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At least 397 records · Page 22

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NASA NTRS1999

Development of Refractory Silicate-YSZ Dual Layer TBCs

Development of advanced thermal barrier coatings (TBCs) is the most promising approach for increasing the efficiency and performance of gas turbine engines by enhancing the temperature capability of hot section metallic components. Spallation of the yttria-stabilized zirconia (YSZ) top coat, induced by the oxidation of the bond coat coupled with the thermal expansion mismatch strain, is considered to be the ultimate failure mode for current state-of-the-art TBCS. Enhanced oxidation resistance of TBCs can be achieved by reducing the oxygen conductance of TBCs below that of thermally grown oxide (TGO) alumina scale. One approach is incorporating an oxygen barrier having an oxygen conductance lower than that of alumina scale. Mullite, rare earth silicates and glass ceramics have been selected as potential candidates for the oxygen barrier. This paper presents the results of cyclic oxidation studies of oxygen barrier/YSZ dual layer TBCs.

He, Yirong↗

NASA NTRS1997

Microstructure and Mechanical Properties of Vacuum Plasma Sprayed Cu-8Cr-4Nb

This paper compares the tensile properties of Cu-8Cr-4Nb material produced by VPS to material previously produced by extrusion. The microstructure of the VPS material is also presented. The combustion chamber liner of rocket motors represents an extreme materials application. The liner hot wall is exposed to a 2760 C (5000 F) flame while the cold side is exposed to cryogenic hydrogen liquid. Materials for use in the combustion chamber liner require a combination of high temperature strength, creep resistance, and low cycle fatigue resistance along with high thermal conductivity. The hot side is also subject to localized cycles between reducing and oxidizing environments that degrade the liner by a process called blanching. A new Cu-8 at.% Cr-4 at% Nb (Cu-8Cr-4Nb) alloy has been developed at NASA Lewis Research Center as a replacement for the currently used alloy, NARloy-z (Cu-3 wt.% Ag-0.5 wt.% Zr). The alloy is strengthened by a fine dispersion of Cr2Nb particles. The alloy has better mechanical properties than NARloy-Z while retaining most of the thermal conductivity of pure copper. The alloy has been successfully consolidated by extrusion and hot isostatic pressing (HIPing). However, vacuum plasma spraying (VPS) offers several advantages over prior consolidation methods. VPS can produce a near net shape piece with the profile of the liner. In addition, oxidation resistant and thermal barrier coatings can be incorporated as an integral part of the liner hot wall during the VPS deposition. The low oxygen VPS Cu-8Cr-4Nb exhibits a higher strength than Cu-8Cr-4Nb produced by extrusion at elevated temperatures and a comparable strength at room temperature. Moduli and ductility were not significantly different. However, the ability to produce parts to near-net shape and maintain the good elevated temperature tensile properties of the extruded Cu-8Cr-4Nb makes VPS an attractive processing method for fabricating rocket engine combustion liners.

Holmes, Richard↗

NASA NTRS2007

High Temperature Materials for Chemical Propulsion Applications

Radiation or passively cooled thrust chambers are used for a variety of chemical propulsion functions including apogee insertion, reaction control for launch vehicles, and primary propulsion for planetary spacecraft. The performance of these thrust chambers is limited by the operating temperature of available materials. Improved oxidation resistance and increased operating temperatures can be achieved with the use of thermal barrier coatings such as zirconium oxide (ZrO2) and hafnium oxide (HfO2). However, previous attempts to include these materials showed cracking and spalling of the oxide layer due to poor bonding. Current research at NASA's Marshall Space Flight Center (MSFC) has generated unique, high temperature material options for in-space thruster designs that are capable of up to 2500 C operating temperatures. The research is focused on fabrication technologies to form low cost Iridium,qF_.henium (Ir/Re) components with a ceramic hot wall created as an integral, functionally graded material (FGM). The goal of this effort is to further de?celop proven technologies for embedding a protective ceramic coating within the Ir/Re liner to form a robust functional gradient material. Current work includes the fabrication and testing of subscale samples to evaluate tensile, creep, thermal cyclic/oxidation, and thermophysical material properties. Larger test articles have also being fabricated and hot-fire tested to demonstrate the materials in prototype thrusters at 1O0 lbf thrust levels.

Elam, Sandra↗

DOE OSTI2025

Improving Conversion of Captured CO 2 on Mixed-Oxide Dual-Function Materials by Low-Concentration Metal Promotion

Reactive carbon capture (RCC) is a promising nascent approach to harness the untapped resource of waste CO 2 to produce fuels and platform chemicals. However, process economics relies on the design of dual-function materials (DFMs) that exhibit maximal conversion of captured CO 2 and high selectivity toward valuable carbon products (e.g., CO). Herein, we report the use of low-concentration (ca. 0.5 wt %) metal promotors (Pt and Au) to improve the conversion of captured CO 2 on a Zn-Al mixed-oxide DFM by >30%, while also more than doubling per-cycle CO yield due to enhanced retention of captured CO 2 and H 2 activation. In situ DRIFTS of bound CO 2 on the DFMs showed distinctions in surface carbonate formation for the Pt- and Au-modified materials that were correlated with product evolution during the reactive desorption step of RCC. Particularly, Pt afforded superior H 2 activation but formed irreversibly-bound bicarbonates, compromising overall productivity, while the Na/Au/ZA DFM predominantly adsorbed CO 2 on Na sites, resulting in polydentate carbonates that are retained until higher temperatures before conversion to CO. In conclusion, these results indicate that adding a low concentration of oxidation-resistant noble metals, especially Au, is an effective strategy for improving key performance metrics of Zn-Al mixed-oxide DFMs to further advance the development of scalable RCC technologies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1988

Response of carbon-carbon composites to challenging environments

This paper presents results from material performance evaluations of oxidation-resistant carbon-carbon composites intended for multiuse aerospace applications, which cover the effects of the following environmental parameters: the oxidizing nature of the environments (including both high and low oxygen partial pressures), high temperatures, moisture, cyclic temperature service, and foreign-object impact. Results are presented for the carbon-carbon material currently in use as the thermal-protection-system material on Space Shuttle, as well as for newer and more advanced structural forms of carbon-carbon composites.

Maahs, Howard G.↗

NASA NTRS1973

Plasma-sprayed metal-glass and metal-glass fluoride coatings for lubrication to 900 C

Plasma-sprayed composites, which have good oxidation-resistance and self-lubricating characteritics to 900 C, were developed. The composites are a nichrome matrix containing dispersed glass for oxidation protection and calcium fluoride for lubrication; they are applied to bearing surfaces by plasma spraying layers about 0.050 centimeters thick which are then machined to 0.025 centimeters. Oscillating bearing tests were performed in air to 900 C at unit radial loads up to 3.5 x 10 to the 7th power N/sq M (5000 psi) and a thrust load of 1960N (440 lbs). Bearings with a composite liner in the bore were in good condition after over 50,000 oscillating cycles accumulated during repeated, bearing temperatures cycles between 25 and 900 C.

Sliney, H. E.↗

NASA NTRS1974

Self-lubricating plasma-sprayed composites for sliding contact bearings to 900 C

Plasma-sprayed composites which have good oxidation-resistance and self-lubricating characteristics to 900 C were developed. The composites are a Nichrome matrix containing dispersed glass for oxidation protection and calcium fluoride for lubrication. They are applied to bearing surfaces in layers about 0.050 cm thick by plasma-spraying; the layers are then machined to a thickness of 0.025 cm. Oscillating bearing tests were performed in air to 900 C at unit radial loads up to 3.5 times 10 to the 7th power Newtons per square meter (5000 psi) and a thrust load of 1960 Newtons (440 lb). Bearings with a composite liner in the bore were in good condition after over 50,000 oscillating cycles accumulated during repeated bearing temperature cycles between 25 and 900 C.

Sliney, H. E.↗

NASA NTRS1974

Plasma-sprayed metal-glass and metal-glass fluoride coatings for lubrication to 900 C

Plasma-sprayed composites, which have good oxidation resistance and self-lubricating characteristics to 900 C, were developed. The composites are a nichrome matrix containing dispersed glass for oxidation protection and calcium fluoride for lubrication; they are applied to bearing surfaces by plasma spraying layers about 0.050 cm thick which are then machined to 0.025 cm. Oscillating bearing tests were performed in air to 900 C at unit radial loads up to 5000 psi and a thrust load of 440 lb. Bearings with a composite liner in the bore were in good condition after over 50,000 oscillating cycles accumulated during repeated bearing temperature cycles between 25 and 900 C.

Sliney, H. E.↗

DOE OSTI2025

A statistical representation of bond coating oxidation under environmental barrier coatings

Environmental barrier coatings (EBCs) protect SiC-based ceramic matrix composites (CMCs) in turbine hot sections from high-temperature volatilization in combustion gases. The formation of a SiO 2 thermally grown oxide (TGO) is expected under the EBC after long-term operation. The oxidation resistance of the EBC is understood as a life-limiting factor for the CMC, and this work predicts long-term oxidation behavior under EBCs through a simple statistical approach. Specimens were exposed to 1350°C isothermal conditions for 100-h thermal cycles in flowing steam for up to 1000 h. The EBC morphology, SiO 2 thickness, and SiO 2 cracking behavior were assessed. Using thousands of SiO 2 thickness measurements across many millimeters of the interface, a realistic representation of the entire TGO was captured via a lognormal distribution. The lognormal fit parameters were extrapolated out to 25 000 h to assess the degree of SiO 2 growth, the spread of SiO 2 thicknesses related to the rough oxidizing interface, and percentages of the intermediate bond coating consumed. In conclusion, local interfacial defects from the coating deposition process are identified as local failure points for EBC—CMC systems.

SiO 2↗

NASA NTRS1995

Thermochemical Degradation Mechanisms for the Reinforced Carbon/Carbon Panels on the Space Shuttle

The wing leading edge and nose cone of the Space Shuttle are fabricated from a reinforced carbon/carbon material (RCC). The material attains its oxidation resistance from a diffusion coating of SiC and a glass sealant. During re-entry, the RCC material is subjected to an oxidizing high temperature environment, which leads to degradation via several mechanisms. These mechanisms include oxidation to form a silica scale, reaction of the SiO2 with the SiC to evolve gaseous products, viscous flow of the glass, and vaporization of the glass. Each of these is discussed in detail. Following extended service and many missions, the leading-edge wing surfaces have exhibited small pinholes. A chloridation/oxidation mechanism is proposed to arise from the NaCl deposited on the wings from the sea-salt laden air in Florida. This involves a local chloridation reaction of the SiC and subsequent re-oxidation at the external surface. Thermodynamic calculations indicate the feasibility of these reactions at active pits. Kinetic calculations predict pore depths close to those observed.

Jacobson, Nathan S.↗

NASA NTRS2004

On-Board Chemical Propulsion Technology

On-board propulsion functions include orbit insertion, orbit maintenance, constellation maintenance, precision positioning, in-space maneuvering, de-orbiting, vehicle reaction control, planetary retro, and planetary descent/ascent. This paper discusses on-board chemical propulsion technology, including bipropellants, monopropellants, and micropropulsion. Bipropellant propulsion has focused on maximizing the performance of Earth storable propellants by using high-temperature, oxidation-resistant chamber materials. The performance of bipropellant systems can be increased further, by operating at elevated chamber pressures and/or using higher energy oxidizers. Both options present system level difficulties for spacecraft, however. Monopropellant research has focused on mixtures composed of an aqueous solution of hydroxl ammonium nitrate (HAN) and a fuel component. HAN-based monopropellants, unlike hydrazine, do not present a vapor hazard and do not require extraordinary procedures for storage, handling, and disposal. HAN-based monopropellants generically have higher densities and lower freezing points than the state-of-art hydrazine and can higher performance, depending on the formulation. High-performance HAN-based monopropellants, however, have aggressive, high-temperature combustion environments and require advances in catalyst materials or suitable non-catalytic ignition options. The objective of the micropropulsion technology area is to develop low-cost, high-utility propulsion systems for the range of miniature spacecraft and precision propulsion applications.

Reed, Brian D.↗

NASA NTRS1993

Protective Coats For High-Temperature Strain Gauges

Addition of some rare-earth oxides to prior alumina (only) coating material increases maximum service temperature of palladium/chromium-wire strain gauges. Pd/Cr wires used at temperatures up to 800 degrees C without excessive drift in electrical resistance. Oxides used: zirconia (ZrO2), yttria (Y2O3), ceria (CeO2), and hafnia (HfO2). Addition of one of these oxides to decrease oxidation of wire at high temperature. Protection against oxidation increases with concentration of rare-earth oxide. Addition of ZrO2 at 4 to 6 weight percent or Y2O3 at 1 weight percent results in smallest drift in electrical resistance.

Lei, Jih-Fen↗

NASA NTRS2001

Robust Low Cost Liquid Rocket Combustion Chamber by Advanced Vacuum Plasma Process

Next-generation, regeneratively cooled rocket engines will require materials that can withstand high temperatures while retaining high thermal conductivity. Fabrication techniques must be cost efficient so that engine components can be manufactured within the constraints of shrinking budgets. Three technologies have been combined to produce an advanced liquid rocket engine combustion chamber at NASA-Marshall Space Flight Center (MSFC) using relatively low-cost, vacuum-plasma-spray (VPS) techniques. Copper alloy NARloy-Z was replaced with a new high performance Cu-8Cr-4Nb alloy developed by NASA-Glenn Research Center (GRC), which possesses excellent high-temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability. Functional gradient technology, developed building composite cartridges for space furnaces was incorporated to add oxidation resistant and thermal barrier coatings as an integral part of the hot wall of the liner during the VPS process. NiCrAlY, utilized to produce durable protective coating for the space shuttle high pressure fuel turbopump (BPFTP) turbine blades, was used as the functional gradient material coating (FGM). The FGM not only serves as a protection from oxidation or blanching, the main cause of engine failure, but also serves as a thermal barrier because of its lower thermal conductivity, reducing the temperature of the combustion liner 200 F, from 1000 F to 800 F producing longer life. The objective of this program was to develop and demonstrate the technology to fabricate high-performance, robust, inexpensive combustion chambers for advanced propulsion systems (such as Lockheed-Martin's VentureStar and NASA's Reusable Launch Vehicle, RLV) using the low-cost VPS process. VPS formed combustion chamber test articles have been formed with the FGM hot wall built in and hot fire tested, demonstrating for the first time a coating that will remain intact through the hot firing test, and with no apparent wear. Material physical properties and the hot firing tests are reviewed.

Holmes, Richard↗

DOE OSTI2023

Impact of titanium content on the thermo-mechanical and oxidation response of TiAlTa

This study aimed to analyze how the addition of titanium (Ti) to TiAlTa alloys affects their mechanical properties (Young’s modulus and hardness) and oxidation behavior. Alloys with three different Ti additions and equi-atomic Al and Ta were fabricated with nominal compositions of 33Ti-33Al-33Ta at%, 50Ti-25Al-25Ta at%, and 70Ti-15Al-15Ta at%. Phase identification of as-processed and compositionally homogenized alloys was conducted by coupling various electron microscopy, diffraction, and chemical analysis techniques. Composition and structures were modeled using CALPHAD-based phase predictions and compared with experimental results. Each of the alloys exhibited a unique set of microstructures with distinctly different ordered precipitates, dependent on cooling rate and chemical composition. Subsequently, nanoindentation tests were performed at temperatures of 25°C, 250°C, 500°C, and 750°C. Oxidation studies were conducted under static air at 750°C for up to 200 h. 33Ti-33Al-33Ta at% and 70Ti-15Al-15Ta at% alloys showed higher hardness and modulus than 50Ti-25Al-25Ta at% at room temperature. The 50Ti-25Al-25Ta at% alloy exhibited higher hardness and modulus values but lower oxidation resistance at 750°C when compared with the other specimens. The X-ray photoelectron spectroscopy experiments were conducted to further analyze the oxides present in the samples. Despite each sample displaying combinations of mixed oxide layers, TiO 2 was the preferred oxide forming in the 50Ti-25Al-25Ta composition, while the other samples preferred to form Al 2 O 3 . In conclusion, the findings from this systematic exploration of phase evolution in the TiAlTa alloy space provide insights for optimized material chemistries, processing, and properties.

36 MATERIALS SCIENCE↗

NASA NTRS1974

Coatings for directional eutectics

Eleven coating systems based on MCrAlY overlay and diffusion aluminide prototypes were evaluated to determine their capability for protecting the gamma/gamma prime-delta directionally solidified eutectic alloy (Ni-20Cb-6Cr-2.5Al) in gas turbine engine applications. Furnace oxidation and hot corrosion, Mach 0.37 burner-rig, tensile ductility, stress-rupture and thermomechanical fatigue tests were used to evaluate the coated gamma/gamma prime-delta alloy. The diffusion aluminide coatings provided adequate oxidation resistance at 1144 K (1600 F) but offered very limited protection in 114 K (1600 F) hot corrosion and 1366 K (2000 F) oxidation tests. A platinum modified NiCrAlY overlay coating exhibited excellent performance in oxidation testing and had no adverse effects upon the eutectic alloy.

Felten, E. J.↗

NASA NTRS1980

Composite wall concept for high temperature turbine shrouds: Survey of low modulus strain isolator materials

Plasma sprayed yttria stabilized zirconium oxide turbine seal specimens, incorporating various low modulus porous metal strain isolator pads between the zirconium oxide and a dense metal substrate, were subjected to cyclic thermal shock testing. Specimens that had a low modulus pad composed of sintered FeNiCrAlY fibermetal survived 1000 thermal shock cycles without spalling of the ceramic. A figure of merit for the low modulus pad materials taking into consideration the elastic modulus, thermal conductivity, strength, and oxidation resistance of the pad was proposed, and showed reasonable agreement with the thermal shock results. A potential surface distress problem on the zirconium oxide, associated with nonuniform temperature distribution and rapid stress relaxation was identified. One approach to solving the surface distress problem through application of laser surface fusion of the zirconium oxide layer showed some promise, but improvements in the laser surface fusion process are necessary to prevent process associated damage to the ceramic.

Bill, R. C.↗

NASA NTRS1974

The effect of yttrium and thorium on the oxidation behavior of Ni-Cr-Al alloys

The investigation reported included a determination of the optimum composition of a Ni-Cr-Al ternary alloy with respect to oxidation resistance and minimum film-spalling tendencies. Yttrium and thorium in small amounts were added to the ternary alloy and an investigation of the oxidation mechanism and the oxide scale adherence was conducted. It was found that the oxidation mechanism of Ni-Cr-Al ternary alloys depends upon the composition of the alloy as well as the time, oxygen pressure, and temperature of oxidation.

Kumar, A.↗

NASA NTRS1987

Fracture of flash oxidized, yttria-doped sintered reaction-bonded silicon nitride

The oxidation behavior of a slip cast, yttria-doped, sintered reaction-bonded silicon nitride after 'flash oxidation' was investigated. It was found that both the static oxidation resistance and flexural stress rupture life (creep deformation) were improved at 1000 C in air compared to those of the same material without flash oxidation. Stress rupture data at high temperatures (1000 to 1200 C) are presented to indicate applied stress levels for oxidation-dependent and independent failures.

Govila, R. K.↗