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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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At least 541 records · Page 30
All sourcesNASA NTRSDOE OSTI
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

Experimental study of ceramic coated tip seals for turbojet engines

Ceramic gas-path seals were fabricated and successfully operated over 1000 cycles from flight idle to maximum power in a small turboshaft engine. The seals were fabricated by plasma spraying zirconia over a NiCoCrAlX bond boat on the Haynes 25 substrate. Coolant-side substrate temperatures and related engine parameters were recorded. Post-test inspection revealed mudflat surface cracking with penetration to the ceramic bond-coat interface.

Biesiadny, T. J.↗
NASA NTRS1985

Long-life high performance fuel cell program

A multihundred kilowatt Regenerative Fuel Cell for use in a space station is envisioned. Three 0.508 sq ft (471.9 cm) active area multicell stacks were assembled and endurance tested. The long term performance stability of the platinum on carbon catalyst configuration suitability of the lightweight graphite electrolyte reservoir plate, the stability of the free standing butyl bonded potassium titanate matrix structure, and the long life potential of a hybrid polysulfone cell edge frame construction were demonstrated. A 18,000 hour demonstration test of multicell stack to a continuous cyclical load profile was conducted. A total of 12,000 cycles was completed, confirming the ability of the alkaline fuel cell to operate to a load profile simulating Regenerative Fuel Cell operation. An orbiter production hydrogen recirculation pump employed in support of the cyclical load profile test completed 13,000 hours of maintenance free operation. Laboratory endurance tests demonstrated the suitability of the butyl bonded potassium matrix, perforated nickel foil electrode substrates, and carbon ribbed substrate anode for use in the alkaline fuel cell. Corrosion testing of materials at 250 F (121.1 C) in 42% wgt. potassium identified ceria, zirconia, strontium titanate, strontium zirconate and lithium cobaltate as candidate matrix materials.

Martin, R. E.↗
NASA NTRS1985

Tape casting as an approach to an all-ceramic turbine shroud seal

Gas path seals have a one-dimensional variation in material requirement. Tape casting is a method which allows the fabrication of thin ceramic sheets, which may be laminated to accommodate these requirements. Using tape casting, thin sheets of zirconia (0.25 mm) were fabricated. These castings were successfully laminated and fired without bloating or delamination, demonstrating the feasibility of this approach.

Cawley, J. D.↗
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

Solar tests of aperture plate materials for solar thermal dish collectors

If a malfunction occurs in a solar thermal point-focus distributed receiver power plant while a concentrator is pointed at the sun, motion of the concentrator may stop. As the sun moves relative to the earth, the spot of concentrated sunlight then slowly walks off the receiver aperture, across the receiver face plate, and perhaps across adjacent portions of the concentrator. Intense local heating by the concentrated sunlight may damage or destroy these parts. The behavior of various materials under conditions simulating walk-off of a parabolic dish solar collector were evaluated. Each test consisted of exposure to concentrated sunlight at a peak flux density of about 7000 kW/square meter for 15 minutes. Types of materials tested included graphite, silicon carbide, silica, various silicates, alumina, zirconia, aluminum, copper, steel, and polytetrafluroethylene. The only material that neither cracked nor melted was grade G-90 graphite. Grade CS graphite, a lower cost commercial grade, cracked half-way across, but did not fail apart. Both of these grades are medium-grain extruded graphites. A graphite cloth (graphitized polyacrylonitrile) showed fair performance when tested as a single thin ply; it might be useful as a multi-ply assembly. High purity slipcast silica showed some promise also.

Jaffe, L. D.↗
NASA NTRS1984

Solar tests of aperture plate materials for solar thermal dish collectors

If a malfunction occurs in a solar thermal point-focus distributed receiver power plant while a concentrator is pointed at the sun, motion of the concentrator may stop. As the sun moves relative to the earth, the spot of concentrated sunlight then slowly walks off the receiver aperture, across the receiver face plate, and perhaps across adjacent portions of the concentrator. Intense local heating by the concentrated sunlight may damage or destroy these parts. The behavior of various materials under conditions simulating walk-off of a parabolic dish solar collector were evaluated. Each test consisted of exposure to concentrated sunlight at a peak flux density of about 7000 kW/square meter for 15 minutes. Types of materials tested included graphite, silicon carbide, silica, various silicates, alumina, zirconia, aluminum, copper, steel, and polytetrafluoroethylene. The only material that neither cracked nor melted was grade G-90 graphite. Grade CS graphite, a lower cost commercial grade, cracked half-way across, but did not fall apart. Both of these grades are medium-grain extruded graphites. A graphite cloth (graphitized polyacrylonitrile) showed fair performance when tested as a single thin ply; it might be useful as a multi-ply assembly. High purity slipcast silica showed some promise also.

Jaffe, L. D.↗
NASA NTRS1986

Si3N4-Based Ceramic With Greater Hot Strength

Zyttrite-doped material outperforms MgO-doped material above 1,200 degrees C. New ceramic material produced by addition of 10 weight percent zyttrite (yttria-stabilized zirconia) to (silicon nitride) offers significantly-improved high-temperature properties (those of MgO-doped Si3N4 ceramic). Work also showed that controlled Si3N4 powder with 10 weight percent zyttrite, significant improvement in room-temperature strength achieved. Variety of high-temperature structural applications are silicon nitride and silicon carbide. Potential for use in aircraft and automobile engines and in electric-power generating systems. Improved properties strongly suggest that the 10-weight percent zyttrite/Si3N4 material has strong potential for high-temperature applications.

Dutta, S.↗
NASA NTRS1986

Composite Refractory Felt/Ceramic Material

Ceramic protective coatings on combustor liners adhere better. Report discloses results of recent combustor-liner research where thick yttria stabilized zirconia ceramic was plasma-sprayed on BRUNSBOND substrates and exposed to nearly stoichiometric combustion. Combustor screening tests exposed 30 test specimens to nearly-stoichiometric flame temperatures of 3,450 degrees F (2,170 K) for 4 cycles. After completion of screening tests, all 30 specimens showed no visible evidence of discoloration or failure. There were no mudflat cracks, felt/ceramic, or backing/felt separations on any panels.

Ercegovic, D. B.↗
NASA NTRS1985

Compatibility of grain-stabilized platinum with candidate propellants for resistojets

Resistojets are candidates for space station auxiliary propulsion, and should be characterized by both long life and multipropellant operations, requirements limited by available materials. Grain stabilized platinum is examined for use as a resistojet thruster material. Use of platinum in other applications indicates it can be used at moderately high temperatures for extended periods of time. Past results indicate that grain-stabilized platinum should be sufficiently inert in candidate propellant environments. Therefore, compatibility of platinum-yttria (P/Y2O3) and platinum-zirconia (Pt/ZrO2) with carbon dioxide, methane, hydrogen and ammonia is examined. A series of 1000 hr tests in CO2, H2, and NH3 is conducted at 1400 C and a series of 1000 hr tests in CH4 is conducted at about 500 C. Scanning electron microscopy, Auger electron spectroscopy and depth profiling analysis are then used to determine the effects of propellants on the material surface, to evaluate possible material contamination and to evaluate grain growth. The results indicate that there is carbon deposition on the surface of the Pt/Y2O3 and Pt/ZrO2 in both the CO2 and CH4 environments. In the H2 environment, the Pt/Y2O3 and Pt/ZrO2 specimen surfaces are roughened. After exposure to the NH3 environment, the Pt/Y2O3 and Pt/ZrO2 are roughened and pitted over the entire heated area with some pitted areas along the grain boundaries. SEM photos show grain growth in cross-sectional views of all the Pt/Y2O3 samples and the Pt/ZrO2 samples, except that tested in methane. Mass loss measurements indicate that Pt/Y2O3 and Pt/ZrO2 would last in excess of 200,000 hr in each propellant environment. However, in NH3 both Pt/Y2O3 and Pt/ZrO2 are severely pitted, with voids up to 50 percent into the material. Pt/Y2O3 and Pt/ZrO2 are not recommended for high temperature service in NH3.

Whalen, M. V.↗
NASA NTRS1985

Transformation toughened ceramics for the heavy duty diesel engine technology program, phase 2

The objective of this program is to develop an insulating structural ceramic for application in a heavy duty adiabatic diesel engine. The approach is to employ transformation toughening (TT) by additions of zirconia-hafnia solid solution (ZHSS). The feasibility of using ZHSS as a toughening agent in mullite and alumina has been demonstrated in Phase 1 of this work. Based on Phase 1 results, a decision was made to concentrate the Phase 2 effort on process optimization of the TT mullite. A strong factor in that decision was the low thermal conductivity and high thermal shock resistance of the mullite. Results of the Phase 2 effort indicate that optimum toughening of mullite by additions of ZHSS is difficult to achieve due to apparent sensitivity to morphology. The 48 ksi room temperature modulus-of-rupture (MOR) achieved in selected specimens is approximately 50% of the original strength target. The MOR deteriorated to 34 ksi at 800 C.

Musikant, S.↗
NASA NTRS1986

Ceramic thermal barrier coatings for electric utility gas turbine engines

Research and development into thermal barrier coatings for electric utility gas turbine engines is reviewed critically. The type of coating systems developed for aircraft applications are found to be preferred for clear fuel electric utility applications. These coating systems consists of a layer of plasma sprayed zirconia-yttria ceramic over a layer of MCrAly bond coat. They are not recommended for use when molten salts are presented. Efforts to understand coating degradation in dirty environments and to develop corrosion resistant thermal barrier coatings are discussed.

Miller, R. A.↗
NASA NTRS1986

Sliding Seal Materials for Adiabatic Engines, Phase 2

An essential task in the development of the heavy-duty adiabatic diesel engine is identification and improvements of reliable, low-friction piston seal materials. In the present study, the sliding friction coefficients and wear rates of promising carbide, oxide, and nitride materials were measured under temperature, environmental, velocity, and loading conditions that are representative of the adiabatic engine environment. In addition, silicon nitride and partially stabilized zirconia disks were ion implanted with TiNi, Ni, Co, and Cr, and subsequently run against carbide pins, with the objective of producing reduced friction via solid lubrication at elevated temperature. In order to provide guidance needed to improve materials for this application, the program stressed fundamental understanding of the mechanisms involved in friction and wear. Electron microscopy was used to elucidate the micromechanisms of wear following wear testing, and Auger electron spectroscopy was used to evaluate interface/environment interactions which seemed to be important in the friction and wear process. Unmodified ceramic sliding couples were characterized at all temperatures by friction coefficients of 0.24 and above. The coefficient at 800 C in an oxidizing environment was reduced to below 0.1, for certain material combinations, by the ion implanation of TiNi or Co. This beneficial effect was found to derive from lubricious Ti, Ni, and Co oxides.

Lankford, J.↗
NASA NTRS1985

Experimental study of ceramic-coated tip seals for turbojet engines

Ceramic gas-path seals were fabricated and successfully operated over 1000 cycles from flight idle to maximum power in a small turboshaft engine. The seals were fabricated by plasma spraying zirconia over a NiCoCrAlX bond coat on the Haynes 25 substrate. Coolant-side substrate temperatures and related engine parameters were recorded. Post-test inspection revealed mudflat surface cracking with penetration to the ceramic bond-coat interface.

Biesiadny, T. J.↗
NASA NTRS1985

Comparison of the contact stress and friction behavior of SiC and ZrO2 materials

Studies were performed to further elucidate the friction and contact-stress characteristics of structural ceramic materials. New data for fully stabilized and partially stabilized zirconia ceramics are compared with prior test results for sintered SiC. The comparison provides further evidence that the high temperature friction characteristics of sintered SiC are strongly influenced by the presence of a viscous surface layer. The results also show that a ceramic material with lower coefficient of friction and higher fracture toughness has increased resistance to strength-reducing surface damage due to contact stress.

Lindberg, L. J.↗
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 NTRS1987

Ceramic Parts for Turbines

Abilities of ceramics to serve as turbine blades, stator vanes, and other elements in hot-gas flow of rocket engines discussed in report. Ceramics prime candidates, because of resistance to heat, low density, and tolerance of hostile environments. Ceramics considered in report are silicon nitride, silicon carbide, and new generation of such ceramic composites as transformation-toughened zirconia and alumina and particulate- or whisker-reinforced matrices. Report predicts properly designed ceramic components viable in advanced high-temperature rocket engines and recommends future work.

Jones, R. D.↗
NASA NTRS1987

Thermal-Barrier Coatings Containing Ytterbia

Resistance to thermal cycling increased. New outer ceramic coating layer for two-layer or graded thermal-barrier coating developed. Ceramic overlay zirconia stabilized with ytterbia and used in conjunction with NiCrAlY or NiCrAlYb bond coats. Two-layer system evaluated in furnace testing at temperatures cycled between 2,025 degrees F and 575 degrees F.

Stecura, Stephan↗