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At least 703 records · Page 39
All sourcesNASA NTRSDOE OSTI
NASA NTRS1987

Experimental evaluation of chromium-carbide-based solid lubricant coatings for use to 760 C

A research program is described which further developed and investigated chromium carbide based self-lubricating coatings for use to 760 C. A bonded chromium carbide was used as the base stock because of the known excellent wear resistance and the chemical stability of chromium carbide. Additives were silver and barium fluoride/calcium fluoride eutectic. The three coating components were blended in powder form, applied to stainless steel substrates by plasma spraying and then diamond ground to the desired coating thickness. A variety of coating compositions was tested to determine the coating composition which gave optimum tribological results. Coatings were tested in air, helium, and hydrogen at temperatures from 25 to 760 C. Several counterface materials were evaluated with the objective of discovering a satisfactory metal/coating sliding combination for potential applications, such as piston ring/cylinder liner couples for Stirling engines. In general, silver and fluoride additions to chromium carbide reduced the friction coefficient and increased the wear resistance relative to the unmodified coating. The lubricant additives acted synergistically in reducing friction and wear.

Dellacorte, Christopher↗
NASA NTRS1981

Automated Plasma Spray (APS) process feasibility study

An automated plasma spray (APS) process was developed to apply two layer (NiCrAlY and ZrO2-12Y2O3) thermal barrier coatings to aircraft and stationary gas turbine engine blade airfoils. The APS process hardware consists of four subsystems: a mechanical positioning subsystem incorporating two interlaced six degree of freedom assemblies (one for coating deposition and one for coating thickness monitoring); a noncoherent optical metrology subsystem (for in process gaging of the coating thickness buildup at specified points on the specimen); a microprocessor based adaptive system controller (to achieve the desired overall thickness profile on the specimen); and commerical plasma spray equipment. Over fifty JT9D first stage aircraft turbine blade specimens, ten W501B utility turbine blade specimens and dozens of cylindrical specimens were coated with the APS process in preliminary checkout and evaluation studies. The best of the preliminary turbine blade specimens achieved an overall coating thickness uniformity of 53 micrometers (2.1 mils), much better than is achievable manually. Comparative evaluations of coating thickness uniformity for manually sprayed and APS coated specimens were performed. One of the preliminary turbine blade evaluation specimens was subjected to a torch test and metallographic evaluation. Some cylindrical specimens coated with the APS process survived up to 2000 cycles in subsequent burner rig testing.

Fetheroff, C. W.↗
NASA NTRS1989

Two-layer thermal barrier coating. I - Effects of composition and temperature on oxidation behavior and failure

The effects of 21 bond and 2 ceramic coating compositions on the specific mass gain, internal crack location at failure, and life of a two-layer thermal barrier coating (TBC) were studied by cyclic testing in a furnace. MAR-M 200 + Hf alloy specimens were completely coated with bond and thermal barrier (ceramic) coatings. Both coatings were applied by air plasma spray deposition. Cyclic test data were obtained at 1110, 1160, and 1220 deg C. The data show that the specific mass gain and the TBC life are significantly affected by the composition of the bond coating and the temperature and only slightly affected by the composition of the ceramic coating.

Stecura, Stephan↗
NASA NTRS1985

Spray Application of Rapidly Solidified Metals

Fast and economical process now available. New process applies rapidly solidified (RS) metal coatings to substrates. RS metals made directly from molten material. Have amorphous or microcrystalline structures and yield coatings having superior wear and corrosion resistance. Mixture of RS metal powder and peening particles sprayed from nozzle against surface coated. Powder and peening particles strike surface simultaneously, and impact bonds powder to surface as uniform coating. New process, which employs shot peening, is safe, fast, and inexpensive.

Chu, H. P.↗
NASA NTRS1979

Automated Plasma Spray (APS) process feasibility study: Plasma spray process development and evaluation

An automated plasma spray (APS) process was developed to apply two layer (NiCrAlY and ZrO2-12Y2O3) thermal-barrier coatings to aircraft gas turbine engine blade airfoils. The APS process hardware consists of four subsystems: a mechanical blade positioner incorporating two interlaced six-degree-of-freedom assemblies; a noncoherent optical metrology subsystem; a microprocessor-based adaptive system controller; and commercial plasma spray equipment. Over fifty JT9D first stage turbine blades specimens were coated with the APS process in preliminary checkout and evaluation studies. The best of the preliminary specimens achieved an overall coating thickness uniformity of + or - 53 micrometers, much better than is achievable manually. Factors limiting this performance were identified and process modifications were initiated accordingly. Comparative evaluations of coating thickness uniformity for manually sprayed and APS coated specimens were initiated. One of the preliminary evaluation specimens was subjected to a torch test and metallographic evaluation.

Fetheroff, C. W.↗
NASA NTRS2023

High Temperature Solid Particle Erosion of Environmental and Thermal Barrier Coatings

Solid particle erosion (SPE) is a common phenomenon observed in gas turbine engines. Particles entrained in the gas flow impact engine hardware resulting in micro-scale damage that leads to deleterious effects such as material removal. For protective coatings, damage due to SPE is a key concern since it can negatively affect the durability of the coating and subsequently the life of the underlying component. In this work, the high temperature SPE behavior of two state-of-the-art environmental barrier coatings (EBCs) deposited via air plasma spray (APS) is investigated using alumina erodent to understand the effect of particle kinetic energy, impingement angle and temperature. The SPE behavior of the EBCs is also compared to APS and electron beam – physical vapor deposition (EB-PVD) thermal barrier coatings (TBCs) to elucidate similarities and differences in the erosion response. The EBCs were more susceptible to SPE than the EB-PVD TBC but had greater SPE resistance compared to the APS TBC. Coating microstructure and porosity were shown to have a strong influence on the observed behavior.

Solid particle erosion↗
NASA NTRS1985

Coating life prediction

The investigation combines both experimental studies and numerical modeling to predict coating life in an oxidizing environment. The experimental work provides both input to and verification of two numerical models. The coatings being examined are an aluminide coating on Udimet 700 (U-700), a low-pressure plasma spray (LPPS) Ni-18Co-17Cr-24Al-0.2Y overlay coating also on U- 700, and bulk deposits of the LPPS NiCoCrAlY coating.

Nesbitt, James A.↗
NASA NTRS1979

Investigation of Proposed Process Sequence for the Array Automated Assembly Task, Phase 2

The technological readiness of the proposed process sequence was reviewed. Process steps evaluated include: (1) plasma etching to establish a standard surface; (2) forming junctions by diffusion from an N-type polymeric spray-on source; (3) forming a p+ back contact by firing a screen printed aluminum paste; (4) forming screen printed front contacts after cleaning the back aluminum and removing the diffusion oxide; (5) cleaning the junction by a laser scribe operation; (6) forming an antireflection coating by baking a polymeric spray-on film; (7) ultrasonically tin padding the cells; and (8) assembling cell strings into solar circuits using ethylene vinyl acetate as an encapsulant and laminating medium.

Mardesich, N.↗
NASA NTRS1996

Portable Spray Booth

Portable spray booth provides for controlled application of coating materials with high solvent contents. Includes contoured shroud and carbon filter bed limiting concentration of fumes in vicinity. Designed to substitute spraying for brush application of solvent-based adhesive prior to installing rubber waterproof seals over joints between segments of solid-fuel rocket motor. With minor adjustments and modifications, used to apply other solvent-based adhesives, paints, and like.

Hansen, Timothy D.↗
NASA NTRS2013

Advanced Materials and Manufacturing for Low-Cost, High-Performance Liquid Rocket Combustion Chambers

A document describes the low-cost manufacturing of C103 niobium alloy combustion chambers, and the use of a high-temperature, oxidation-resistant coating that is superior to the standard silicide coating. The manufacturing process involved low-temperature spray deposition of C103 on removable plastic mandrels produced by rapid prototyping. Thin, vapor-deposited platinum-indium coatings were shown to substantially improve oxidation resistance relative to the standard silicide coating. Development of different low-cost plastic thrust chamber mandrel materials and prototyping processes (selective laser sintering and stereolithography) yielded mandrels with good dimensional accuracy (within a couple of mils) for this stage of development. The feasibility of using the kinetic metallization cold-spray process for fabrication of free-standing C1O3 thrusters on removable plastic mandrels was also demonstrated. The ambient and elevated temperature mechanical properties of the material were shown to be reasonably good relative to conventionally processed C103, but the greatest potential benefit is that coldsprayed chambers require minimal post-process machining, resulting in substantially lower machining and material costs. The platinum-iridium coating was shown to provide greatly increased oxidation resistance over the silicide when evaluated through oxyacetylene torch testing to as high as 300 F (= 150 C). The iridium component minimizes reaction with the niobium alloy chamber at high temperatures, and provides the high-temperature oxidation resistance needed at the throat.

Williams, Brian E.↗
NASA NTRS1990

Low dielectric fluorinated poly(phenylene ether ketone) film and coating

The present invention relates to film and coating materials prepared from novel fluorinated poly(phenylene ether ketones). A fluorinated poly(phenylene ether ketone) is prepared by reacting a bisphenol with 1,1,1,3,3,3 hexafluoro-2,2-bis 4-(4-halobenzoyl) phenyl propane (wherein halo is fluoro or chloro), which is a novel monomer formed as the reaction product of halobenzene (wherein halo is fluoro or chloro) and 1,1,1,3,3,3 hexafluoro-2,2-bis (p-chloro formyl phenyl) propane. Especially beneficial results of this invention are that films and coating materials prepared from the novel fluorinated poly(phenylene ether ketone) are essentially optically transparent/colorless and have a lower dielectric constant than otherwise comparable, commercially available poly(phenylene ether ketones). Moreover, unlike the otherwise comparable commercially available materials, the novel fluorinated poly(phenylene ether ketones) of the present invention can be solution cast or sprayed to produce the films and coatings. Furthermore, the long term thermal stability of the polymers of the present invention is superior to that of the commercially available materials.

Cassidy, Patrick E.↗
NASA NTRS2007

Electroform/Plasma-Spray Laminates for X-Ray Optics

Electroform/plasma-spray laminates have shown promise as lightweight, strong, low-thermal-expansion components for xray optics. The basic idea is to exploit both (1) the well-established art of fabrication of optical components by replication and (2) plasma spraying as a means of reinforcing a thin replica optic with one or more backing layer(s) having tailorable thermomechanical properties. In x-ray optics as in other applications, replication reduces the time and cost of fabrication because grinding and polishing can be limited to a few thick masters, from which many lightweight replicas can thereafter be made. The first step in the fabrication of a component of the type in question is to make a replica optic by electroforming a thin layer of nickel on a master. Through proper control of the electroforming process conditions, it is possible to minimize residual stress and, hence, to minimize distortion in the replica. Next, a powder comprising ceramic particles coated with a metal compatible with the electroformed nickel is plasma-sprayed onto the backside of the nickel replica. Then through several repetitions and variations of the preceding steps or perhaps a small compressive stress, alternating layers of electroformed nickel and plasma-sprayed metal-coated ceramic powder are deposited. The thicknesses of the layers and the composition of the metal-coated ceramic powder are chosen to optimize the strength, areal mass density, and toughness of the finished component. An important benefit of using both electroforming and plasma spraying is the possibility of balancing stresses to a minimum level, which could be zero or perhaps a small net compressive stress designed to enhance the function of the component in its intended application.

Ulmer, Melville P.↗
NASA NTRS2025

Radiation-Resistant Ti/BN Coatings: Insights From 171 Days Exposure to Space Radiation and Atomic Oxygen in Low Orbit

Atmospheric Plasma Spray (APS) and Vacuum Plasma Spray (VPS) techniques were used to develop Ti/2 vol.% hBN coatings, for extreme space environments and tested aboard the International Space Station as part of the MISSE-17 (Materials International Space Station Experiments) program. The coatings were exposed to atomic oxygen, space radiation, and low-orbit thermal cycling. VPS coatings showed a 56% increase in microhardness, a 26% rise in elastic modulus, minimal porosity and crack density changes compared to APS coatings. The change in mechanical properties is attributed to the formation of TiO, TiO₂ and TiN from nitrogen retention, alongside radiation-induced dislocations, which enhanced surface hardening. The oxidation of titanium led to the formation of TiO and TiO₂, while boron nitride was retained and underwent transmutation in VPS coatings. XPS and EDS analyses confirmed the enhanced space-environment resistance of VPS coatings, making them ideal for long-term spacecraft protection in lunar and Martian conditions.

Abhijith Kunneparambil Sukumaran↗
NASA NTRS2004

Modification of Bushing Test Rig and Research of Variable Inlet Guide Vane Bushings For Further Development of PM304 Bushings

PS304 is a high temperature solid lubricant coating comprised of a nickel-chrome binder, chrome oxide hardener, barium-calcium fluoride high temperature lubricant, and silver as the low temperature lubricant. This coating is used to lubricate Oil-Free Foil Air Bearings as they experience friction and wear during start up and shut down. The coating deposition process begins with undercutting the shaft. This area is then sandblasted to provide a rough surface for the coating to adhere to. The coating powder is then sent through the plasma spray gun and a reasonably thick layer is applied to the undercut area of the shaft. The coating is then ground down even with the surface of the shaft and gets a nice polished finish. The foil air bearings use the solid lubricant, as mentioned above, during start up and shut down. During normal operating conditions, generally above 2000RPM, the bearings utilize air as their lubricant. Foil air bearings are comprised of a thin top foil and a corrugated bump foil. They have an interference fit with the shaft before operation. As the air gets "trapped" between the top foil and the shaft, it presses the top foil against the bump foil, in turn compressing the bumps. As the bumps compress, it allows for the air to separate the top foil from the shaft, therefore, utilizing the trapped air as its lubricant.

Yanke, Anne↗
NASA NTRS1988

Antireflection Overcoat For Submillimeter Wavelengths

Coating thickness not critical. Polytetrafluoroethylene antireflection overcoat reduces specular reflectance of opaque baffle coating by factor of nearly 2 at millimeter and infrared wavelengths. Easily applied by spraying Teflon(TM) Wet Lubricant (or equivalent) on opague coated surface. Though technique makes it difficult to control thickness of overcoat, experimental and theoretical studies indicate thickness has little effect because antireflective property based on creating graded-index absorber.

Smith, Sheldon M.↗
DOE OSTI2025

Support of Adhesion Mechanisms in Al 2 O 3 Aerosol Deposition Through Laser-Induced Particle Impact Testing

Aerosol deposition (AD) is a kinetic spray process capable of depositing ceramic coatings at room temperature, but AD process development is generally a laborious exploration of a large process parameter space. Here, this paper presents a case study investigating whether laser-induced particle impact testing (LIPIT) could be applied to expedite development of an alumina (Al 2 O 3 ) coating on nickel (Ni): Specifically, whether LIPIT measurements could predict critical velocities of adhesion on Ni and Al 2 O 3 , and the effect of ball milling the Al 2 O 3 powder. Because LIPIT has a diffraction-limited lower bound on imageable particle size, the usefulness of Al 2 O 3 powder agglomerates as a proxy for single particles was additionally studied. Overall, LIPIT measurements and AD sprays agreed that ball milling dramatically improves adhesion. Additionally, LIPIT measurements of critical velocity of adhesion of Al 2 O 3 powder agglomerates on Ni and Al 2 O 3 substrates (150 meters per second [m/s] and 250 m/s, respectively) quantitatively agreed with predictions from a previously published model based on picoindentation and molecular dynamics simulations. Together, these findings support the established hypothesis that Al 2 O 3 adheres via a dislocation-mediated mechanism in AD, that Al 2 O 3 powder agglomerates adhere as individual constituent particles rather than collectively, and that, for this case study, LIPIT measurements were predictive of AD process parameters.

Al2O3↗
NASA NTRS1998

Residual Stresses Modeled in Thermal Barrier Coatings

Thermal barrier coating (TBC) applications continue to increase as the need for greater engine efficiency in aircraft and land-based gas turbines increases. However, durability and reliability issues limit the benefits that can be derived from TBC's. A thorough understanding of the mechanisms that cause TBC failure is a key to increasing, as well as predicting, TBC durability. Oxidation of the bond coat has been repeatedly identified as one of the major factors affecting the durability of the ceramic top coat during service. However, the mechanisms by which oxidation facilitates TBC failure are poorly understood and require further characterization. In addition, researchers have suspected that other bond coat and top coat factors might influence TBC thermal fatigue life, both separately and through interactions with the mechanism of oxidation. These other factors include the bond coat coefficient of thermal expansion, the bond coat roughness, and the creep behavior of both the ceramic and bond coat layers. Although it is difficult to design an experiment to examine these factors unambiguously, it is possible to design a computer modeling "experiment" to examine the action and interaction of these factors, as well as to determine failure drivers for TBC's. Previous computer models have examined some of these factors separately to determine their effect on coating residual stresses, but none have examined all the factors concurrently. The purpose of this research, which was performed at DCT, Inc., in contract with the NASA Lewis Research Center, was to develop an inclusive finite element model to characterize the effects of oxidation on the residual stresses within the TBC system during thermal cycling as well as to examine the interaction of oxidation with the other factors affecting TBC life. The plasma sprayed, two-layer thermal barrier coating that was modeled incorporated a superalloy substrate, a NiCrAlY bond coat, and a ZrO2-8 wt % Y2O3 ceramic top coat. We examined the effect on stress during burner rig thermal cycling of the following independent variables: creep in the bond coat and top coat, oxidation, bond coat coefficient of thermal expansion, number of thermal cycles, and interfacial roughness. All these factors were suspected of influencing TBC failure. The model showed that all the material properties studied had a significant effect on the coating's residual stresses if the interface of the bond coat was rough. Bond coat expansion, bond coat oxidation, and bond coat creep had the highest effect on coating stresses, and these were highly interactive. The model also showed that the mechanism of stress generation during thermal cycling changed with the number of thermal cycles. Bond coat and top coat creep dominated stress generation during early thermal cycles, greatly increasing delamination stresses at the peaks of the bond coat. Therefore, creep is the prime driver for delamination cracking early in life, but cracking is limited to the bond coat peak region. Oxidation of the bond coat, on the other hand, tended to dominate stress generation during later cycles by greatly increasing delamination stresses over bond coat valleys. These results indicate that oxidation is the driver for the continued cracking necessary to cause ceramic layer spallation.

Freborg, A. M.↗
NASA NTRS2011

Marshall Convergent Spray Formulation Improvement for High Temperatures

The Marshall Convergent Coating-1 (MCC-1) formulation was produced in the 1990s, and uses a standard bisphenol A epoxy resin system with a triamine accelerator. With the increasing heat rates forecast for the next generation of vehicles, higher-temperature sprayable coatings are needed. This work substitutes the low-temperature epoxy resins used in the MCC-1 coating with epoxy phenolic, epoxy novalac, or resorcinolinic resins (higher carbon content), which will produce a higher char yield upon exposure to high heat and increased glass transition temperature. High-temperature filler materials, such as granular cork and glass ecospheres, are also incorporated as part of the convergent spray process, but other sacrificial (ablative) materials are possible. In addition, the use of polyhedral oligomeric silsesquioxanes (POSS) nanoparticle hybrids will increase both reinforcement aspects and contribute to creating a tougher silacious char, which will reduce recession at higher heat rates. Use of expanding epoxy resin (lightweight MCC) systems are also useful in that they reduce system weight, have greater insulative properties, and a decrease in application times can be realized.

Scarpa, Jack↗