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At least 505 records · Page 28
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Microstructure Investigation and Mechanical Properties of Coated Zircaloy Cladding

Accident Tolerant Fuel concepts have been developed and tested in diverse research programs presently around the world. Industry teams have developed proprietary coating compositions and geometries, but significant knowledge gaps exist in terms of the resulting properties of the coating and the cladding and how those components impact each other in reactor conditions. Furthermore, the national laboratory and university teams currently studying the industry concepts are limited in their ability to freely disseminate and discuss results obtained on commercial coatings. The Advanced Fuels Campaign is therefore working to develop an understanding of ‘generic’ coatings applied to commercial nuclear cladding alloys free of these constraints. This milestone report provides insights in the microstructure of a 7-micrometer Cr coating on Zircaloy-2 and a 5- micrometer coating on Zry-4 as reference materials. SEM and TEM methods were utilized to describe and identify the interface, while nanoindentation was used to determine hardness and E-Moduli of coating and cladding material. This milestone summarizes the acquired knowledge to build a necessary verified foundation for future simulation and qualification efforts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Development of Standardized Property Requirements, Measurement Methods, and Reporting Guidance for Coatings

The diverse research programs presently in progress around the world have advanced a large number of coated cladding concepts to various stages of maturity. Industry teams have developed leading coating compositions and geometries, but significant disparity exists in the importance placed on different coating properties, as well as the applicability and standardization of the various methods used to measure these properties. This milestone report provides an initial assessment of the most important coating properties and the experimental methods available for their determination to lay the foundation for standardized reporting and development of comprehensive datasets for modeling efforts. This report has determined that the residual stress of the coating is the most crucial property to investigate, yet it has received minimal attention to date due to a knowledge gap about the growth and formation of the brittle Laves phase under reactor conditions. The significance of residual stress of the coating is further enhanced by its connection and interdependence with other important properties like creep and coating failure mechanisms. This milestone proposes an importance rating for residual stress properties and their associated measurement techniques to fill in knowledge. Furthermore, techniques to investigate the outlined properties are discussed, and their capabilities and limitations are illustrated to provide guidance on their use.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

High Temperature Thermal Barrier Coating Evaluation of Yttrium Aluminum Garnet for Gas Turbine Applications

The Solution Precursor Spray Process (SPPS) process has been shown to overcome the durability and property challenges of applying yttrium aluminum garnet (YAG) coating for high temperature thermal barrier coating (TBC) applications (1200°C+) but only limited testing has been performed in representative application environments. In this study, YAG coatings were developed to optimize microstructure and tailor properties for combustion components in an industrial gas turbine. Thermal conductivity, erosion resistance and furnace cycling durability were used to validate YAG properties against the standard yttria-stabilized zirconia coating (YSZ). Graded and multi-layered microstructures were applied to enhance performance while maintaining durability. Further YAG process development was required to replicate coating properties and optimize deposition on more complex fuel injector nozzle and combustion liner components. Rig testing of both components was performed and compared against the baseline YSZ coating validating the high temperature capability and lower thermal conductivity of the SPPS YAG coating. The components in both tests were cycled for a minimum of ten cycles with the fuel injector test targeting a higher operating temperature while the combustor liner operated at standard conditions. A development engine test is planned to further validate performance in a gas turbine engine of this promising material.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Enhancing Steam-Side Heat Transfer via Microdroplet Ejection using Inorganic Coatings

During condensation of water on a superhydrophobic nanostructured surfaces, droplets coalesce and jump (droplet ejection) due to the release of excess surface energy. Meticulously designed nanostructured surfaces or coatings capable of droplet ejection can enhance heat transfer performance by easy removal of droplets during condensation. In the present work, the capabilities of the Nelumbo droplet ejection coatings technology currently used in commercial heat exchangers are explored and optimized for materials and conditions relevant to steam condensers. Specifically, this includes (1) adapting and optimizing the procedures and chemistries to deposit droplet ejecting coatings on materials used in the steam condenser, (2) testing of the heat transfer, durability, and fouling of the fabricated coatings under a variety of steam condenser relevant conditions, and (3) modeling of the impact of droplet dynamics and interfacial properties on heat transfer in steam condensers. We experimentally demonstrated that at low supersaturation conditions (S~1.02), developed superhydrophobic nanostructured surface gives a 40% higher peak heat transfer flux and a 17% higher peak overall heat transfer coefficient (U) with droplet ejection mechanism compared to the dropwise condensation mechanism on the same nanostructured surface. Though the experimentally observed droplet ejection mechanism was short-lived (~3 min) due to the limitation of the chiller to maintain a constant supersaturation condition in fabricated steam condenser. And large variations in water inlet temperature (+ to - 2 degrees C) caused flooding of nanostructure (Wenzel state) at higher supersaturation (S > or = 1.12). This is an important finding because typical supersaturation levels in field operation are over 1.8 and as such, either the flooding potential for these materials should be improved or operation at lower supersaturation may be required to maximize heat transfer efficiency. If supersaturation conditions can be maintained reliably in the steam condenser in addition to droplet ejection mechanism during condensation, this could provide a potential 2% reduction in water flow rate which equates to a savings of over 3900 gallons of water per minute for a 500 MW steam turbine and over $0.3MM savings annually given a 0.02 cent marginal water withdrawal cost. It is also worth noting that these savings are based on improvement of droplet ejection coatings over coatings capable of performing consistent dropwise mechanism in in-field surface condensers. Savings due to the droplet ejections coatings when compared to bare substrates could be much higher. Additionally, the present work provides the importance of steam condenser operating conditions and insights into the challenges in modeling the condensing droplet dynamics on surfaces.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Ultra-High Temperature Thermal Barrier Coating Development and Validation

The most effective method to improve industrial gas turbine power is to increase firing temperature. To maintain component durability at these higher temperatures, thermal barrier coatings (TBC’s) are playing an increasing role in protecting turbine hardware. TBC’s have been successfully used on Solar Turbines’ combustor liners and turbine airfoils, but there is a need for TBC’s that can operate at higher temperatures. Based on recent, favorable rig testing experience, Solar recognized that yttrium aluminum garnet (YAG) TBC’s made by the Solution Precursor Plasma Spray Process (SPPS) has great potential for higher turbine temperatures. This testing verified the thermal cycle durability of the SPPS YAG TBC’s, as well as demonstrated that the temperature drop through the SPPS YAG TBC was twice that measured across a companion APS YSZ TBC. The SPPS YAG TBC with the potential for a 200°C improvement in temperature capability represents a materials breakthrough. The SPPS process also produces a number of unique microstructural features that confer superior properties. SPPC TBC’s have ultra-fine splats that increase toughness and erosion resistance, and the process can be tailored to produce through-thickness cracks for strain-tolerance and control porosity for lower thermal conductivity and increase coating abradability. This proposal would include further development of SPPS YAG density-graded coatings, optimization of the application process, and validation of higher temperature capability and durability through rig and engine testing of coated combustion liners and turbine outer air seals. The technology would be advanced from a TRL 3 to a proposed TRL 6 by overcoming processing concerns on efficiency, application distance and optimization of a graded coating without impacting coating durability by demonstrating the coating performance on components in rig and development gas turbine engine testing.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Temperature-Following Thermal Barrier Coatings for High Efficiency Engines (Final Report)

HRL Laboratories and General Motors (GM), pursued this effort to increase the efficiency of internal combustion engines (ICEs) by developing and implementing temperature-following thermal barrier coatings (TBCs) to decrease heat loss from the combustion chamber. HRL developed microsphere TBCs based on hollow high-temperature alloy spheres with average diameter of 50 μm and wall thickness ~1 μm (microspheres) that achieve unprecedented low thermal conductivity and heat capacity (10X lower than the state of the art) while offering exceptional environmental and mechanical resistance.> In current ICEs, approximately 29% of the fuel’s energy is lost to the cooling system and about 22% goes into moving the car. By limiting heat losses from the combustion chamber with insulating coatings, fuel energy can be redirected into additional piston work and into the exhaust stream. The additional energy that goes into the exhaust stream can be turned into useful work through the use of an exhaust energy recovery device, such as turbocompounding and/or through driving a turbocharger to increase the power density of the engine allowing downsizing. Insulating coatings for piston crowns have been pursued in the past, but previous materials—typically ceramics—exhibited low thermal conductivity but retained high heat capacity. Such materials reduce heat losses but stabilize at a high surface temperature. The high surface temperature heats the incoming gases, which lowers volumetric efficiency and increases propensity for knock, resulting in degraded engine performance. This program developed an innovative new material that combines low thermal conductivity with low heat capacity. These unique properties allow it to follow rapid changes in gas temperature during each combustion cycle. A metallic microsphere TBC has been demonstrated that exhibits increased surface temperature during the combustion period, resulting in reduced heat transfer losses, while still returning to a low surface temperature during the gas exchange period. A 10X lower thermal conductivity and heat capacity than state-of-the-art thermal barrier coatings has been demonstrated. These unprecedented thermal properties are achieved through the coating architecture, which consists of closed pores on the microscale and exhibits a total porosity of 90% to 95%. By selecting a high-temperature nickel alloy as the coating material, the ductility and strength of metals can be harnessed to achieve much better durability and damage tolerance than brittle ceramic coatings can achieve.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Managing Sn-supply to tune surface characteristics of vapor-diffusion coating of Nb3Sn

Nb₃Sn promises better RF performance (Q and E_{acc}) than niobium at any given temperature because of superior superconducting properties. Nb₃Sn-coated SRF cavities are now produced routinely by growing a few microns thick Nb₃Sn films inside Nb cavities via the tin vapor diffusion technique. Sn evaporation and consumption during the growth process notably affect the quality of the coating. Aiming at favorable surface characteristics that could enhance the RF performance, many coatings were produced by varying Sn sources and temperature profiles. Coupon samples were examined using different material characterization techniques, and a selected few sets of coating parameters were used to coat 1.3 GHz single-cell cavities for RF testing. The Sn supply’s careful tuning is essential to manage the microstructure, roughness, and overall surface characteristics of the coating. We summarize the material analysis of witness samples and discuss the performance of several Nb₃Sn-coated single-cell cavities linked to Sn-source characteristics and observed Sn consumption during the film growth process.

Pudasaini, U.↗
DOE OSTI2022

In-situ optical monitoring of gas turbine blade coatings under operational extreme environments

High temperature material systems consisting of thermal barrier coatings and the underlying superalloys are key to achieving higher gas temperatures which in turn control engine efficiencies and reduce emissions. With engine temperatures in excess of the limits that metallic blades and vanes can endure, advanced monitoring techniques that ensure the integrity and durability of these coatings are paramount to continuous and safe operation. Optical methods have the benefit of being non-invasive and are able to capture data under limited access available for monitoring the hot-section of turbines. Addressing Topic 5 on Advanced Instrumentation, the research and development effort for this project titled “In situ optical monitoring of gas turbine blade coatings under operational extreme environments” was completed by University of Central Florida researchers, including Raghavan (PI) and Ghosh (co-PI). In this project, the research team leveraged intrinsic properties of coatings and rare-earth dopants as active and intelligent “sensors” through their optical properties. The outcomes of this project pave the way for diagnostics of turbine blade coatings, under operating environments, through the development of the sensing thermal barrier coating configurations, calibration and associated instrumentation while ensuring coating integrity and durability goals are concurrently met.

42 ENGINEERING↗
DOE OSTI2023

Development of Hydrogen Permeation Barrier and Matrix Interaction Protection Coatings for TZM Enclosure of Hydride Moderators (Microreactor Program M3 Report)

It is important to develop a high-performance enclosure solution for hydride-based microreactor moderation components to effectively suppress hydride thermal decomposition and prevent hydrogen loss in harsh in-reactor environments. Currently, the DOE-NE Microreactor Program (MR program) is investigating the titanium-zirconium-molybdenum (TZM) canned yttrium hydride (YH 2-x ) solution, which provides acceptable hydrogen retainment performance up to ~700 °C. However, improvements in the enclosure are necessary for increasing long-term operation temperature beyond 700 °C and enhancing short-term survivability at even higher temperatures during power transients. One potential solution is the addition of a dedicated hydrogen permeation barrier, which can potentially improve the enclosure's performance. Furthermore, the hydride moderator components will be inserted into the microreactor matrix, which may consist of materials that are not chemically inert against TZM. Therefore, the TZM might need to be protected from the external environment through the application of another surface protection coating. To address these critical issues, two types of barrier coatings optimized for TZM-based moderator enclosure has been developed. A multilayer coating approach has been used to identify TZM-compatible barrier materials. Behavior of these coating designs against H 2 permeation and long-term high-temperature graphite matrix interactions has been examined in detail. Additionally, the developed coatings' behavior when exposed to both high-temperature thermal cycling and heavy-ion irradiation has also been investigated. Overall, the development of these barrier coatings is essential for achieving maturity for the metal hydride moderator technology. The results in this report will provide crucial insights into the behavior of the developed coatings and their potential for improving the long-term performance of TZM-based moderator enclosures.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Strain to failure measurements of Cr coatings with different processing

Differently processed Cr coatings on Zircaloy cladding were assessed for coating strain to failure. This report includes i) quantification of Cr coating strain to failure for several coating variants, ii) incorporation of high throughput analysis developed utilizing artificial intelligence, and iii) develop a hoop direction coating strain to failure testing approach for high temperatures that doesn’t require digital image correlation strain measurements. Room temperature strain to failure measurements indicated that heat treatment had an impact on strain to failure of the coating, with increasing heat treatment temperature increasing the average strain to failure of the Cr coating.

36 MATERIALS SCIENCE↗
NASA NTRS1974

Refinement in black chrome for use as a solar selective coating

Black chrome is significant as a solar selective coating because the current extensive use of black chrome in the electroplating industry as a durable decorative finish makes black chrome widely available on a commercial scale and potentially low in cost as a solar selective coating. Black-chrome deposits were modified by underplating with dull nickel or by being plated on rough surfaces. Both of these procedures increased the visible absorptance. There was no change in the infrared reflectance for the dull-nickel - black-chrome combination from that reported for the bright-nickel - black-chrome combination. However, the bright-nickel - black-chrome coating plated on rough surfaces indicated a slight decrease in infrared reflectance. As integrated over the solar spectrum for air mass 2, the reflectance of the dull-nickel - black-chrome coating was 0.077, of the bright-nickel - black-chrome coating plated on a 0.75-micron (30-microinch) surface was 0.070, of the bright-nickel - black-chrome coating plated on a 2.5 micron (100-microinch) surface was 0.064. The corresponding values for the bright-nickel - black-chrome coating on a 0.0125-micron (0.5-microinch) surface, two samples of black nickel, and two samples of Nextrel black paint were 0.132, 0.123, 0.133, and 0.033, respectively.

Mcdonald, G. E.↗
NASA NTRS1976

Development of an improved coating for polybenzimidazole foam

An improved coating system was developed for Polybenzimidazole (PBI) foam to provide coating stability, ruggedness, moisture resistance, and to satisfy optical property requirements (alpha sub (s/epsilon) or = 0.4 and epsilon 0.8) for the space shuttle. The effort was performed in five tasks: Task 1 to establish material and process specifications for the PBI foam, and material specifications for the coatings; Task 2 to identify and evaluate promising coatings; Task 3 to establish mechanical and thermophysical properties of the tile components; Task 4 to determine by systems analysis the potential weight trade-offs associated with a coated PBI TPS; and Task 5 to establish a preliminary quality assurance program. The coated PBI tile was, through screening tests, determined to satisfy the design objectives with a reduced system weight over the baseline shuttle silica LRSI TPS. The developed tile provides a thermally stable, extremely rugged, low thermal conductivity insulator with a well characterized optical coating.

Neuner, G. J.↗
NASA NTRS1976

Two-layer thermal barrier coating for turbine airfoils - furnace and burner rig test results

A simple, two-layer plasma-sprayed thermal barrier coating system was developed which has the potential for protecting high temperature air-cooled gas turbine components. Of those coatings initially examined, the most promising system consisted of a Ni-16Cr-6Al-0.6Y (in wt%) thermal barrier coating (about 0.005 to 0.010 cm thick) and a ZrO2-12Y2O3 (in wt%) thermal barrier coating (about 0.025 to 0.064 cm thick). This thermal barrier substantially lowered the metal temperature of an air-cooled airfoil. The coating withstood 3,200 cycles (80 sec at 1,280 C surface temperature) and 275 cycles (1 hr at 1,490 C surface temperature) without cracking or spalling. No separation of the thermal barrier from the bond coating or the bond coating from the substrate was observed.

Stecura, S.↗
NASA NTRS1977

Two-layer thermal barrier coating for high temperature components

A simple two-layer plasma-sprayed thermal barrier coating system was developed which has the potential for protecting high temperature air-cooled gas turbine components. Of the initially examined coatings, the most promising system is an Ni-16Cr-6Al-0.6Y (in wt%) bond coating (about 0.005 to 0.010 cm thick) and a ZrO2-12Y2O3 (in wt%) thermal barrier coating (about 0.025 to 0.064 cm thick). This thermal barrier substantially lowered the metal temperature of the air-cooled airfoil. The coating withstood 3200 cycles (80 s at 1280 C surface temperature) and 275 cycles (1 hr at 1490 C surface temperature) without cracking or spalling. No separation of the thermal barrier from the bond coating or the bond coating from the substrate was observed.

Stecura, S.↗
NASA NTRS1978

Development of sputtering process to deposit stoichiometric zirconia coatings for the inside wall of regeneratively cooled rocket thrust chambers

Thermal barrier coatings of yttria stabilized zirconia and zirconia-ceria mixtures were deposited by RF reactive sputtering. Coatings were 1-2 mils thick, and were deposited on copper cylinders intended to simulate the inner wall of a regeneratively cooled thrust chamber. Coating stoichiometry and adherence were investigated as functions of deposition parameters. Modest deposition rates (approximately 0.15 mil/hr) and subambient sustrate temperatures (-80 C) resulted in nearly stoichiometric coatings which remained adherent through thermal cycles between -196 and 400 C. Coatings deposited at higher rates or substrates temperatures exhibited greater oxygen deficiences, while coatings deposited at lower temperatures were not adherent. Substrate bias resulted in structural changes in the coating and high krypton contents; no clear effect on stoichiometry was observed.

Busch, R.↗
NASA NTRS1979

Wide-temperature-spectrum self-lubricating coatings prepared by plasma spraying

Self-lubricating, multicomponent coatings, which lubricate over a wide range of operating conditions, are described. The coatings were successfully applied by plasma-spraying mixed powders onto superalloy substrates. They were evaluated in friction and wear experiments, and in sliding contact bearing tests. These coatings are wear resistant by virtue of their self lubricating characteristics rather than because of extreme hardness; a further benefit is low friction. Experiments with simple pin on disk sliding specimens and oscillating plain cylindrical bearing tests were performed to evaluate the tribological properties of the coatings. It was shown that coatings of nichrome, glass and calcium fluoride are self-lubricating from about 500 to 900 C, but give high friction at the lower temperatures. The addition of silver to the coating composition improved the low temperature bearing properties and resulted in coatings which are self-lubricating from cryogenic temperatures to at least 870 C; they are therefore, wide temperature spectrum, self-lubricating compositions.

Sliney, H. E.↗
NASA NTRS1979

Internally coated air-cooled gas turbine blading

Ten candidate modified nickel-aluminide coatings were developed using the slip pack process. These coatings contain additives such as silicon, chromium and columbium in a nickel-aluminum coating matrix with directionally solidified MAR-M200 + Hf as the substrate alloy. Following a series of screening tests which included strain tolerance, dynamic oxidation and hot corrosion testing, the Ni-19A1-1Cb (nominal composition) coating was selected for application to the internal passages of four first-stage turbine blades. Process development results indicate that a dry pack process is suitable for internal coating application resulting in 18 percent or less reduction in air flow. Coating uniformity, based on coated air-cooled blades, was within + or - 20 percent. Test results show that the presence of additives (silicon, chromium or columbium) appeared to improve significantly the ductility of the NiA1 matrix. However, the environmental resistance of these modified nickel-aluminides were generally inferior to the simple aluminides.

Hsu, L.↗
NASA NTRS1979

Effects of yttrium, aluminum, and chromium concentrations in bond coatings on the performance of zirconia-yttria thermal barriers

A cyclic furnace study was conducted between 990 - 280 C and 1095 - 280 C to evaluate the effects of yttrium, chromium, and aluminum concentrations in nickel base alloy bond coatings and also the effect of the bond coating thickness on the performance of yttria-stabilized zirconia thermal barrier coatings. The presence and the concentration of yttrium is very critical. Without yttrium, rapid oxidation of Ni-Al, Ni-Cr, and Ni-Cr-Al bond coatings causes zirconia thermal barrier coatings to fail very rapidly. Concentrations of chrominum and aluminum in Ni-Cr-Al-Y bond coating have a very significant effect on the thermal barrier coating life. This effect, however, is not as great as that due to yttrium. Furthermore, the thickness and the thickness uniformity also have a very significant effect on the life of the thermal barrier system.

Stecura, S.↗