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At least 775 records · Page 43
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Metallic Environmentally Resistant Coating Rapid Innovation Initiative

Lightweight alloys such as aluminum (Al) and titanium (Ti) are often specified for space systems to minimize mass while maintaining structural integrity [1,2]. Such alloys however, have poor tribological response (high friction and wear), especially in extreme space environments, which becomes worse with the additional presence of lunar regolith. This leads to short lifetimes and premature failures that will ultimately limit long term operations on the lunar surface [2]. This project is addressing this technology gap by developing advanced wear- and radiation-resistant coatings for lightweight parts to extend the life-time and sustainability of both lunar and Martian assets. Ceramics were considered for their high wear resistance, but were rejected because of their low fracture toughness, which would be especially problematic for structural components. The novel and existing coating technologies and deposition methods are being tested in this project. The coating materials are Boron Nitride-Aluminum (BN-Al), Nickle Titanium (NiTi), Aluminum Oxide (AlO3), Ti64 with hBN at 2 and 10 vol percent (Ti-2vol%hBN and Ti-10vol%hBN), and the deposition techniques are high pressure cold-spray (CS) and ambient and vacuum plasma-spray (APS and VPS) [3,4,5]. BN-Al, NiTi, Ti-2vol%hBN, and Ti-10vol%hBN were applied with all three deposition techniques, and AlO3 was applied only using the APS deposition technique. A tungstenite (WS2) film was applied to the NiTi VPS coating. The coating and deposition technique configurations are being tested against several key end-use performance parameters. The parameters include the capabilities of the coatings under wear environments such as regolith simulant, thermal cycling from high (120°C) to cryogenic (-173°C), high vacuum (~10-7 torr), and pre- and post-exposure to ionizing particle radiation. Wear tests include pin on disk, three-body abrasion, and surface erosion by high velocity regolith impacts. The initial down selection is being performed using on virgin and environmental exposure samples using pin on disk and three body abrasion wear tests. From preliminary assessment of this testing, a few configurations were eliminated. Ti-10vol%hBN could not be applied using CS application and NiTi could not be applied using APS or CS application so these configurations did not get tested. Early pin on disk wear tests showed poor wear performance of BN-Al so this coating was eliminated early in the testing process. AlO3 on Al substrate did not survive thermal cycling, but wear testing is continuing for AlO3 on Ti substrate. A more detailed analysis is being con-ducted to further reduce the number of configuration for phase II and III. Phase II testing will include conventionally and additively manufactured substrates with surface erosion testing. In phase III, the coatings will be applied to three mechanism types: channel and slot, ball and socket, and a hinge joint. Each will demonstrate a different type of wear incidence. The mechanisms and their base materials are of direct interest to the end users and infusion points: the Human Landing System (HLS) and the Lunar Surface Innovation Initiative (sustained lunar surface operations). The technology development project is based out of Marshall Space Flight Center, has partnered with Florida International University (Miami, FL) and Plasma Processes (Huntsville, Al), and is supported by a group of NASA mentors from different centers.

dust mitigation↗
DOE OSTI2024

Residual Stress in Cold Spray SS304L Measured Via Neutron Diffraction and Comparison of Analytical Models to Predict the Residual Stress

Here, this study employs neutron diffraction to investigate the relationship between residual stress and coating thickness in cold sprayed 304L austenitic stainless steel. Results show that shot peening predominantly impacts the residual stress profile, leading to substantial in-plane compressive force. The impact of laser heating, a widely used method to alter cold spray's microstructural properties, on the coating's residual stress is also analyzed. The findings indicate that the maximum compressive residual stress in the in-plane component is mainly independent of coating thickness, which suggests that the material properties determine the maximum residual stress. The cold sprayed deposits possessed compressive, nearly biaxial strain and stresses. After laser heating, these stresses were replaced by tensile residual stresses. Two analytical models, the Tsui and Clyne and the Boruah models, for predicting residual stresses are also evaluated, and both models provide reasonable fits to the experimental data. At this point, the deviations between the experimental results and the models are principally caused by the inability of the current models to address plastic deformation and relaxation, and the residual stresses generated by thermal gradients.

36 MATERIALS SCIENCE↗
NASA NTRS1996

The Development of Novel, High-Flux, Heat Transfer Cells for Thermal Control in Microgravity

In order to meet the future needs of thermal management and control in space applications such as the Space Lab, new heat-transfer technology capable of much larger heat fluxes must be developed. To this end, we describe complementary numerical and experimental investigations into the fundamental fluid mechanics and heat-transfer processes involved in a radically new, self contained, heat transfer cell for microgravity applications. In contrast to conventional heat pipes, the heat transfer in this cell is based on a forced droplet evaporation process using a fine spray. The spray is produced by a novel fluidic technology recently developed at Georgia Tech. This technology is based on a vibration induced droplet atomization process. In this technique, a liquid droplet is placed on a flexible membrane and is vibrated normal to itself. When the proper drop size is attained, the droplet resonates with the surface motion of the membrane and almost immediately bursts into a shower of very fine secondary droplets. The small droplets travel to the opposite end of the cell where they impact a heated surface and are evaporated. The vapor returns to the cold end of the cell and condenses to form the large droplets that are fragmented to form the spray. Preliminary estimates show that a heat transfer cell based on this technology would have a heat-flux capacity that is an order of magnitude higher than those of current heat pipes designs used in microgravity applications.

Smith, Marc K.↗
NASA NTRS1974

Plasma tests of sprayed coatings for rocket thrust chambers

Several plasma-sprayed coating systems were evaluated for structural stability in hydrogen plasma and in oxygen plasma mixed with hydrogen plasma. The principal test heat flux was 15 Btu per inch squared seconds. The system consisted of a number of thin 0.002 to 0.020 in. layers of metal oxides and/or metals. The principal materials included are molybdenum nichrome, alumina, and zirconia. The study identifies important factors in coating system fabrication and describes the durability of the coating systems in the test environments. Values of effective thermal conductivity for some of the systems are indicated.

Curren, A. N.↗
NASA NTRS2003

Development of Efficient Real-Fluid Model in Simulating Liquid Rocket Injector Flows

The characteristics of propellant mixing near the injector have a profound effect on the liquid rocket engine performance. However, the flow features near the injector of liquid rocket engines are extremely complicated, for example supercritical-pressure spray, turbulent mixing, and chemical reactions are present. Previously, a homogeneous spray approach with a real-fluid property model was developed to account for the compressibility and evaporation effects such that thermodynamics properties of a mixture at a wide range of pressures and temperatures can be properly calculated, including liquid-phase, gas- phase, two-phase, and dense fluid regions. The developed homogeneous spray model demonstrated a good success in simulating uni- element shear coaxial injector spray combustion flows. However, the real-fluid model suffered a computational deficiency when applied to a pressure-based computational fluid dynamics (CFD) code. The deficiency is caused by the pressure and enthalpy being the independent variables in the solution procedure of a pressure-based code, whereas the real-fluid model utilizes density and temperature as independent variables. The objective of the present research work is to improve the computational efficiency of the real-fluid property model in computing thermal properties. The proposed approach is called an efficient real-fluid model, and the improvement of computational efficiency is achieved by using a combination of a liquid species and a gaseous species to represent a real-fluid species.

Cheng, Gary↗
NASA NTRS1987

Self-lubricating coatings for high-temperature applications

Some present-day aeropropulsion systems impose severe demands on the thermal and oxidative stability of lubricant, bearing, and seal materials. These demands will be much more severe for operational systems around the turn of the century. Solid lubricants with maximum temperature capabilities of about 1100 C are known. Unfortunately, none of the solid lubricants with the highest temperature capabilities are effective below approximately 400 C. However, research shows that silver and stable fluorides, such as calcium and barium fluoride act synergistically to provide lubrication from below room temperature to approximately 900 C. Plasma-sprayed, self-lubricating composite coatings that were developed at Lewis are described. Background information is given on coatings, designed as PS100 and PS101, that contain the solid lubricants in a Nichrome matrix. These coatings have low friction coefficients over a wide temperature range, but they have inadequate wear resistance for some long-duration applications. Wear resistance was dramatically improved in a recently developed coating PS200, by replacing the Nichrome matrix material with metal-bonded chromium carbide containing dispersed silver and calcium fluoride/barium fluoride eutectic (CaF2/BaF2). The lubricants control friction and the carbide matrix provides excellent wear resistance. Successful tests of these coatings are discussed.

Sliney, Harold E.↗
DOE OSTI2023

Superhydrophobic composite asymmetric electrospun membrane for sustainable vacuum assisted air gap membrane distillation

Membrane distillation (MD) relies on superhydrophobic membranes that must achieve the competing goals of high liquid entry pressure (LEP) and high permeability. Here, in this study, we developed the first superhydrophobic composite electrospun asymmetric membrane using fluorinated graphite (FG). We also provided among the first comparisons of the relative benefits of membrane asymmetry and composite coatings via 3D electrospinning and spraying. FG particles increased the roughness and reduced the zeta potential of the membranes. Superhydrophobic composite membranes had a contact angle of 157° (sliding angle of 7°) and an LEP of 327 kPa. Long-term MD testing revealed that FG particles could increase MD's sustainability while decreasing membrane wetting. Vacuum-assisted air gap membrane distillation (V-AGMD) showed that the composite asymmetric membrane outperformed the non-asymmetric version (composite nanofiber) membrane by 21 % in average water flux and 25 % in average thermal efficiency because of the asymmetric structure of the membrane. The numerical model developed for the V-AGMD system also successfully predicted the water flux generated experimentally from the composite nanofiber and composite asymmetric membranes. Our results confirmed that electrospun asymmetric FG membranes with high contact angle, low sliding angle, high permeability, and high gained output ratio (GOR) would be promising candidates for sustainable MD.

36 MATERIALS SCIENCE↗
NASA NTRS2002

A Review of Single Source Precursors for the Deposition of Ternary Chalcopyrite Materials

The development of thin-film solar cells on flexible, lightweight, space-qualified durable substrates (i.e. Kapton) provides an attractive solution to fabricating solar arrays with high specific power, (W/kg). The syntheses and thermal modulation of ternary single source precursors, based on the [{LR}2Cu(SR')2In(SR')2] architecture in good yields are described. Thermogravimetric analyses (TGA) and Low temperature Differential Scanning Caloriometry, (DSC) demonstrate that controlled manipulation of the steric and electronic properties of either the group five-donor and/or chalcogenide moiety permits directed adjustment of the thermal stability and physical properties of the precursors. TGA-Evolved Gas Analysis, confirms that single precursors decompose by the initial extrusion of the sulphide moiety, followed by the loss of the neutral donor group, (L) to release the ternary chalcopyrite matrix. X-ray diffraction studies, EDS and SEM on the non-volatile pyrolized material demonstrate that these derivatives afford single-phase CuInS2/CuInSe2 materials at low temperature. Thin-film fabrication studies demonstrate that these single source precursors can be used in a spray chemical vapor deposition process, for depositing CuInS2 onto flexible polymer substrates at temperatures less than 400 C.

Banger, K. K.↗
NASA NTRS1979

Particle size and velocity measurement in flames by laser anemometer

Simultaneous droplet size and velocity measurements by a particle counting Laser Doppler Anemometer (LDA) in kerosene fuel sprays under burning and non-burning conditions are presented. Particle sizes are derived from pulse height analysis of the mean LDA signals and velocities are simultaneously determined by measuring Doppler shift frequencies. The measurements show that droplet velocity is a function of droplet diameter for burning and non-burning conditions, and spatially averaged size distributions are derived from velocity data. A comparison of results obtained under burning and non-burning conditions show changes in size distribution due to preferential vaporization of small droplets, acceleration due to thermal expansion of gases, and corresponding changes in droplet momentum.

Chigier, N. A.↗
NASA NTRS1983

Development of strain tolerant thermal barrier coating systems, tasks 1 - 3

Insulating ceramic thermal barrier coatings can reduce gas turbine airfoil metal temperatures as much as 170 C (about 300 F), providing fuel efficiency improvements greater than one percent and durability improvements of 2 to 3X. The objective was to increase the spalling resistance of zirconia based ceramic turbine coatings. To accomplish this, two baseline and 30 candidate duplex (layered MCrAlY/zirconia based ceramic) coatings were iteratively evaluated microstructurally and in four series of laboratory burner rig tests. This led to the selection of two candidate optimized 0.25 mm (0.010 inch) thick plasma sprayed partially stabilized zirconia ceramics containing six weight percent yttria and applied with two different sets of process parameters over a 0.13 mm (0.005 inch) thick low pressure chamber sprayed MCrAlY bond coat. Both of these coatings demonstrated at least 3X laboratory cyclic spalling life improvement over the baseline systems, as well as cyclic oxidation life equivalent to 15,000 commercial engine flight hours.

Anderson, N. P.↗
DOE OSTI2022

Surface engineering with oxidized Ti 3 C 2 T x MXene enables efficient and stable p-i-n-structured CsPbI 3 perovskite solar cells

All-inorganic CsPbI 3 perovskite has a near-ideal band gap, high thermal stability, and simple material composition, thus presenting a promising option for developing perovskite/Si tandem solar cells. However, CsPbI 3 undergoes a rapid phase transition under exposure to moisture and exhibits a significant performance gap relative to other perovskite compounds, particularly in the p-i-n structure favored for perovskite/Si tandems. In this work, we demonstrate highly efficient and stable p-i-n-structured CsPbI 3 perovskite solar cells by surface engineering the CsPbI 3 layer with oxidized Ti 3 C 2 T x MXene (OMXene) nanoplates via spray coatings. OMXene provides a physical barrier against moisture and improves charge separation at the perovskite-electron transporting layer interface via an enhanced electric field. Consequently, we demonstrated CsPbI 3 /OMXene-based p-i-n devices with efficiencies of 19.69% for 0.096-cm 2 cells and 14.64% for 25-cm 2 minimodules. The encapsulated minimodule showed good stability, retaining ~85% of the initial efficiency under simultaneous damp heat (85°C/85% relative humidity) and 1-sun light soaking for over 1,000 h.

14 SOLAR ENERGY↗
NASA NTRS2005

NASA Research Center Contributions to Space Shuttle Return to Flight (SSRTF)

Contributions provided by the NASA Research Centers to key Space Shuttle return-to-flight milestones, with an emphasis on debris and Thermal Protection System (TPS) damage characterization, are described herein. Several CAIB recommendations and Space Shuttle Program directives deal with the mitigation of external tank foam insulation as a debris source, including material characterization as well as potential design changes, and an understanding of Orbiter TPS material characteristics, damage scenarios, and repair options. Ames, Glenn, and Langley Research Centers have performed analytic studies, conducted experimental testing, and developed new technologies, analysis tools, and hardware to contribute to each of these recommendations. For the External Tank (ET), these include studies of spray-on foam insulation (SOFI), investigations of potential design changes, and applications of advanced non-destructive evaluation (NDE) technologies to understand ET TPS shedding during liftoff and ascent. The end-to-end debris assessment included transport analysis to determine the probabilities of impact for various debris sources. For the Orbiter, methods were developed, and validated through experimental testing, to determine thresholds for potential damage of Orbiter TPS components. Analysis tools were developed and validated for on-orbit TPS damage assessments, especially in the area of aerothermal environments. Advanced NDE technologies were also applied to the Orbiter TPS components, including sensor technologies to detect wing leading edge impacts during liftoff and ascent. Work is continuing to develop certified TPS repair options and to develop improved methodologies for reinforced carbon-carbon (RCC) damage progression to assist in on-orbit repair decision philosophy.

Cockrell, Charles E., Jr.↗
NASA NTRS1982

Use of fiber like materials to augment the cycle life of thick thermoprotective seal coatings

Some experimental and analytical studies of plasma sprayed ZrO2-Y2O3 thick seal thermoprotective materials over NiCrAlY bond coats with testing to 1040 deg C in a Mach 0.3 burner flame are reviewed. These results indicate the need for material to have both compliance and sufficient strength to function successfully as a thick thermoprotective seal material. Fibrous materials may satisfy many of these requirements. A preliminary analysis simulating the simplified behavior of a 25 mm cylindrical SiO2-fiber material indicated significant radial temperature gradients, a relatively cool interface and generally acceptable stresses over the initial portion of the thermal cycle. Subsequent testing of these fiberlike materials in a Mach 0.3 Jet A/air burner flame confirmed these results.

Hendricks, R. C.↗
NASA NTRS1982

An experimental investigation of interfacial temperatures in blade-seal material rubbing of aircraft compressors

Results are presented for the rubbing of rotating (100 m/s) titanium blade specimens, with different plasma-sprayed tip coating, against an abradable porous seal material at two different incursion rates. In general, there was a good correspondence between the average transverse force of rubbing and the seal specimen surface temperature. Instantaneous seal surface temperature measurement showed a significant temperature jump before and after each rubbing with a high rate of cooling during each revolution and a high overall temperature level. Numerical predictions of both blade and seal temperature agreed well for the bare blade tip experiments but were consistently high for the coated blades. This suggests that the thermal properties of the coatings may significantly affect the temperatures and hence the wear characteristics of the system.

Emery, A. F.↗
NASA NTRS2002

NASA Glenn/AADC Collaboration Optimized Erosion Coatings for Inlet Guide Vanes

There is a need for lightweight, durable materials and structures to reduce the weight of propulsion systems. Polymer matrix composites (PMC's) are promising materials for aerospace applications because of their high strength-to-weight ratio relative to metals. Unfortunately, they are limited to applications where they are not exposed to hightemperature oxidizing atmospheres and/or particulates from ingested air. This is because oxidation and erosion occur on the surface, leading to weight loss, nodulation, and/or cracking on the surface, and a consequent decline of mechanical properties over time. Although prior research has shown that oxidation can be slowed when metallic or ceramic coatings are applied onto PMC's, there remains a need for erosion-resistant coatings that protect PMC's from high-velocity particulates in the engine flow path. These erosionresistant coatings could extend the life of polymer composites. Polymer composites are heavily damaged without an erosion-resistant coating because they are not as hard as metallic engine structures. The effectiveness and life of the coatings depends on their inherent properties as well as on the interaction between the coating and the PMC. Since polymers, in general, have high thermal expansion coefficients in comparison to metals and ceramics, failure of the coatings often occurs at this interface. The objective of this research is to develop strategies to improve this interface and tailor overlays for erosion resistance. The bondcoat, which was developed at the NASA Glenn Research Center, is composed of zinc blended with polyimides to improve the compatibility between the PMC and the overlay material. Initial coating trials at AADC produced vanes that had poor bonding between the overlay and bondcoats. Subsequently, Glenn successfully demonstrated that high-quality plasma-sprayed erosion coating systems could be applied to these guide vanes. Inlet guide vanes from AE 3007 engines fiber composites were coated using a coating system composed of a bondcoat and a hard topcoat. Optimization of the plasma spray process has led to plans for future erosion testing in gas turbine engine environments.

Sutter, James K.↗
NASA NTRS1980

Program to develop sprayed, plastically deformable compressor shroud seal materials

A study of fundamental rub behavior for 10 dense, sprayed materials and eight current compressor clearance materials was conducted. A literature survey of a wide variety of metallurgical and thermophysical properties was conducted and correlated to rub behavior. Based on the results, the most promising dense rub material was Cu-9A1. Additional studies on the effects of porosity, incursion rate, blade solidity, and ambient temperature were carried out on aluminum bronze (Cu-9Al-1Fe) with and without a 515B Feltmetal underlayer. A further development effort was conducted to assess the property requirements of a porous, aluminum bronze, seal material. Strength, thermal cycle capabilities, erosion and oxidation resistance, machinability, and abradability at several porosity levels were examined.

Schell, J. D.↗
NASA NTRS1984

Thermal barrier coating life prediction model development

The objective of this program is to develop an integrated life prediction model accounting for all potential life-limiting Thermal Barrier Coating (TBC) degradation and failure modes including spallation resulting from cyclic thermal stress, oxidative degradation, hot corrosion, erosion, and foreign object damage (FOD). The mechanisms and relative importance of the various degradation and failure modes will be determined, and the methodology to predict predominant mode failure life in turbine airfoil application will be developed and verified. An empirically based correlative model relating coating life to parametrically expressed driving forces such as temperature and stress will be employed. The two-layer TBC system being investigated, designated PWA264, currently is in commercial aircraft revenue service. It consists of an inner low pressure chamber plasma-sprayed NiCoCrAlY metallic bond coat underlayer (4 to 6 mils) and an outer air plasma-sprayed 7 w/o Y2O3-ZrO2 (8 to 12 mils) ceramic top layer.

Demasi, J.↗
NASA NTRS1991

Chemical spray pyrolysis of Tl-Ba-Ca-Cu-O high-T(sub c) superconductors for high-field bitter magnets

The deposition of Tl-Ba-Ca-Cu-O thick films by spray pyrolyzing a Ba-Ca-Cu-O precursor film and diffusing thallium into the film to form the superconducting phase is examined. This approach was taken to reduce exposure to thallium and its health and safety hazards. The Tl-Ba-Ca-Cu-O system was selected because it has very attractive features which make it appealing to device and manufacturing engineering. Tl-Ba-Ca-Cu-O will accommodate a number of superconducting phases. This attribute makes it very forgiving to stoichiometric fluctuations in the bulk and film. It has excellent thermal and chemical stability, and appears to be relatively insensitive to chemical impurities. Oxygen is tightly bound into the systems, consequently there is no orthorhombic (conductor) to tetragonal (insulator) transition which would affect a component's lifetime. More significantly, the thallium based superconductors appear to have harder magnetic properties than the other high-Tc oxide ceramics. Estimates using magnetoresistance measurements indicate that at 77 K Tl2Ba2CaCu2O10 will have an upper critical field, H(sub c2) fo 26 Tesla for applied fields parallel to the c-axis and approximately 1000 Tesla for fields oriented in the a-b plane. Results to date have shown that superconducting films can be reproducibly deposited on 100 oriented MgO substrates. One film had a zero resistance temperature of 111.5 K. Furthermore, x ray diffraction analysis of the films showed preferential c-axis orientation parallel to the plane of the substrate. These results have now made it possible to consider the manufacture of a superconducting tape wire which can be configured into a topology useful for high-field magnet designs. The research which leads to the preparation of these films and plans for further development are reviewed.

Derochemont, L. Pierre↗