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At least 523 records · Page 29

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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 have been successfully applied by plasma-spraying mixed powders onto superalloy substrates. They have been 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 NTRS1980

An experimental, low-cost, silicon-aluminide high-temperature coating for superalloys

An evaluation of a duplex silicon-slurry/aluminide coating is presented. The coating is cyclically tested in Mach 1 combustion gases for oxidation and thermal fatigue resistance at 1093 C and in Mach 0.3 gases for hot-corrosion resistance at 900 C. The base metal superalloys are ViA and B-1900. The coated B-1900 specimens performed much better in oxidation than similar specimens coated with aluminides and almost as well as the more expensive Pt-Al and MCrAlY (where M is Ni and/or Co) coatings deposited by the physical vapor deposition process. The coating also provided good hot corrosion protection. Metallographic, X-ray, and electron microprobe studies are used to characterize the coating, determine failure mechanisms, and study some of the changes due to exposure.

Young, S. G.↗

NASA NTRS1979

Development of high viscosity coatings for advanced Space Shuttle applications

Laboratory studies for increasing the thermal resistance of high viscosity coatings for silica reusable surface insulation are presented. The coatings are intended for the reentry temperature associated with advanced Space Shuttle applications which will involve aerodynamic shear forces during entry from earth orbits. Coating viscosity was increased by (1) reduction in the concentration of the low viscosity additive B2O3; (2) reduction in the particle size of the constituent powders in coatings; and (3) addition of a high viscosity glass former (GeO2). A coating system was produced by combining the three methods which showed apparent higher viscosity than the current coating, while satisfying all the current Shuttle Orbiter coating requirements.

Garofalini, S. H.↗

NASA NTRS1981

Degradation of a two-layer thermal barrier coating under thermal cycling

A two-layer plasma-sprayed thermal barrier coating on a directionally solidified nickel-base eutectic alloy substrate was characterized prior to and after thermal cycling to 1095 C in an accelerated furnace test. The coating was comprised of an inner layer of Ni-16.4Cr-5.1Al-0.15Y (wt%) bond coat and an outer layer of ZrO2-7.9Y2O3 (wt%) thermal barrier. Characterization of the bond coat revealed that substantial amounts of yttrium and aluminum were oxidized during plasma-spraying in air. The oxidation of these elements reduced the protective capacity of the bond coat so that, on thermal exposure, severe degradation of the bond coat resulted and large amounts of nickel oxide formed. This nickel oxide was demonstrated to grow outward into the thermal barrier, which appears to have increased the stresses in the thermal barrier and contributed to its failure near the thermal barrier-bond coat interface.

Maier, R. D.↗

NASA NTRS1981

Thermal barrier coatings for thermal insulation and corrosion resistance in industrial gas turbine engines

Four thermal barrier coatings were subjected to a 500-hour gas turbine engine test. The coatings were two yttria stabilized zirconias, calcium ortho silicate and calcium meta titanate. The calcium silicate coating exhibited significant spalling. Yttria stabilized zirconia and calcium titanate coatings showed little degradation except in blade leading edge areas. Post-test examination showed variations in the coating due to manual application techniques. Improved process control is required if engineering quality coatings are to be developed. The results indicate that some leading edge loss of the coating can be expected near the tip.

Vogan, J. W.↗

NASA NTRS1981

Progress in Protective Coatings for Aircraft Gas Turbines: A Review of NASA Sponsored Research

Problems associated with protective coatings for advanced aircraft gas turbines are reviewed. Metallic coatings for preventing titanium fires in compressors are identified. Coatings for turbine section are also considered, Ductile aluminide coatings for protecting internal turbine-blade cooling passage surface are also identified. Composite modified external overlay MCrAlY coatings deposited by low-pressure plasma spraying are found to be better in surface protection capability than vapor deposited MCrAlY coatings. Thermal barrier coating (TBC), studies are presented. The design of a turbine airfoil is integrated with a TBC, and computer-aided manufacturing technology is applied.

Merutka, J. P.↗

NASA NTRS1982

Ceramic thermal barrier coatings for gas turbine engines

The results of studies concerning the high temperature corrosion resistance of ZrO2-Y2O3, ZrO2-MgO, and Ca2SiO4 plasma-sprayed coatings, which may be used as gas turbine engine thermal barriers, are reported. The coatings were evaluated in atmospheric burner rig and pressurized passage tests, using GT No. 2 fuel in pure form and with sodium, sulfur and vanadium corrosive impurities doping. It is found that, while the coatings performed well in both pressurized passage and burner rig tests with pure fuel chemical reactions between the ceramic coatings and combustion gases/condensates resulted in coating degradation with impure fuels. Chemical reactions between the ceramic coatings and vanadium compounds played a critical role in coating degradation.

Bratton, R. J.↗

NASA NTRS1982

Processing of fused silicide coatings for carbon-based materials

The processing and oxidation resistance of fused Al-Si and Ni-Si slurry coatings on ATJ graphite was studied. Ni-Si coatings in the 70 to 90 percent Si range were successfully processed to melt, wet, and bond to the graphite. The molten coatings also infiltrated the porosity in graphite and reacted with it to form SiC in the coating. Cyclic oxidation at 1200 C showed that these coatings were not totally protective because of local attack of the substrate, due to the extreme thinness of the coatings in combination with coating cracks.

Smialek, J. L.↗

NASA NTRS1983

Improved performance thermal barrier coatings

Thermal barrier coatings offer an attractive approach to improving the durability and efficiency of the hot section of heat engines. The coatings typically consist of an inner alloy bond coating about 0.01 cm thick resistant to oxidation and hot corrosion and an outer ceramic layer, usually a stabilized zirconia, 0.01-0.05 cm thick. Here, the materials, thermomechanical stress, and hot corrosion problems associated with thermal barrier coatings are reviewed along with the capabilities and limitations of current technology. The coatings discussed include ZrO2-Y2O3/NiCrAlY, ZrO2-Y2O3/NiCoCrAlY, ZrO2-MgO/NiCoCrAlY, CaO-SiO2/Co-Cr-Al-Y, and CaO-SiO2/NiCrAlY systems. It is emphasized that the performance of thermal barrier coatings is governed by many complex and interrelated factors, so that optimization of these coatings always involves certain tradeoffs.

Levine, S. R.↗

NASA NTRS1984

Durable solid lubricant coatings for foil gas bearings to 315 deg C

The durability and friction characteristics of bonded solid lubricant films on compliant gas bearings were measured. Coating compositions, which were judged to be suitable for use to at least 315 C, were selected for this study. Most of the data were obtained with polyimide-bonded graphite fluoride coatings and with silicate-bonded graphite coatings. These coatings were applied to the bore of Inconel 750 foil bearings. The journals were A286 stainless steel, with a rms surface finish of 0.2 microns. The foils were subjected to repeated start/stop cycles under a 14 kPa (2 psi) bearing unit load. Sliding contact occurred during lift-off and coast down at surface velocities less than 6 m/s (3000 rpm). Testing continued until 9000 cycles were accumulated or until a rise in starting torque indicated that the coating had failed. The coatings were evaluated in the temperature range from 25 C to 315 C. Comparisons in coating performance as well as discussions of their properties and methods of application are given.

Wagner, R. C.↗

NASA NTRS1984

Sputtering as a Technique for Applying Tribological Coatings

Friction and wear induced mechanical failures may be controlled to extend the life of tribological components through the interposition of selected solid materials between contacting surfaces. Thin solid films of soft and hard materials are appropriate to lower friction and enhance the wear resistance of precision tribo-elements. Thin film coating technologies that have been developed may be used to interpose thin solid layers between contacting surfaces to reduce friction or to extend wear life. Film deposition technologies developed include chemical vapor deposition (CVD) and physical vapor deposition (PVD). Sputter coating is a PVD process for thin film deposition. It allows close control of coating thickness and composition and is well-suited for the deposition of tribological coatings. In this paper, the utility of magnetron sputtering for the deposition of tribological coatings is examined. Experimental results obtained when coated bodies are tested under a number of tribological operating conditions are presented. It is shown that when film adhesion problems are resolved, sputtering can be an effective means of depositing tribological coatings.

S Ramalingam↗

NASA NTRS1984

Overlay metallic-cermet alloy coating systems

A substrate, such as a turbine blade, vane, or the like, which is subjected to high temperature use is coated with a base coating of an oxide dispersed, metallic alloy (cermet). A top coating of an oxidation, hot corrosion, erosion resistant alloy of nickel, cobalt, or iron is then deposited on the base coating. A heat treatment is used to improve the bonding. The base coating serves as an inhibitor to interdiffusion between the protective top coating and the substrate. Otherwise, the protective top coating would rapidly interact detrimentally with the substrate and degrade by spalling of the protective oxides formed on the outer surface at elevated temperatures.

Gedwill, M. A.↗

NASA NTRS1983

Processing of fused silicide coatings for carbon-based materials

Smialek, J. L.↗

NASA NTRS1983

Anisotropic thermal expansion effects in plasma-sprayed ZrO2-8 percent Y2O3 coatings

The thermal expansion properties of plasma-sprayed ZrO2-8-wt pct Y2O3 coatings, detached from the substrate, have been examined. Coatings were heat-treated in air or in argon. Anisotropic effects in the longitudinal (planar to the substrate surface) and transverse (perpendicular to the substrate surface) directions were measured and related to the coating structure. The thermal expansion coefficient of the coating is discussed in terms of the material's properties, such as the crack network and interlamellar boundary distribution. A precise model for the expansion behavior of coatings still needs attention, since no description of all of the contributing variables exists. A quantitative analysis of thermal properties of coatings will aid in future design and modeling of coating systems.

Berndt, C. C.↗

NASA NTRS1985

Experimental test program for evaluation of solid lubricant coating as applied to compliant foil gas bearings to 315 deg C

An experimental apparatus and test procedure was developed to compare the performance of two solid lubricant coatings for air lubricated compliant foil gas bearings in the temperature range of 25 to 315 C. Polyimide bonded additive (SBGC) were tested extensively for durability and frictional characteristics. A partial arc bearing constructed of Inconel X-750 was coated on the bore with one of these coatings. The foil was subjected to repeated start/stop cycles. Performance comparisons reveal that although both coatings survive thousands of start/stop cycles, only the PBGF coated bearing achieves the specified 9000 start/stops. There is enough wear on the SBGC coated bearing to warrant termination of the test prior to 9000 start/stop cycles due to coating failure. The frictional characteristics of the PBGF are better at the elevated temperatures than at lower temperatures; a marked increase in sliding friction occurs as the temperature decreases. The SBGC maintains relatively constant frictional characteristics independent of operating temperature.

Wagner, R. 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 NTRS1983

Energy efficient engine, high pressure turbine thermal barrier coating. Support technology report

This report describes the work performed on a thermal barrier coating support technology task of the Energy Efficient Engine Component Development Program. A thermal barrier coating (TBC) system consisting of a Ni-Cr-Al-Y bond cost layer and ZrO2-Y2O3 ceramic layer was selected from eight candidate coating systems on the basis of laboratory tests. The selection was based on coating microstructure, crystallographic phase composition, tensile bond and bend test results, erosion and impact test results, furnace exposure, thermal cycle, and high velocity dynamic oxidation test results. Procedures were developed for applying the selected TBC to CF6-50, high pressure turbine blades and vanes. Coated HPT components were tested in three kinds of tests. Stage 1 blades were tested in a cascade cyclic test rig, Stage 2 blades were component high cycle fatigue tested to qualify thermal barrier coated blades for engine testing, and Stage 2 blades and Stage 1 and 2 vanes were run in factory engine tests. After completion of the 1000 cycle engine test, the TBC on the blades was in excellent condition over all of the platform and airfoil except at the leading edge above midspan on the suction side of the airfoil. The coating damage appeared to be caused by particle impingement; adjacent blades without TBC also showed evidence of particle impingement.

Duderstadt, E. C.↗

NASA NTRS1983

Failure during thermal cycling of plasma-sprayed thermal barrier coatings

The thermal cycling behavior of plasma-sprayed ZrO2-12 wt pct Y2O3 coatings was studied. Coatings were produced with and without bond coats of Ni-Cr-Al-Zr and in some cases the substrates were heated to above the optimum temperature prior to spraying. The coatings (attached to the substrate) were thermal cycled to 1200 C and their cracking behavior was followed by acoustic emission (AE) techniques. It was possible to examine the failure mechanisms by statistical analysis of the AE data and to evaluate the influence of preheating and bond coating. It is shown that the AE spectrum changes when a bond coat is used because of the presence of microcracks which, in turn, dissipate energy and improve the coating integrity. The preheating effect is reflected by a decrease in the peak count rate and an increase in the temperature at which AE activity is initiated.

Berndt, C. C.↗