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At least 649 records · Page 36
All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

Organic matrix composite protective coatings for space applications

Successful use of composites in low earth orbit (LEO) depends on their ability to survive long-term exposure to atomic oxygen (AO), ultraviolet radiation, charged particle radiation, thermal cycling, and micrometeoroid and space debris. The AO environment is especially severe for unprotected organic matrix composites surfaces in LEO. Ram facing unprotected graphite/epoxy flown on the 69-month Long Duration Exposure Facility (LDEF) mission lost up to one ply of thickness (5 mils) resulting in decreased mechanical properties. The expected AO fluence of the 30 year Space Station Alpha mission is approximately 20 times that seen on LDEF. This exposure would result in significant material loss of unprotected ram facing organic matrix composites. Several protective coatings for composites were flown on LDEF including anodized aluminum, vacuum deposited coatings, a variety of thermal control coatings, metalized Teflon, and leafing aluminum. Results from the testing and analysis of the coated and uncoated composite specimens flown on LDEF's leading and trailing edges provide the baseline for determining the effectiveness of protectively coated composites in LEO. In addition to LDEF results, results from shuttle flight experiments and ground based testing will be discussed.

Dursch, Harry W.↗
NASA NTRS1995

Overview of thermal barrier coatings in diesel engines

An understanding of delamination mechanisms in thermal barrier coatings has been developed for diesel applications through nondestructive evaluation, structural analysis modeling and engine evaluation of various thermal barrier coatings. This knowledge has resulted in improved thermal barrier coatings which survive abusive cyclic fatigue tests in high output diesel engines. Significant efforts are still required to improve the plasma spray processing capability and the economics for complex geometry diesel engine components. Data obtained from advanced diesel engines on the effect of thermal barrier coatings on engine fuel economy and emission has not been encouraging. Although the underlying metal component temperatures have been reduced through the use of thermal barrier coating, engine efficiency and emission trends have not been promising.

Yonushonis, T. M.↗
NASA NTRS1995

Properties of plasma sprayed bond coats

Increasing bond coat oxidation resistance has been clearly linked to increasing durability of the ceramic layer of TBC's. However, recent studies have shown that significant differences in TBC life can be achieved for different bond coats that have little or no difference in oxidation behavior. These results suggest bond coat properties other than oxidation resistance can also influence TBC life. A determination of which properties affect TBC life and an understanding of how these properties affect TBC life could be valuable in designing new, more durable TBC's. Unfortunately, there is little existing information on the physical and mechanical properties of bond coat materials and there are fewer comparative studies that can be used to determine which properties are important to TBC life. This paper compares the properties of three bond coat compositions that have similar oxidation behavior but different TBC lives. Analysis of the properties indicates that the coefficient of thermal expansion and stress relaxation (creep) behavior of the three alloys are strongly correlated to the observed differences in TBC life.

Brindley, W. J.↗
NASA NTRS1995

Solid film lubricants and thermal control coatings flown aboard the EOIM-3 MDA sub-experiment

Additional experimental data were desired to support the selection of candidate thermal control coatings and solid film lubricants for the McDonnell Douglas Aerospace (MDA) Space Station hardware. The third Evaluation of Oxygen Interactions With Materials Mission (EOIM-3) flight experiment presented an opportunity to study the effects of the low Earth orbit environment on thermal control coatings and solid film lubricants. MDA provided five solid film lubricants and two anodic thermal control coatings for EOIM-3. The lubricant sample set consisted of three solid film lubricants with organic binders one solid film lubricant with an inorganic binder, and one solid film lubricant with no binder. The anodize coating sample set consisted of undyed sulfuric acid anodize and cobalt sulfide dyed sulfuric acid anodize, each on two different substrate aluminum alloys. The organic and inorganic binders in the solid film lubricants experienced erosion, and the lubricating pigments experienced oxidation. MDA is continuing to assess the effect of exposure to the low Earth orbit environment on the life and friction properties of the lubricants. Results to date support the design practice of shielding solid film lubricants from the low Earth orbit environment. Post-flight optical property analysis of the anodized specimens indicated that there were limited contamination effects and some atomic oxygen and ultraviolet radiation effects. These effects appeared to be within the values predicted by simulated ground testing and analysis of these materials, and they were different for each coating and substrate.

Murphy, Taylor J.↗
NASA NTRS1995

The tribology of PS212 coatings and PM212 composites for the lubrication of titanium 6A1-4V components of a Stirling engine space power system

The Stirling space power machine incorporates a linear alternator to generate electrical power. The alternator is a reciprocating device that is driven by a solar or nuclear-powered Stirling engine. The power piston and cylinder are made of titanium 6A1-4V (Ti6-4) alloy, and are designed to be lubricated by a hydrodynamically-generated gas film. Rubbing occurs during starts and stops and there is a possibility of an occasional high speed rub. Since titanium is known to have a severe galling tendency in sliding contacts, a 'backup,' self-lubricating coating on the cylinder and/or the piston is needed. This report describes the results of a research program to study the lubrication of Ti6-4 with the following chromium carbide based materials: plasma-sprayed PS212 coatings and sintered PM212 counterfaces. Program objectives are to achieve adherent coatings on Ti6-4 and to measure the friction and wear characteristics of the following sliding combinations under conditions simulative of the Stirling-driven space power linear alternator: Ti6-4/Ti6-4 baseline, Ti6-4/PS212 coated Ti6-4, and Ps212 coated Ti6-4/PM212

Sliney, Harold E.↗
NASA NTRS1995

Laboratory electron exposure of TSS-1 thermal control coating

RM400, a conductive thermal control coating, was developed for use on the exterior shell of the tethered satellite. Testing was performed by the Engineering Physics Division to quantify effects of the space environment on this coating and its conductive and optical properties. Included in this testing was exposure of RM400 to electrons with energies ranging from 0.1 to 1 keV, to simulate electrons accelerated from the ambient space plasma when the tethered satellite is fully deployed. During this testing, the coating was found to luminesce, and a prolonged exposure of the coating to high-energy electrons caused the coating to darken. This report describes the tests done to quantify the degradation of the thermal control properties caused by electron exposure and to measure the luminescence as a function of electron energy and current density to the satellite.

Vaughn, J. A.↗
NASA NTRS1995

Mechanical properties testing and results for thermal barrier coatings

The paper reports on several years of mechanical testing of thermal barrier coatings. The test results were generated to support the development of durability models for the coatings in heat engine applications. The test data that are reviewed include modulus, static strength, and fatigue strength data. The test methods and results are discussed, along with the significant difficulties inherent in mechanical testing of thermal barrier coating materials. The materials include 7 percent wt. and 8 percent wt. yttria, partially stabilized zirconia as well as a cermet material. Both low pressure plasma spray and electron-beam physical vapor deposited coatings were tested. The data indicate the basic trends in the mechanical properties of the coatings over a wide range of isothermal conditions. Some of the trends are correlated with material density.

Thomas A. Cruse↗
NASA NTRS1996

Temperature measurement involving nanostructured thermal barrier coating using a multiwavelength pyrometer

It has been reported that erroneous results were obtained when a conventional pyrometer was used to measure the surface temperature of turbine engine components. Temperatures discrepancies were observed in components which were identical, except that one had its measured surface covered by a nanostructured thermal barrier coating (TBC) whereas the other component's surface was not so coated. These components were placed in an identical environment, receiving identical heat fluxes. A pyrometer measured the TBC covered surface hundreds degrees lower. These coatings were about 25 (mu)m thick, consisting of hundreds of layers of finer structures. The TBC's had very low thermal conductivity, heat flux calculations indicated that the temperatures of the coated surface should exhibit much higher temperature than the uncoated surface. Because these coatings were transparent to radiation from the visible to the infrared region, the temperatures measured by the pyrometer should be the temperature of the covered surface. Turbo components' performance and service life depend critically on the temperatures that it would experience; it is therefore important to know accurately and confidently the real surface temperature. Out of these concerns, an investigation into the measurement of nanostructured material surface temperature was carried out.

Ng, Daniel↗
NASA NTRS1997

Reduction of Calcofluor in Solithane Conformal Coatings of Printed Wiring Boards

An investigation on the outgassing of a pigment employed as a fluorescent medium in conformal coatings has been performed. The conformal coatings in question are used to protect printed wiring boards from environmental hazards such as dust and moisture. The pigment is included in the coating at low concentration to allow visual inspection of the conformal coating for flaw detection. Calcofluor, the fluorescent pigment has been found to be a significant outgasser under vacuum conditions and a potential source of contamination to flight hardware. A minimum acceptable concentration of Calcofluor for flaw detection is desirable. Tests have been carried out using a series of Solithane(TM) conformal coating samples, with progressively lower Calcofluor concentrations, to determine the minimum required concentration of Calcofluor. It was found that the concentration of Calcofluor could be reduced from 0.115% to 0.0135% without significant loss in the ability to detect flaws, while at the same time significant reductions in Calcofluor outgassing and possible contamination of systems could be realized.

Miller, Michael K.↗
NASA NTRS1995

Plasma Sprayed Bondable Stainless Surface (BOSS) Coatings for Corrosion Protection and Adhesion Treatments

Plasma-sprayed Bondable Stainless Surface (BOSS) coatings are being developed under the Solid Propulsion Integrity Program's (SPIP) Bondlines Package. These coatings are designed as a steel case preparation treatment prior to insulation lay-up. Other uses include the exterior of steel cases and bonding surfaces of nozzle components. They provide excellent bondability - rubber insulation and epoxy bonds fail cohesively within the polymer - for both fresh surfaces and surfaces having undergone natural and accelerated environmental aging. They have passed the MSFC requirements for protection of inland and sea coast environment. Because BOSS coatings are inherently corrosion resistant, they do not require preservation by greases or oils. The reduction/elimination of greases and oils, known bondline degraders, can increase SRM reliability, decrease costs by reducing the number of process steps, and decrease environmental pollution by reducing the amount of methyl chloroform used for degreasing and thus reduce release of the ozone-depleting chemical in accordance with the Clean Air Act and the Montreal Protocol. The coatings can potential extend the life of RSRM case segments and nozzle components by eliminating erosion due to multiple grit blasting during each use cycle and corrosion damage during marine recovery. Concurrent work for the Air Force show that other BOSS coatings give excellent bondline strength and durability for high-performance structures of aluminum and titanium.

Davis, G. D.↗
NASA NTRS1997

Thermal Fatigue Testing of ZrO2-Y2O3 Thermal Barrier Coating Systems using a High Power CO2 Laser

In the present study, the mechanisms of fatigue crack initiation and propagation, and of coating failure, under thermal loads that simulate diesel engine conditions, are investigated. The surface cracks initiate early and grow continuously under thermal Low Cycle Fatigue (LCF) and High Cycle Fatigue (HCF) stresses. It is found that, in the absence of interfacial oxidation, the failure associated with LCF is closely related to coating sintering and creep at high temperatures. Significant LCF and HCF interactions have been observed in the thermal fatigue tests. The fatigue crack growth rate in the ceramic coating strongly depends on the characteristic HCF cycle number, N*(sub NCF), which is defined as the number of HCF cycles per LCF cycle. The crack growth rate is increased from 0.36 microns/LCF cycle for a pure LCF test to 2.8 microns/LCF cycle for a combined LCF and HCF test at N*(sub NCF) about 20,000. A surface wedging model has been proposed to account for the HCF crack growth in the coating systems. This mechanism predicts that HCF damage effect increases with increasing surface temperature swing, the thermal expansion coefficient and the elastic modulus of the ceramic coating, as well as with the HCF interacting depth. A good agreement has been found between the analysis and experimental evidence.

Zhu, Dongming↗
NASA NTRS1997

Effects of Fiber Coatings on Tensile Properties of Hi-Nicalon SiC/RBSN Tow Composites

Uncoated Hi-Nicalon silicon carbide (SiC) fiber tows and those coated with a single surface layer of pyrolytic boron nitride (PBN), double layers of PBN/Si-rich PBN, and boron nitride (BN)/SiC coatings deposited by chemical vapor deposition (CVD) method were infiltrated with silicon slurry and then exposed to N2, for 4 hr at 1200 and 1400 C. Room temperature ultimate tensile fracture loads and microstructural characterization of uncoated and CVD coated Hi-Nicalon SiC fiber reinforced reaction-bonded silicon nitride (RBSN) tow composites were measured to select suitable interface coating(s) stable under RBSN processing conditions. Results indicate that room temperature ultimate fracture loads of the uncoated Hi-Nicalon SiC/RBSN tow composites nitrided at both temperatures were significantly lower than those of the uncoated Hi-Nicalon tows without slurry infiltration. In contrast, all CVD coated Hi-Nicalon SiC/RBSN tow composites retained a greater fraction of the dry tow fracture load after nitridation at 1200 C, but degraded significantly after nitridation at 1400 C. Reaction between metal impurities (Fe and Ni) present in the attrition milled silicon powder and uncoated regions of SiC fibers appears to be the probable cause for fiber degradation.

Bhatt, Ramakrishna T.↗
NASA NTRS1998

Modeling Oxidation Induced Stresses in Thermal Barrier Coatings

The use of thermal barrier coatings (TBC's) in gas turbines has increased dramatically in recent years, due mainly to the need for component protection from ever increasing service temperatures. Oxidation of the bond coat has been identified as an important contributing factor to spallation of the ceramic top coat during service. Additional variables found to influence TBC thermal cycle life include bond coat coefficient of thermal expansion, creep behavior of both the ceramic and bond coat layers, and modulus of elasticity. The purpose of this work was to characterize the effects of oxidation on the stress states within the TBC system, as well as to examine the interaction of oxidation with other factors affecting TBC life.

Ferguson, B. L.↗
NASA NTRS1998

Effects of Fiber Coating Composition on Mechanical Behavior of Silicon Carbide Fiber-Reinforced Celsian Composites

Celsian matrix composites reinforced with Hi-Nicalon fibers, precoated with a dual layer of BN/SiC by chemical vapor deposition in two separate batches, were fabricated. Mechanical properties of the composites were measured in three-point flexure. Despite supposedly identical processing, the composite panels fabricated with fibers coated in two batches exhibited substantially different mechanical behavior. The first matrix cracking stresses (sigma(sub mc)) of the composites reinforced with fibers coated in batch 1 and batch 2 were 436 and 122 MPa, respectively. This large difference in sigma(sub mc) was attributed to differences in fiber sliding stresses(tau(sub friction)), 121.2+/-48.7 and 10.4+/-3.1 MPa, respectively, for the two composites as determined by the fiber push-in method. Such a large difference in values of tau(sub friction) for the two composites was found to be due to the difference in the compositions of the interface coatings. Scanning Auger microprobe analysis revealed the presence of carbon layers between the fiber and BN, and also between the BN and SiC coatings in the composite showing lower tau(sub friction). This resulted in lower sigma(sub mc) in agreement with the ACK theory. The ultimate strengths of the two composites, 904 and 759 MPa, depended mainly on the fiber volume fraction and were not significantly effected by tau(sub friction) values, as expected. The poor reproducibility of the fiber coating composition between the two batches was judged to be the primary source of the large differences in performance of the two composites.

Bansal, Narottam P.↗
NASA NTRS1998

Tailoring Thin Film-Lacquer Coatings for Space Applications

Thin film coatings have the capability of obtaining a wide range of thermal radiative properties, but the development of thin film coatings can sometimes be difficult and costly when trying to achieve highly specular surfaces. Given any space mission's then-nal control requirements, there is often a need for a variation of solar absorptance (alpha(sub s)), emittance (epsilon) and/or highly specular surfaces. The utilization of thin film coatings is one process of choice for meeting challenging thermal control requirements because of its ability to provide a wide variety of alpha(sub s)/epsilon ratios. Thin film coatings' radiative properties can be tailored to meet specific thermal control requirements through the use of different metals and the variation of dielectric layer thickness. Surface coatings can be spectrally selective to enhance radiative coupling and decoupling. The application of lacquer to a surface can also provide suitable specularity for thin film application without the cost and difficulty associated with polishing.

Peters, Wanda C.↗
NASA NTRS1988

Advanced Porous Coating for Low-Density Ceramic Insulation Materials

The need for improved coatings on low-density reusable surface insulation (RSI) materials used on the space shuttle has stimulated research into developing tougher coatings. The processing of a new porous composite "coating" for RST called toughened unipiece fibrous insulation Is discussed. Characteristics including performance in a simulated high-speed atmospheric entry, morphological structure before and after this exposure, resistance to Impact, and thermal response to a typical heat pulse are described. It is shown that this coating has improved impact resistance while maintaining optical and thermal properties comparable to the previously available reaction-cured glass coating.

Leiser, Daniel B.↗
NASA NTRS1999

The Successful Transfer of Space Derived Convergent Spray Technology(TM): An Application for Industrial Roof Coatings and Interstate Bridge Repair

Although the levels of volatile organic compound (VOC) emissions from industrial roof coatings and paint operations have been reduced in recent years, the roof coating partnership was an effort to further reduce VOC emission levels and to also demonstrate the use of reclaimed automobile tire rubber as a filler material in roof coating systems. Different materials and coatings were evaluated and tested before the final selection was used to coat the roofs of two small buildings at NASA's MSFC (Marshall Space Flight Center) during fiscal year 1997. The primary objective of the Bridge repair partnership was to strategically leverage public and private sector funds for the purpose of developing a bridge repair process that was cheaper, better, and faster than conventional methods. It was also, imperative that this process be environmentally friendly and capable of performing under extreme conditions for a period of not less than 2 years.

McMillan, Vernotto↗
NASA NTRS1999

Space Environmental Effects on Colored Coatings and Anodizes

Colored coatings and anodizes are used on spacecraft as markers and astronaut visual aids. These materials must be stable in the space environment and withstand atomic oxygen, ultraviolet radiation, particulate radiation, thermal cycling, and high vacuum without significant change in optical and mechanical properties. A variety of colored coatings and anodizes have been exposed to simulated space environments at Marshall Space Flight Center and also actual space environment as part of the Passive Optical Sample Assembly (POSA) - I flight experiment. Colored coatings were developed by AZ Technology, Huntsville, AL, under a NASA contract for International Space Station (ISS). These include yellow, red, blue, and black paints suitable for Extra-Vehicular Activity (EVA) visual aids and ISS emblems. AaChron, Inc., Minneapolis, MN, developed stable colored anodizes, also in yellow, red, blue, and black, for astronaut visual aids. These coatings were exposed in the laboratory to approximately 550 equivalent sun-hours of solar ultraviolet radiation and approximately 1 x 10(exp 21) atoms/sq cm of atomic oxygen in vacuum. The AZ Technology yellow colored coating, designated TMS800IY, and all four AaChron colored anodizes were flown on POSA-I. POSA-I was a Risk Mitigation Experiment for ISS. It was attached to the exterior of the Mir space station docking module by EVA and was exposed for 18 months. The laboratory-simulated space environment, the natural space environment and the unique environment of an orbiting, active space station and their effects on these developmental materials are discussed.

Kamenetzky, Rachel R.↗