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At least 505 records · Page 28

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NASA NTRS1982

Creep of plasma-sprayed-ZrO2 thermal-barrier coatings

Specimens of plasma-sprayed-zirconia thermal-barrier coatings with three different porosities and different initial particle sizes were deformed in compression at initial loads of 6900, 13,800, and 24,100 kPa (1000, 2000, and 3500 psi) and temperatures of 1100, 1250, and 1400 C. The coatings were stabilized with lime, MgO, and two different concentrations of Y2O3. Creep began as soon as the load was applied and continued at a constantly decreasing rate until the load was removed. Temperature and stabilization had a pronounced effect on creep rate while the stress, particle size, and porosity had a lesser effect. Creep deformation was due to cracking and particle sliding.

Firestone, R. F.↗

NASA NTRS1983

Development of strain tolerant thermal barrier coating systems, tasks 1 - 3

Insulating ceramic thermal barrier coatings can reduce gas turbine airfoil metal temperatures as much as 170 C (about 300 F), providing fuel efficiency improvements greater than one percent and durability improvements of 2 to 3X. The objective was to increase the spalling resistance of zirconia based ceramic turbine coatings. To accomplish this, two baseline and 30 candidate duplex (layered MCrAlY/zirconia based ceramic) coatings were iteratively evaluated microstructurally and in four series of laboratory burner rig tests. This led to the selection of two candidate optimized 0.25 mm (0.010 inch) thick plasma sprayed partially stabilized zirconia ceramics containing six weight percent yttria and applied with two different sets of process parameters over a 0.13 mm (0.005 inch) thick low pressure chamber sprayed MCrAlY bond coat. Both of these coatings demonstrated at least 3X laboratory cyclic spalling life improvement over the baseline systems, as well as cyclic oxidation life equivalent to 15,000 commercial engine flight hours.

Anderson, N. P.↗

NASA NTRS1984

Performance of thermal barrier coatings in high heat flux environments

Thermal barrier coatings were exposed to the high temperature and high heat flux produced by a 30 kW plasma torch. Analysis of the specimen heating rates indicates that the temperature drop across the thickness of the 0.038 cm ceramic layer was about 1100 C after 0.5 sec in the flame. An as-sprayed ZrO2-8%Y2O3 specimens survived 3000 of the 0.5 sec cycles with failing. Surface spalling was observed when 2.5 sec cycles were employed but this was attributed to uneven heating caused by surface roughness. This surface spalling was prevented by smoothing the surface with silicon carbide paper or by laser glazing. A coated specimen with no surface modification but which was heat treated in argon also did not surface spall. Heat treatment in air led to spalling in as early as 2 cycle from heating stresses. Failures at edges were investigated and shown to be a minor source of concern. Ceramic coatings formed from ZrO2-12%Y2O3 or ZrO2-20%Y2O3 were shown to be unsuited for use under the high heat flux conditions of this study.

Miller, R. A.↗

NASA NTRS1984

Deposition stress effects on thermal barrier coating burner rig life

A study of the effect of plasma spray processing parameters on the life of a two layer thermal barrier coating was conducted. The ceramic layer was plasma sprayed at plasma arc currents of 900 and 600 amps onto uncooled tubes, cooled tubes, and solid bars of Waspalloy in a lathe with 1 or 8 passes of the plasma gun. These processing changes affected the residual stress state of the coating. When the specimens were tested in a Mach 0.3 cyclic burner rig at 1130 deg C, a wide range of coating lives resulted. Processing factors which reduced the residual stress state in the coating, such as reduced plasma temperature and increased heat dissipation, significantly increased coating life.

Watson, J. W.↗

NASA NTRS1984

Failure analysis of plasma-sprayed thermal barrier coatings

Thermally induced failure processes of plasma-sprayed thermal barrier coatings are examined. Cracking processes give rise to noise which was monitored by acoustic emission (AE) techniques. The sequential failure of coatings was examined from samples which were thermally cycled. Coatings of yttria-stabilized zirconia with and without a NiCrAlZr bond coat were plasma-sprayed onto U700 alloy rod. In some cases the substrate was intentionally overheated during deposition of the thermal protection system to check how this process variable influenced the AE response of the specimen. In this way a qualitative appraisal of how process variables affect coating integrity could be discerned in terms of cracking behavior. Results from up to seven consecutive thermal cycles are reported here. Coating failure was observed in all cases. Failure of the thermal protection system is progressive, since cracking and crack growth were observed prior to ultimate failure. Thus castastrophic failure occurs at some stage when there is a transformation from the microcrack to a macrocrack network.

Berndt, C. C.↗

NASA NTRS1984

Interference phenomena in the refraction of a surface polariton by vertical dielectric barriers

A normal mode analysis is used to calculate the transmission and reflection coefficients for a surface polariton propagating along the interface between a surface active medium and a dielectric and incident normally on a vertical dielectric barrier of finite thickness or a thin dielectric film of finite length. The efficiencies of conversion of the surface polariton into transmitted and reflected bulk waves are also determined. The radiation patterns associated with the latter waves are presented.

Shen, T. P.↗

NASA NTRS1984

Barriers and dispersal surfaces in minimum-time interception

A method is proposed for mapping the barrier, dispersal, and control-level surfaces for a class of minimum-time interception and pursuit-evasion problems. Minimum-time interception of a target moving in a horizontal plane is formulated in a coordinate system whose origin is at the interceptor's terminal position and whose x-axis is along the terminal line of sight. This approach makes it possible to discuss the nature of the interceptor's extremals, using its extremal trajectory maps (ETMs), independently of target motion. The game surfaces are constructed by drawing sections of the isochrones, or constant minimum-time loci, from the interceptor and target ETMs. In this way, feedback solutions for the optimal controls are obtained. An example involving the interception of a target moving in a straight line at constant speed is presented.

Rajan, N.↗

NASA NTRS1984

Oxidation behavior of a thermal barrier coating

Thermal barrier coatings, consisting of a plasma sprayed calcium silicate ceramic layer and a CoCrAlY or NiCrAlY bond coat, were applied on B-1900 coupons and cycled hourly in air in a rapid-response furnace to maximum temperatures of 1030, 1100, or 1160 C. Eight specimens were tested for each of the six conditions of bond-coat composition and temperature. Specimens were removed from test at the onset of failure, which was taken to be the formation of a fine surface crack visible at 10X magnification. Specimens were weighed periodically, and plots of weight gain vs time indicate that weight is gained at a parabolic rate after an initial period where weight was gained at a much greater rate. The high initial oxidation rate is thought to arise from the initially high surface area in the porous bond coat. Specimen life (time to first crack) was found to be a strong function of temperature. However, while test lives varied greatly with time, the weight gain at the time of specimen failure was quite insensitive to temperature. This indicates that there is a critical weight gain at which the coating fails when subjected to this test.

Miller, R. A.↗

NASA NTRS1984

Acoustic emission evaluation of plasma-sprayed thermal barrier coatings

Acoustic emission techniques have recently been used in a number of studies to investigate the performance and failure behavior of plasma-sprayed thermal barrier coatings. Failure of the coating is a complex phenomena, especially when the composite nature of the coating is considered in the light of possible failure mechanisms. Thus it can be expected that both the metal and ceramic components (i.e., the bond coat and ceramic overlay) of a composite thermal protection system influence the macroscopic behavior and performance of the coating. The aim of the present work is to summarize the 'state-of-the-art' in terms of this initial work and indicate where future progress may be made.

Berndt, C. C.↗

NASA NTRS1984

An investigation of enhanced capability thermal barrier coating systems for diesel engine components

Material systems and processes for the development of effective and durable thermal barriers for heavy duty diesel engines were investigated. Seven coating systems were evaluated for thermal conductivity, erosion resistance, corrosion/oxidation resistance, and thermal shock resistance. An advanced coating system based on plasma sprayed particle yttria stabilized zirconia (PS/HYSZ) was judged superior in these tests. The measured thermal conductivity of the selected coating was 0.893 W/m C at 371 C. The PS/HYSZ coating system was applied to the piston crown, fire deck and valves of a single cylinder low heat rejection diesel engine. The coated engine components were tested for 24 hr at power levels from 0.83 MPa to 1.17 MPa brake mean effective pressure. The component coatings survived the engine tests with a minimum of distress. The measured fire deck temperatures decreased 86 C (155 F) on the intake side and 42 C (75 F) on the exhaust side with the coating applied.

Holtzman, R. L.↗

NASA NTRS1985

Thermal barrier coating system

An oxide thermal barrier coating comprises ZrO3-Yb2O3 that is plasma sprayed onto a previously applied bond coating. The zirconia is partially stabilized with about 124 w/o ytterbia to insure cubic, monoclinic, and terragonal phases.

Stecura, S.↗

NASA NTRS1984

Oxidation-based model for thermal barrier coating life

A procedure is described for modeling the lives of thermal barrier coatings subjected to high-temperatrue environments. The models is used to calculate cycles-to-failure as a function of heating cycle duration. It is based on the presumption that oxidation is the single important time-dependent factor which limits the life of these coatings, and that oxidation-induced strains combine with cyclic strains to promote slow crack growth in the ceramic layer. Good agreement is obtained between calculated and experimental lives for specimens tested in a furnace. This shows that an oxidation-based approach is promising. The importance of reproducible specimen preparation is also discussed.

Miller, R. A.↗

NASA NTRS1984

Field funneling and range straggling in partially depleted silicon surface-barrier detectors

The effects of field funneling and range straggling have been quantitatively observed in the measurement of charge collected from alpha-particle tracks in silicon surface-barrier charged-particle detectors. The method described may be used for the straight-forward measurement of charge collection from heavy ions in these and other semiconductor devices.

Zoutendyk, J. A.↗

NASA NTRS1984

Deposition stress effects on the life of thermal barrier coatings on burner rigs

Watson, J. W.↗

NASA NTRS1984

Performance of thermal barrier coatings in high heat flux environments

Thermal barrier coatings were exposed to the high temperature and high heat flux produced by a 30 kW plasma torch. Analysis of the specimen heating rates indicates that the temperature drop across the thickness of the 0.038 cm ceramic layer was about 1100 C after 0.5 sec in the flame. An as-sprayed ZrO2-8 percent Y2O3 specimens survived 3000 of the 0.5 sec cycles with falling. Surface spalling was observed when 2.5 sec cycles were employed but this was attributed to uneven heating caused by surface roughness. This surface spalling was prevented by smoothing the surface with silicon carbide paper or by laser glazing. A coated specimen with no surface modification but which was heat treated in argon also did not surface spall. Heat treatment in air led to spalling in as early as 1 cycle from heating stresses. Failures at edges were investigated and shown to be a minor source of concern. Ceramic coatings formed from ZrO2-12 percent Y2O3 or ZrO2-2O percent Y2O3 were shown to be unsuited for use under the high heat flux conditions of this study.

Miller, R. A.↗

NASA NTRS1984

Life modeling of atmospheric and low pressure plasma-sprayed thermal-barrier coating

The cycles-to-failure vs cycle duration data for three different thermal barrier coating systems, which consist of atmospheric pressure plasma-sprayed ZrO2-8 percent Y2O3 over similarly deposited or low pressure plasma sprayed Ni-base alloys, are presently analyzed by means of the Miller (1980) oxidation-based life model. Specimens were tested at 1100 C for heating cycle lengths of 1, 6, and 20 h, yielding results supporting the model's value.

Miller, R. A.↗

NASA NTRS1985

GaAs Schottky barrier photo-responsive device and method of fabrication

A gallium arsenide photo-responsive device is provided with an intermediate, transparent layer of a refractory metal or alkaline earth metal forming a tenacious bond between a non-hydroscopic oxide layer and a noble metal Schottky barrier layer. The device has a gallium arsenide substrate with a predetermined type conductivity and a gallium arsenide epitaxial layer with the same type conductivity but a lower charge carrier concentration grown on the substrate. The oxide layer is formed to cover the epitaxial layer, and the transparent metal layer followed by the noble metal layer are deposited upon the oxide layer. An interdigitated ohmic contact is then formed upon the noble metal layer.

Alcorn, G. E.↗

NASA NTRS1985

Rocket thrust chamber thermal barrier coatings

A research program was conducted to generate data and develop analytical techniques to predict the performance and reliability of ceramic thermal barrier coatings in high heat flux environments. A finite element model was used to analyze the thermomechanical behavior of coating systems in rocket thrust chambers. Candidate coating systems (using a copper substrate, NiCrAlY bond coat and ZrO2.8Y2O3 ceramic overcoat) were selected for detailed study based on photomicrographic evaluations of experimental test specimens. The effects of plasma spray application parameters on the material properties of these coatings were measured and the effects on coating performance evaluated using the finite element model. Coating design curves which define acceptable operating envelopes for seleted coating systems were constructed based on temperature and strain limitations. Spray gun power levels was found to have the most significant effect on coating structure. Three coating systems were selected for study using different power levels. Thermal conductivity, strain tolerance, density, and residual stress were measured for these coatings. Analyses indicated that extremely thin coatings ( 0.02 mm) are required to accommodate the high heat flux of a rocket thrust chamber and ensure structural integrity.

Batakis, A. P.↗