. Freestanding atmospheric plasma spray (APS) REDS coatings (for RE = Y, La, Nd, Gd, Yb, Lu) were exposed to 10 mg of CMAS (Ca33-Mg9-Al13-Si45 in single cation mol%) in stagnant lab air at 1250C. APS YbDS was compared to a dense spark plasma sintered (SPS) phase-pure Yb2Si2O7 and a nominal 20 vol% phase-mixture of Yb 2 SiO 5 in Yb 2 Si 2 O 7 (20YbMS/YbDS). CMAS mass was held constant but specimen surface areas varied, yielding a range of loading between ~6 and 10 mg/cm2. CMAS was loaded as a cylindrical rod atop the specimen surface, polished to 4000 grit, and heated to temperature in a Linseis L74/HS/1700 heating microscope. The heating microscope measured the evolution of molten CMAS diameter, height, and contact angle. Molten CMAS diameter at 1150C and contact angle measurements after two hours of exposure at 1250C yielded a positive trend with rare-earth cation size. There was no statistically significant difference in CMAS wetting behavior between SPS YbDS and 20YbMS/YbDS. Post-exposure specimens were examined in plan view and cross-section with XRD, SEM, and EDS. CMAS spreading was cross-examined using plan view SEM, while reactivity utilized plan view XRD and cross-sectional SEM/EDS.

Clark Luckhardt↗

NASA NTRS2000

Investigation of Potential Thermal Processing Techniques for the Enhancement of PS300 High Temperature Solid Lubricant Coatings

Contemporary trends in rotating machinery development have produced a continuous evolution towards ever increasing speeds and higher operating temperatures. This process has been particularly evident in aerospace and automotive applications such as turbochargers. The combination of high temperature and high speed has exceeded the capacity of mainstream liquid lubrication technology. The NASA Glenn Research Center has been at the forefront in developing innovative solid lubricants for the oil free protection of rotating machinery under these extreme environmental conditions. The most recent of these is the PS 300 series of plasma sprayed solid lubricant coatings. St Louis University and NASA Glenn Research Center entered into this cooperative agreement to investigate potential thermal processing techniques for the enhancement of the PS 304 solid lubricant.

Benoy, Patricia A.↗

NASA NTRS1998

The Evaluation of a Modified Chrome Oxide Based High Temperature Solid Lubricant Coating for Foil Gas Bearings

This paper describes the friction and wear performance of PS304, a modified chrome oxide based coating, for foil gas bearings. PS304 contains 60 wt% NiCr binder, 20 wt% Cr2O3 hardener, and 10 wt% each Ag, and BaF2/CaF2 lubricants. For evaluation, the coating is plasma spray deposited onto test journals which are slid against a superalloy partial arc foil bearing. The test load was 10 KPa (1.5 psi) and the bearings were run under start/stop cyclic conditions. The data show good wear performance of the bearing, especially at temperatures above 25 deg. C. Bearing friction was moderate (micron approx. or equal to 0.4) over the entire temperature range. Based upon the results obtained, the PS304 coating has promise for high temperature, oil-free turbomachinery applications.

DellaCorte, Chris↗

NASA NTRS2017

Revisiting the Birth of 7YSZ Thermal Barrier Coatings: Steve Stecura

Thermal barrier coatings are widely used in all turbine engines, typically using a 7 wt% Y2O3-ZrO2 formulation. Extensive research and development over many decades have refined the processing and structure of these coatings for increased durability and reliability. New compositions demonstrate some unique advantages and are gaining in application. However, the "7YSZ" formulation predominates and is still in widespread use. This special composition has been universally found to produce nanoscale precipitates of metastable t' tetragonal phase, giving rise to a unique toughening mechanism via ferro-elastic switching under stress. This note recalls the original study that identified superior properties of 6 to 8 wt% YSZ plasma sprayed thermal barrier coatings, published in 1978. The impact of this discovery, arguably, continues in some form to this day. At one point, 7YSZ thermal barrier coatings were used in every new aircraft and ground power turbine engine produced worldwide. It is a tribute to its inventor, Dr. Stephan J. Stecura, NASA retiree.

turbine blades↗

NASA NTRS1986

A new chromium carbide-based tribological coating for use to 900 deg C with particular reference to the Stirling engine

A new chromium carbide-based coating (PS 200) is described. This coating is shown to have good friction and wear properties over a wide temperature range. A nickel alloy-bonded chromium carbide coating was used as a baseline material for comparison with experimental formulated coatings. Coatings were plasma sprayed onto metal disks, then diamond ground to a thickness of 0.025 cm. Friction and wear were determined using a pin on disk tribometer at temperatures from 25 to 900 C in hydrogen, helium, and air. Pin materials included several metallic alloys and silicon carbide. It was found that appropriate additions of metallic silver and of barium fluoride/calcium fluoride eutectic to the baseline carbide composition significantly reduced friction coefficients while preserving, and in some cases, even enhancing wear resistance. The results of this study demonstrate that PS 200 is a promising coating composition to consider for high temperature aerospace and advanced heat engine applications. The excellent results in hydrogen make this coating of particular interest for use in the Stirling engine.

Sliney, H. E.↗

NASA NTRS1986

A new chromium carbide-based tribological coating for use to 900 C with particular reference to the Stirling engine

A new chromium carbide-based coating (PS 200) is described. This coating is shown to have good friction and wear properties over a wide temperature range. A nickel alloy-bonded chromium carbide coating was used as a baseline material for comparison with experimentally formulated coatings. Coatings were plasma sprayed onto metal disks, then diamond ground to a thickness of 0.025 cm. Friction and wear were determined using a pin on disk tribometer at temperatures from 25 to 900 C in hydrogen, helium, and air. Pin materials included several metallic alloys and silicon carbide. It was found that appropriate additions of metallic silver and of barium fluoride/calcium fluoride eutectic to the baseline carbide composition significantly reduced friction coefficients while preserving, and in some cases, even enhancing wear resistance. The results of this study demonstrate that PS 200 is a promising coating composition to consider for high temperature aerospace and advanced heat engine applications. The excellent results in hydrogen make this coating of particular interest for use in the Stirling engine.

Sliney, Harold E.↗

NASA NTRS1985

Finite element analysis of residual stress in plasma-sprayed ceramic

Residual stress in a ZrO2-Y2O3 ceramic coating resulting from the plasma spraying operation is calculated. The calculations were done using the finite element method. Both thermal and mechanical analysis were performed. The resulting residual stress field was compared to the measurements obtained by Hendricks and McDonald. Reasonable agreement between the predicted and measured moment occurred. However, the resulting stress field is not in pure bending.

Mullen, R. L.↗

NASA NTRS1989

Adherent Thermal Barrier For Combustion Chamber

In improved method, fabrication begins with machining of aluminum mandrel to requisite cylindrical shape. Heat-barrier coating - yttria-stablized zirconia - plasma-sprayed on mandrel to thickness of 0.076 mm. Nickel/chromium layer about 0.025 mm thick sprayed on zirconia. Thin zirconia coating reduces maximum operating temperature of copper wall of chamber from 844 to 334 K. At lower temperature, copper liner stronger and undergoes less strain and less tendency to distort and crack.

Quentmeyer, Richard J.↗

NASA NTRS2002

A Systems Approach to the Solid Lubrication of Foil Air Bearings for Oil-Free Turbomachinery

Foil air bearings are self-acting hydrodynamic bearings which rely upon solid lubricants to reduce friction and minimize wear during sliding which occurs at start-up and shut-down when surface speeds are too low to allow the formation of a hydrodynamic air film. This solid lubrication is typically accomplished by coating the non-moving foil surface with a thin, soft polymeric film. The following paper introduces a systems approach in which the solid lubrication is provided by a combination of self lubricating shaft coatings coupled with various wear resistant and lubricating foil coatings. The use of multiple materials, each providing different functions is modeled after oil-lubricated hydrodynamic sleeve bearing technology which utilizes various coatings and surface treatments in conjunction with oil lubricants to achieve optimum performance. In this study, room temperature load capacity tests are performed on journal foil air bearings operating at 14,000 rpm. Different shaft and foil coating technologies such as plasma sprayed composites, ceramic, polymer and inorganic lubricant coatings are evaluated as foil bearing lubricants. The results indicate that bearing performance is improved through the individual use of the lubricants and treatments tested. Further, combining several solid lubricants together yielded synergistically better results than any material alone.

DellaCorte, Christopher↗

NASA NTRS2004

Friction and Wear Characteristics of Cu-4Al Foil Bearing Coating at 25 and 650 degree C

The friction and wear performance of a Cu-4Al top foil coating has been investigated in Generation I foil air bearings. The copper alloy was applied by a novel deposition technique (ion diffusion) and the journal was coated with PS304, a plasma spray deposited high temperature composite solid lubricant coating. The ion diffusion coating process deposits a desirable smooth layer compared to other methods like cathodic arc deposition. The tribological performance of bearings with and without Cu-4Al foil coatings were evaluated through start-stop tests on an air bearing test rig at 25 and 650 C. The results indicate that the Cu-4Al assists during the initial break-in period, gives more stable friction performance with respect to temperature, and appears to prevent top foil wear at high temperature. The measured load capacity coefficient was 0.5, which was comparable to earlier testing of more advanced design Generation III bearings coated with standard cathodic arc deposited Cu-4Al. However, further studies are needed to determine if deeper penetration of the copper alloy into the foil would help make the transition in friction behavior from contact with the Cu-4Al coated foil to contact with the base foil material more gradual. Also, future work is recommended to assess the performance of ion diffusion coatings with different Cu-based alloy compositions and to investigate the effect the coating has on the elastic modulus of the foil material.

Stanford, Malcolm K.↗

NASA NTRS1972

Detection of lack of fusion using opaque additives, phase 1

Two major problems in welded aluminum spacecraft structure, reliable nondestructive inspection for incomplete weldment penetration and the rapid oxidation of aluminum surfaces left exposed to the atmosphere are investigated. The approach employed to solve both problems was to employ copper as a coating to prevent oxidation of the aluminum and as an opaque additive in the weldment to enhance X-ray detection in the event of incomplete penetration. Both plasma spray and vacuum vapor deposition techniques were evaluated for depositing the copper. A series of welded panels was made using three thicknesses of vacuum-vapor-deposited copper. All weldments were nondestructively inspected by X-ray, then excised into tensile and bend specimens. Mechanical tests were conducted and all data evaluated. It was determined that the vacuum-vapor-deposited coating was superior to a plasma sprayed coating of the same thickness. The vacuum-vapor-deposited coating was more uniform in thickness, provided complete coverage of the aluminum, and was free of cracks and porosity.

Cook, J. L.↗

NASA NTRS1979

Array Automated Assembly, Phase 2

The baseline process sequence using nontextured square wafers was integrated. Difficulties encountered include: (1) replacement of the N-250 spray on diffusion source with PX-10 source; and (2) modification of the firing for printed silver and aluminum contracts is required to accommodate the change of wafer size and shape. Results indicate that the cells processed through the entire process sequence except laser scribe and spray on AR coating indicate the process sequence is feasible. Greater cell conversion efficiency is presented.

Taylor, W. E.↗