Recent advances in the thermal barrier coatings for extreme environments
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36 MATERIALS SCIENCE↗
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Results for “extreme environment materials”
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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Electrochemical Impedance Spectroscopy of Alloys in a Simulated Space Shuttle Launch Environment
Corrosion studies began at NASA/Kennedy Space Center in 1966 during the Gemini/Apollo Programs with the evaluation of long-term protective coatings for the atmospheric protection of carbon steel. An outdoor exposure facility on the beach near the launch pad was established for this purpose at that time. The site has provided over 35 years of technical information on the evaluation of the long-term corrosion performance of many materials and coatings as well as on maintenance procedures. Results from these evaluations have helped NASA find new materials and processes that increase the safety and reliability of our flight hardware, launch structures, and ground support equipment. The launch environment at the Kennedy Space Center (KSC) is extremely corrosive due to the combination of ocean salt spray, heat, humidity, and sunlight. With the introduction of the Space Shuttle in 1981, the already highly corrosive conditions at the launch pad were rendered even more severe by the acidic exhaust from the solid rocket boosters. Over the years, many materials have been evaluated for their corrosion performance under conditions similar to those found at the launch pads. These studies have typically included atmospheric exposure and evaluation with conventional electrochemical methods such as open circuit potential (OCP) measurements, polarization techniques, and electrochemical impedance spectroscopy (EIS). The atmosphere at the Space Shuttle launch site is aggressive to most metals and causes severe pitting in many of the common stainless steel alloys such as type 304L stainless steel (304L SS). A study was undertaken to find a more corrosion resistant material to replace the existing 304L SS tubing. This paper presents the results from atmospheric exposure as well as electrochemical measurements on the corrosion resistance of AL-6XN (UNS N08367) and 254-SMO (UNS S32154). Type 304L SS (UNS S30403) was used as a control. Conditions at the Space Shuttle launch pad were simulated by using a hydrochloric acid (HC1) and alumina (Al203) slurry rinse for the atmospheric exposure and an electrolyte consisting of 3.55% sodium chloride (NaC1) with increased concentrations of hydrochloric acid (HC1) for the electrochemical measurements. The results from both types of measurements revealed the superior corrosion performance of the higher-alloyed materials. Unlike 304L SS, 254-SMO and AL-6XN exhibited a significantly improved resistance to corrosion as the concentration of hydrochloric acid in he 3.55% NaCl electrolyte solution was increased.
Calle, L. M.↗
Chemical and Radiological Compatibility Testing of 3D Printed Materials
To dramatically increase the adaptability, performance, and safety of processes in support of the Defense Waste Processing Facility (DWPF), Savannah River National Lab (SRNL) plans to perform chemical and radiological compatibility testing on a wide variety of 3D printed materials of interest. The 3D printing process provides numerous strategic operational benefits such as rapid prototyping of complex designs and geometry specific to the needs of the nuclear waste disposition process, as well as on-demand rapid prototyping and iteration with materials that aren’t as accessible through traditional manufacturing methods. Reaction chemistry in simulated waste batches can be matched closely to its radioactive counterpart, but glass reactor vessels have limitations. Vessel geometry can play a big factor in mixing transport limitations, process chemistry, and degradation reaction kinetics. In addition, additive manufacturing allows for much more detailed vessel design than traditional alternatives. Waste processing techniques in DWPF also encounter extreme chemical environments including high pH, strong acids, abrasive slurries, and significant irradiation. To meet these challenges, a matrix of various polymer, ceramic, and metal additive manufacturing materials have been exposed to a suite of chemical environments of interest as well as radioactive dose (such as gamma radiation from 60 Co) to properly test their durability under these conditions. Mass change has been monitored over a period of up to a week in these conditions, as well as added characterization for surface modification through Scanning Electron Microscopy/Electron Dispersive X-ray analysis (SEM/EDX). Further chemical characterization has been monitored through Fourier-Transform InfraRed Spectroscopy (FTIR), with planned investigation via thermal and tensile strength degradation. While the direct product of this research is identification of material(s) that can withstand specific hazardous environments encountered by the mercury water wash tank in DWPF process simulation experiments, the reference base of materials will be used for many other nuclear processes in the pursuit of rapidly developed, cost-efficient, and highly specific devices for environmental remediation and much more.
Wilson, Nathan W. [Savannah River National Laborat↗
The “Hole” Story in Ionized Water from the Perspective of Ehrenfest Dynamics
The radiolysis of liquid water and the radiation-matter interactions that happen in aqueous environments are important to the elds of chemistry, materials, and environmental sciences, as well as biological and physiological response to extreme conditions and medical treatments. The initial stage of radiolysis is the ultrafast response, or hole dynamics, that trigger chemical processes within complex energetic landscapes that may include reactivity. A fundamental understanding necessitates the use of theoretical methods that are capable of simulating both ultrafast coherence and non-adiabatic energy transfer pathways. In this work, we carry out an ab initio Ehrenfest dynamic study in order to provide a more complete description of the ultrafast dynamics and reactive events initiated by photoionization of water. Furthermore, after sudden ionization, the range of processes that include hole trapping and transfer, large OH oscillations, proton transfer and subsequent relay, formation of the metastable Zundel complex, and long-lived coherence, are identied and new insight into their driving forces are elucidated.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Impact of secondary salts, temperature, and pH on the colloidal stability of graphene oxide in water
The stability of graphene oxide (GO) in water is extremely relevant because of its application as an adsorbent material, as well as for its fate and behavior in the environment. Zeta potential was used to study the effect of secondary salts (carbonate, sulfate, and phosphate), temperature (20 to 60 °C), and pH (5 to 9) on the stability of six different GOs produced from natural, synthetic, and amorphous graphite—with and without the use of attrition milling. Generally, GOs produced with attrition-milled graphites had lower ζ-potentials than their unmilled counterparts because of their smaller particle sizes and higher concentration of oxygen-containing functional groups. It was observed that GO produced from graphite and synthetic graphite had ζ-potential values lower than –30 mV, even at 30 °C. However, it was observed that all the GOs studied were unstable in the presence of carbonate and sulfate salts at concentrations between 170 and 1695 mg L –1 , as they reached a ζ-potential of –4.1 mV. Density-functional theory electronic structure calculations suggested that the instability of GO in the presence of carbonate and sulfate was caused by the abstraction of a proton resulting in interaction energies E int of 28.3 and 168.9 kJ mol –1 , respectively. Our results suggest that temperatures above 30 °C, as well as carbonate and sulfate salts at concentrations relevant to arid and semi-arid regions, could promote the formation of agglomerates of GO, thus limiting its use and mobility in water.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Mass-Loss Buttons Monitor Material Degradation
Small button-sized samples attached to parent materials are simple way of monitoring degradation of parent in harsh environments. Samples determine effects of multiple exposures to environmental extremes without disturbing fit or function of parent. They are less costly and more convenient than complex instrumentation normally required to measure complete temperature/pressure time history of parent component.
Webster, C. N.↗
Comets and the origin of life; Proceedings of the Fifth College Park Colloquium on Chemical Evolution, University of Maryland, College Park, MD, October 29-31, 1980
Papers are presented concerning the characteristics of comets and their possible role in the origin of life. Specific topics include the characteristics, origin and structure of the cometary nucleus, cometary chemical abundances, the nature of interplanetary dust and its entry into terrestrial planet atmospheres, and the mechanism of ray closure in comet tails. Attention is also given to chemically evolved interstellar dust as a source of prebiotic material, the relation of comets to paleoatmospheric photochemistry, comets as a vehicle for panspermia, limits to life posed by extreme environments, and the status of cometary space missions as of 1980.
Ponnamperuma, C.↗
Alignment-Insensitive Lower-Cost Telescope Architecture
This architecture features an active wavefront sensing and control scheme along with methods for measuring the relative positions of the primary to aft optics, such as the secondary mirror, and should enable larger and cheaper telescope architectures needed for future applications. A wavefront source/sensor is placed at the center of curvature of the primary mirror. The system provides continuous light onto a primary mirror that is retro-reflected onto itself. This allows the wavefront controller to constantly update the positions of the primary mirror segments (or deformable mirror actuators). Another function of this innovation involves using a concave mirror on the back of the secondary mirror (or other aft optic) that has the same center-of-curvature location (in defocus) as the primary mirror. The two return beams can be aligned next to each other on a detector, or radially on top of each other. This provides a means with which to measure the relative position of the primary to the secondary (or other aft optics), thus allowing for the removal of misalignment of the center-of-curvature source/sensor (meaning it doesn't need precision placement) and also provides a means with which to monitor the relative alignment over time. This innovation does not require extremely good thermal stability on the primary mirror and can thus be used in any thermal environment and with cheaper materials. In addition to this, the architecture lets one phase (or align) the primary mirror independent of whether a star or scene is in the field. The segmented, spherical primary allows for cost-effective three-meter class (e.g. Midex and Discovery) missions as well as enabling 30-meter telescope solutions that can be manufactured in a reasonable amount of time. The continuous wavefront sensing and control architecture enables missions for low-Earth-orbit.
Feinberg, Lee↗
Retractable Sensor Poster for ANIMMA 2023 Conference
Material Test Reactors (MTRs) such as the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL) are used to irradiate nuclear fuels and materials to evaluate their performance after high levels of exposure to a reactor in-pile environment. The test environment within these reactors are extremely harsh and long-term exposure causes sensor decalibration or failure. Most tests only require data points at daily intervals meaning that the sensor does not necessarily need to be in place continuously for the full experiment. One proposed solution to the issue described above is to have a sensor which can be periodically inserted through a guide tube into the test region and retracted; this would act as a reference check on the sensors installed permanently. If a compact and robust enough design can be made, it has the potential to extend the life of the sensor and keep it within calibration. This LRS entry is for a poster summarizing a presentation that will be given at the ANIMMA 2023 conference. The poster will be on display in the Measurement Sciences Laboratory booth at ANIMMA. Most of the material on this poster came from LRS entry INL/CON-23-72797.
42 ENGINEERING↗
Structures and Materials Research at NASA Langley Research Center
NASA explores the unknown in air and space, innovates for the benefit of humanity, and inspires the world through discovery. The Structures and Materials discipline at NASA Langley Research Center supports this mission through advanced materials and manufacturing approaches applied to innovative structural concepts. We start with synthesizing novel material systems and applying tools and methods to predict and validate their static, dynamic, durability and damage tolerance behavior. We mature materials from test tube to test flight by developing manufacturing techniques that enable the advancement of aerospace structures from concept to reality. We develop advanced measurement techniques for health management and nondestructive evaluation. We draw on our structures and materials core capabilities to enable safe, reliable lightweight aerospace structures for application in all environments. You will find the results of our work in the assembly of large structures in space and on other planets, vehicles that carry crew into space, vehicles that operate at high speeds and in extreme environments, and technology for passenger and crew safety in commercial aviation. This presentation will provide an overview of Langley Research Center’s role within the agency, then focus on how current Structures and Materials research areas support a variety of NASA missions in space operations, exploration, and aeronautics.
Structures↗
Ultrasonic Measurements of Temperature Distribution in Extreme Environments: Results of Power Plant Testing
The most hardened insertion sensors do not perform reliably in extreme environmental conditions. We address this problem by developing an ultrasonic thermometry system for the measurements of segmental temperature distributions (MSTD) in solid materials and, specifically, across containments of energy conversion processes. The MSTD approach uses an echogenically segmented ultrasound propagation path, structured to contain engineered or naturally occurring echogenic features. In pulse-echo mode, these features produce a train of echoes in response to an external pulse of ultrasonic excitation created and acquired by a transducer located outside the extreme environment. The delays between the echoes encode the information on the temperature distribution in the corresponding segments of the ultrasonic propagation path, which we use to reconstruct an unknown temperature profile. This note describes the preliminary results and initial experience in applying the developed MSTD ultrasonic thermometry system to the measurements of temperatures in a utility-scale 500MW coal-fired boiler.
John, Mason↗
Space Weather Impacts on Spacecraft Design and Operations in Auroral Charging Environments
Spacecraft in low altitude, high inclination (including sun-synchronous) orbits are widely used for remote sensing of the Earth s land surface and oceans, monitoring weather and climate, communications, scientific studies of the upper atmosphere and ionosphere, and a variety of other scientific, commercial, and military applications. These systems are episodically exposed to environments characterized by a high flux of energetic (approx.1 to 10 s kilovolt) electrons in regions of very low background plasma density which is similar in some ways to the space weather conditions in geostationary orbit responsible for spacecraft charging to kilovolt levels. While it is well established that charging conditions in geostationary orbit are responsible for many anomalies and even spacecraft failures, to date there have been relatively few such reports due to charging in auroral environments. This presentation first reviews the physics of the space environment and its interactions with spacecraft materials that control auroral charging rates and the anticipated maximum potentials that should be observed on spacecraft surfaces during disturbed space weather conditions. We then describe how the theoretical values compare to the observational history of extreme charging in auroral environments and discuss how space weather impacts both spacecraft design and operations for vehicles on orbital trajectories that traverse auroral charging environments.
Minow, Joseph I.↗
5G Enabled Energy Innovation: Advanced Wireless Networks for Science (Workshop Report)
Rapidly expanding, new telecommunications infrastructure based on 5G technologies will disrupt and transform how we design, build, operate, and optimize scientific infrastructure and the experiments and services enabled by that infrastructure, from continental-scale sensor networks to centralized scientific user facilities, from intelligent Internet of Things devices to supercomputers. Concurrently, 5G will introduce, or exacerbate, challenges related to protecting infrastructure and associated scientific data as well as to fully leveraging opportunities related to expanded infrastructure scale and complexity. The U.S. Department of Energy (DOE) Office of Science operates scientific infrastructure, supporting some of the nation’s most advanced intellectual discoveries, spanning the country and including 30 world-class user facilities from supercomputers to accelerators. Along with field experiments and remote observatories, every aspect of DOE’s scientific enterprise will be affected by 5G, which amounts to a complete renovation of the underpinnings of the nation’s information infrastructure. In this report we explore the scientific opportunities and new research challenges associated with 5G, ranging from scalability to heterogeneity to cybersecurity. The rapid commercial deployment of 5G opens the opportunity to rethink and reinvent DOE’s scientific infrastructure and experimentation, from intelligent sensor networks at unprecedented scales to a digital continuum of cyberinfrastructure spanning low-power sensors, high-performance computing embedded within and at the edge of the network, and DOE’s large-scale user instrument and computing facilities. New programming paradigms, workflow and data frameworks, and AI-based system design, operation, and autonomous adaptation and optimization will be necessary in order to exploit these new opportunities. Field deployments and centralized scientific instruments can also be revolutionized, moving (without traditional performance penalties) from wired to wireless connectivity for data and control systems, improving flexibility, and opening new sensing modalities, including the use of the 5G electromagnetic spectrum itself as an environmental probe. For DOE science, in contrast to commercial 5G applications and settings, devices will be deployed in extreme environments such as cryogenically cooled instrument control systems and in remote settings with harsh conditions, requiring the design of new materials for RF communication and edge processing to operate in these regimes. Concurrently, 5G infrastructure comprises both hardware and sophisticated software systems - currently closed and proprietary. The cybersecurity challenges to 5G-empowered reinvention mirror the complexity and variety of new 5G features, from virtualization to private network slices to ubiquitous access. Research is also needed in order to accelerate the development of secure and open 5G software infrastructure, reducing reliance on hardware and software produced outside the United States and providing the transparency and rigorous evaluation and testing afforded through open software. Twelve broad research thrusts are laid out in four chapters, with a companion fifth chapter (and three additional research thrusts) underscoring the needs and opportunities for an aggressive testbed program co-designed by networking experts and scientists involved in the 15 research thrusts. The urgency of undertaking this research is fueled by a global, accelerating deployment of new telecommunications infrastructure that is designed for entertainment and commercial applications - barely scratching the surface of what 5G can do to extend U.S. leadership in scientific discovery.
42 ENGINEERING↗
High temperature solid lubricants - When and where to use them.
This paper reviews the state of the art of solid lubrication for moderate to extremely high temperature lubrication (to 1600 F). Lubricating characteristics, stability in various environments, and relevant machine design considerations are discussed. Lubricating materials discussed include MoS2, WS2, graphite, graphite fluoride, the high temperature polymide polymer, and calcium fluoride based coatings and composites. The scope of the information includes results from wear testers, ball bearings, and journal bearings.
Sliney, H. E.↗
On the Use of Accelerated Test Methods for Characterization of Advanced Composite Materials
A rational approach to the problem of accelerated testing for material characterization of advanced polymer matrix composites is discussed. The experimental and analytical methods provided should be viewed as a set of tools useful in the screening of material systems for long-term engineering properties in aerospace applications. Consideration is given to long-term exposure in extreme environments that include elevated temperature, reduced temperature, moisture, oxygen, and mechanical load. Analytical formulations useful for predictive models that are based on the principles of time-based superposition are presented. The need for reproducible mechanisms, indicator properties, and real-time data are outlined as well as the methodologies for determining specific aging mechanisms.
Gates, Thomas S.↗
Overview of the Development and Testing of the Heatshield for Extreme Entry Environment Technology (HEEET) TPS
Over the last 5 years, the Heatshield for Extreme Entry Environment Technology (HEEET) project has been working to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations such as Venus and Saturn. A key aspect of the project has been the development of the manufacturing and integration processes/procedures necessary to build a heat shield utilizing the HEEET 3D-woven material. This has culminated in the building of a 1-meter diameter Engineering Test Unit (ETU) representative of what would be used for a Saturn probe. The present talk provides an overview of recent testing of NASA's Heatshield for Extreme Entry Environment Technology (HEEET) 3D Woven TPS. Under the current program, the ETU has been subjected to Thermal and Mechanical loads typical of deep space mission to Saturn. Thermal testing of HEEET coupons has performance up to 4,500 watts per centimeter squared at 5 atmospheres stagnation pressure and successful shear performance up to 3000 pascals at 1,650 watts per centimeter squared at 2.6 atmospheres pressure.
HEEET↗
Mechanical Properties of Carbon Fiber Reinforced Composites Exposed to Cryogenic Conditions and Space Radiation via Simulation and Testing
As NASA missions extend beyond low Earth orbit, increasing reliance is placed on carbon fiber reinforced polymer (CFRP) composites for spacecraft structures where mass efficiency, durability, and long-term reliability are critical. In service, these materials are subjected to a combination of ultraviolet radiation, vacuum, ionizing radiation, atomic oxygen, and extreme thermal excursions under sustained mechanical loading. Flight systems such as the Boeing Starliner and SpaceX Dragon employ external composite structures that will experience these environments for extended durations. Although prior spaceflight and ground studies have reported limited changes in bulk mechanical properties, the synergistic effects of these environments on composite microstructure, particularly at the fiber matrix interphase, remain insufficiently characterized and represent a potential qualification and reliability risk. This study investigates the effects of short-term cryogenic exposure on a radiation shielding carbon epoxy composite, SC2020, as a ground-based analog for space relevant thermal extremes. The SC2020 material system has previously flown on the International Space Station under the Materials International Space Station Experiment (MISSE) program. Composite specimens were exposed to liquid nitrogen for 6 and 24 hours and evaluated using a multiscale characterization framework that combined ASTM D3039 tensile testing, Atomic Force Microscopy (AFM) based interphase analysis, and helium gas permeability measurements. Tensile testing showed no statistically significant or permanent degradation in global strength or modulus following cryogenic exposure. In contrast, AFM measurements revealed reductions in interphase modulus, weakened adhesion, and increased nanoscale heterogeneity, indicating localized degradation mechanisms not captured by conventional bulk testing. Gas permeability measurements showed a progressive increase in helium diffusion with exposure duration, consistent with micro-void formation or partial interfacial debonding. The results indicate that cryogenic exposure initiates degradation at the fiber matrix interphase while leaving global mechanical properties largely unchanged over short durations. These findings underscore the importance of multiscale diagnostics for identifying early-stage damage mechanisms that may influence long term performance and qualification margins for spaceflight composite structures. The data presented establish a cryogenic baseline for comparison with forthcoming MISSE flight exposure results and support ongoing NASA Established Program to Stimulate Competitive Research (EPSCoR) efforts aimed at improving composite qualification methodologies, risk assessment, and reliability prediction for space environments.
composite reliability↗
THE DEFINITION AND INTERPRETATION OF TERRESTRIAL ENVIRONMENT DESIGN INPUTS FOR VEHICLE DESIGN CONSIDERATIONS
The description and interpretation of the terrestrial environment (0-90 km altitude) is an important driver of aerospace vehicle structural, control, and thermal system design. NASA is currently in the process of reviewing the meteorological information acquired over the past decade and producing an update to the 1993 Terrestrial Environment Guidelines for Aerospace Vehicle Design and Development handbook. This paper addresses the contents of this updated handbook, with special emphasis on new material being included in the areas of atmospheric thermodynamic models, wind dynamics, atmospheric composition, atmospheric electricity, cloud phenomena, atmospheric extremes, sea state, etc. In addition, the respective engineering design elements will be discussed relative to the importance and influence of terrestrial environment inputs that require consideration and interpretation for design applications. Specific lessons learned that have contributed to the advancements made in the acquisition, interpretation, application and awareness of terrestrial environment inputs for aerospace engineering applications are discussed.
Johnson, Dale L.↗