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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 901 records · Page 50
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Aluminization Coatings and Glass Seals for High Temperature Systems - CRADA 536 (Final Report)

The objective of this project was to demonstrate the suitability of PNNL’s Reactive Air Aluminization (RAA) coatings (US Patent Numbers 10,577,694, 10,378,094, and 9,481,923) for use in high-temperature systems. In particular, PNNL and Utility Global undertook a collaborative effort to explore the applicability of these coatings in Utility Global’s high-temperature hydrogen reactors where they would be used to prepare the sealing surfaces of the reactor technology. Utility Global instructed PNNL regarding their needs relating to further development of glass seal technologies suitable for use in their systems. This effort entailed alkaline earth-based silicate glass development and characterization; evaluation and characterization of reliability and compatibility of the coatings with glass seals, working environments, and substrates; performance demonstrations of representative cells and intermediate cells sealed using the glass seals and/or coatings of interest; and incorporation of the aluminization coatings and glass seals into Utility Global reactors for testing.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Commissioning of dedicated furnace for Nb3Sn coatings of 2.6GHz single cell cavities

We present the results of commissioning a dedicated fur- nace for Nb3Sn coatings of 2.6 GHz single cell cavities. Nb3Sn is a desired coating due to its high critical temper- ature and smaller surface resistance compared to bulk Nb. Usage of Nb3Sn coated cavities will greatly reduce operat- ing costs due to decreased dependance on cryo cooling. Tin is deposited by use of a tin chloride nucleation agent and tin vapor diffusion. Analysis of the resultant coating was performed using SEM/EDS to verify successful formation of Nb3Sn. Witness samples in line of sight of the source were used in order to understand the coating efficacy.

Kulyavtsev, P. A.↗
DOE OSTI2023

Preservation of the High Quality Factor and Accelerating Gradient of Nb3Sn-coated Cavity During Pair Assembly

Two CEBAF 5-cell accelerator cavities have been coated with Nb3Sn film using the vapor diffusion technique. One cavity was coated in the Jefferson Lab Nb3Sn cavity coating system, and the other in the Fermilab Nb3Sn coating system. Both cavities were measured at 4 K and 2 K in the vertical dewar test in each lab and then assembled into a cavity pair at Jefferson Lab. Previous attempts to assemble Nb3Sn cavities into a cavity pair degraded the superconducting properties of Nb3Sn-coated cavities. This contribution discusses the efforts to identify and mitigate the pair assembly challenges and will present the results of the vertical tests before and after pair assembly. Notably, one of the cavities reached the highest gradient above 80 mT in the vertical test after the pair assembly.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

Residual Stress Measurements of Cr-coated Cladding

Accident-tolerant fuel concepts for light-water reactor applications have been developed and tested in diverse research programs around the world. Industry teams have developed coated cladding concepts using different coating application methods, such as physical vapor deposition and coldspraying. Recently, variations in thickness and application method were investigated, and their effects on the microstructure and mechanical properties were reported. The results suggest an increase in performance in an unirradiated state, however, it remains unclear what phenomenon drove this performance. One explanation to this performance is associated with the coating process imparting a residual stress. Residual stress analysis was performed on coatings produced with various process parameters to understand how a thin layer of Cr impacts the mechanical properties after coating application and after simulated operating conditions. The gathered information is intended to address safety concerns or support margin identification related to accident-tolerant fuels and to support subsequent modeling and simulation efforts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Development of Refractory Alloys and Refractory Coatings for Advanced Nuclear Reactors

The next generation of nuclear reactors will benefit from materials that enable operation at higher temperatures (>500°C), higher irradiation doses (up to 200 displacements per atom (dpa)), and the use of more corrosive and reactive coolants. This work package represents the first experimental steps towards a longer-term effort to develop refractory materials for nuclear energy applications which will enable operation under these conditions. Specifically, this work package focuses on additive manufacturing of refractories as both a refractory liner coating deposited onto the interior surface of a metallic tubular backbone and as bulk refractory alloys. During fiscal year 23 (FY23), several refractory metal coating systems and bulk alloys were examined and selected using a decision criteria matrix. The refractory metal coating systems included molybdenum, tungsten, and zirconium as refractory coatings on backbones of either carbon-carbon (C/C) or silicon carbide-silicon carbide (SiC/SiC) ceramic matrix composites. The bulk refractory alloys included C-103, WTa, and WNiFe as bulk alloys. During FY24 additional bulk refractory alloys and metallic backbones were evaluated using the decision criteria matrix based on input from the AMMT leadership team. These included 316 SS and 316H SS for the metallic backbones and Mo-La, Ta, and Nb1Zr as bulk refractory alloys. The primary focus for the FY24 effort was placed on establishing the capabilities to deposit refractory coatings based on the results of the scoring in the decision criteria matrix and finalizing the additively manufactured TZM studies which were incorporated into the AMMT program from the microreactor program. Further efforts were dedicated to establishing the capabilities to additively manufacture down-selected bulk refractory alloys.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Improving Stability of an Optical Fiber pH Sensor with a Calcined Polyethylenimine-Coating at High Pressures and Temperatures

With an increased interest in subsurface gas storage technology for various energy applications, monitoring wellbore structural stability and subsurface geochemistry has become more pressing, and pH is a key parameter to measure. As high pressure and elevated temperatures in subsurface conditions are comparatively harsh relative to that expected for most standard pH sensor designs, any pH monitoring hardware must be designed for extended exposure to high pressures and temperatures. We previously reported that an optical fiber pH sensor functionalized with a calcined polyethylenimine coating had shown some promise as a high temperature and pressure pH sensor but with some drifting when operating for longer than 8 hours. In this paper, we investigated the coating composition and potential cause of the drifting and improved the stability of the prepared coating to minimize sensor drift under simulated wellbore conditions. Scanning electron microscopy (SEM) had previously shown moderate cracking at high pressures over short tests. By applying X-ray photoelectron spectroscopy (XPS) to characterize the sensor coating before and after one week of testing in an H2/CH4 gas blend at 80 °C and 900 psi, a compositional change in the coating was observable, which may indicate susceptibility to alteration by subsurface gas storage conditions. Non-reducing (CH4, N2) environments were also tested, and confirmed that both temperature and pressure were also contributing to the drift.

energy infrastructure↗
DOE OSTI2024

Computational design of high entropy alloy coating for hydrogen turbine applications

This project aims to develop novel high entropy alloy (HEA)-based coatings to protect critical components in hydrogen-fueled turbine power system. The HEA-coatings will demonstrate superior performance in hydrogen combustion environment to commercial NiCoCrAlY coating in current natural gas turbine system. The HEA coating facilitates the formation of a protective scale of alpha-alumina to slow down the inward diffusion of oxidizing species and the outward diffusion of metal elements, and possesses ultrahigh corrosion and spallation resistance to prolong the service lifetime of critical components in hydrogen turbine power system. Aimed to accelerate the discovery of novel HEA coating compositions, high throughput computational modeling including CALPHAD and density functional theory and machine learning are performed to predict phase stability, oxygen permeability, oxidation rate constant, coefficient of thermal expansion, and mechanical properties. Based on the modeling and machine learning prediction, experimental validation is performed. Preliminary results will be presented and approaches to minimize oxidation will be discussed.

alloy design↗
DOE OSTI2026

High Entropy Rare-earth Oxide (HERO) Coatings for Refractory Alloys

The HERO coating was developed to protect refractory alloys for application in the harsh hot section of the turbine engine environment addressing ARPA-E ULTIMATE Project Topic 2: Coating Development. The effort was both innovative in its utilization of high entropy rare earth oxides as well as transformational in our approach: holistic design of a single layer thermal/environmental barrier coating (T/EBC) for refractory alloys, with an excellent coefficient of thermal expansion (CTE) match to the alloy substrate, chemical compatibility with the underlying alloy, low oxidant permeability, stability in combustion environments, low thermal conductivity, thermal shock resistance, and resistance to degradation by siliceous debris (calcium magnesium alumino-silicates-CMAS). The high entropy rare earth oxide approach enables two critical coating properties: tailoring CTE match to the substrate and, most significantly, substantially reduced thermal conductivity. The summation of these proposed coating capabilities goes well beyond the technical requirements specified in the ULTIMATE program objectives, and additionally is essential for a successful first stage turbine blade application.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Uncertainties in the effects of organic aerosol coatings on polycyclic aromatic hydrocarbon concentrations and their estimated health effects

We used the CAM5 model to examine how different particle-bound polycyclic aromatic hydrocarbon (PAH) degradation approaches affect the spatial distribution of benzo(a)pyrene (BaP). Three approaches were evaluated: NOA (no effect of OA coatings state on BaP), shielded (viscous OA coatings shield BaP from oxidation under cool and dry conditions) and ROI-T (viscous OA coatings slow BaP oxidation in response to temperature and humidity). Results show that BaP concentrations vary seasonally, influenced by emissions, deposition, transport and degradation approach, all of which are influenced by meteorological conditions. All simulations predict higher population-weighted global average (PWGA) fresh BaP concentrations during December–January–February (DJF) compared to June–July–August (JJA), due to increased emissions from household activities and reduced removal processes during colder months. The shielded and ROI-T approaches, which account for OA coatings, result in 2–6 times higher BaP concentrations in DJF compared to NOA. The shielded simulation predicts the highest PWGA fresh BaP concentration (1.3 ng m −3 ), with 90 % of BaP protected from oxidation. In contrast, the ROI-T approach forecasts lower concentrations in middle to low latitudes, as it assumes less effective OA coatings under warmer, more humid conditions. Evaluations against observed BaP concentrations show the shielded approach performs best, with a normalized mean bias (NMB) within ± 20 %. The combined incremental lifetime cancer risk (ILCR) for both fresh and oxidized PAHs is similar across simulations, emphasizing the importance of considering both forms in health risk assessments. This study highlights the critical role of accurate degradation approaches in PAH modeling.

63 RADIATION, THERMAL, AND OTHER ENVIRON. POLLUTAN↗
DOE OSTI2026

Measurement report: Role of organic coating and chemical composition on ice nucleation potential of atmospheric particles in European Arctic

Understanding the ice nucleation (IN) potential of Arctic aerosols is critical for predicting their influence on cloud formation and water cycles in this vulnerable region. This study investigates the role of particle composition, organic coatings, and aerosol sources in modulating ice nucleating particle (INPs) abundance across five aerosol samples collected at the Gruvebadet Observatory Station in Ny-Ålesund, Svalbard. The IN potential of Arctic aerosol particles was studied by investigating chemical, morphological, and INP abundance measurements. Single-particle analyses revealed distinct differences in mixing state, organic volume fraction (OVF), and organic coating morphology across samples. OVF distributions were linked to particle origin, with marine-influenced Na-rich particles often exhibiting thin organic coatings, while long-range transported particles showed thicker organic coatings. Biogenic contributions, though variable, were linked to heat-sensitive INPs, suggesting a role for labile biological macromolecules under certain meteorological conditions. Spearman rank correlation analysis between particle composition and immersion-mode INP concentrations at two freezing temperatures indicated that organic-rich and Na-rich particles were positively associated with enhanced INP abundance. However, discrepancies in INP abundance were observed for particles with thicker organic coatings, where the morphological configuration of the organic material may play a role. The results highlight that Arctic INP variability is governed not only by chemical composition but also by the morphological configuration of organic material, which can either enhance or inhibit ice nucleation depending on its abundance, distribution, thickness, and mixing state. These findings underscore the combined influence of source regions, atmospheric processing, and organic–inorganic interactions in shaping Arctic aerosol freezing behavior.

Lata, Nurun Nahar [Pacific Northwest National Labo↗
NASA NTRS1966

Improved method of edge coating flat ribbon wire

Method to coat the edges of flat ribbon wire is devised by using enamel with modified flow properties due to addition of 2 to 4 percent silicon. Conventional coating procedes several edge coatings to minimize oxidation and additional conventional coats are applied after edge coating to build up thickness.

Source record↗
NASA NTRS1972

Hydrogen plasma tests of some insulating coating systems for the nuclear rocket thrust chamber

Several plasma-sprayed and slurry-coated insulating coating systems were evaluated for structural stability in a low-pressure hot hydrogen environment at a maximum heat flux of 19.6 million watts/sq meter. The heat was provided by an electric-arc plasma generator. The coating systems consisted of a number of thin layers of metal oxides and/or metals. The materials included molybdenum, nichrome, tungsten, alumina, zirconia, and chromia. The study indicates potential usefulness in this environment for some coatings, and points up the need for improved coating application techniques.

Current, A. N.↗
NASA NTRS1971

Investigation of environmental effects on coatings for thermal control of large space vehicles

The objective of significantly advancing the state-of-the-art of white, spacecraft-radiator coatings has been realized in a comprehensive goal-oriented, pigmented-coatings research program. Considered were inorganic pigments and coatings, silicone polymers and coatings, the design and construction of a combined ultraviolet-plus-proton irradiation facility, the development of zinc orthotitanate pigment and coatings, and the effects on several low alpha sub s/epsilon paints of combined ultraviolet and proton irradiation.

Zerlaunt, G. A.↗
NASA NTRS1971

Protective coatings for columbium applied in the field.

The various aspects of field repair of columbium alloy panels with protective coatings designed as part of the Space Shuttle thermal protection system are examined. The field repair of the coatings is accomplished by employing ceramic cement repairs, and reapplying the fused slurry silicide coating. Techniques are described which improve the practicality of these repairs by employing torch heating. The repair coating quality is demonstrated by testing which simulates flight temperature, pressure, stress and acoustic vibration conditions as a function of time. Conclusions on the present status of field repair coatings are presented and recommendations are given for appropriate future activities relative to the use on an operational Space Shuttle system.

Carter, J.↗
NASA NTRS1972

Ultraviolet and charged particle irradiation of proposed solar cell coverslide materials and conductive coatings for the Helios spacecraft

Coverslide materials consisting of Corning 7940 fused silica, multilayers of titanium and manganese oxides (blue reflector), and indium oxide (conductive-coating) were exposed to 16 UVSC up to 800 EUVSH in vacuum. Slight changes in optical transmittance and optical absorptance were found in the (200-360) millimicron regions of the fused silica and conductive coating respectively. Exposure to 4 KeV protons and 4.5 KeV electrons in vacuum, produced decreases of several percent in transmittance, (200-360) millimicron region in the fused silicas after total fluxes less or = 10 to the 14th power particles/sq cm. Sheet resistance of the conductive coating increased above 1.0 kilo-ohm/square after a total flux less or = 10 to the 14th power particles/sq cm. Solar cells with coverglasses utilizing the indium oxide conductive coating were exposed to 1 Mev electrons and 1 Mev protons in air and in vacuum. Total fluxes ranged from 10 to the 11th power particles/sq cm to 10 to the 15th power particle/sq cm. There was no appreciable degradation in the resistance of the conductive coating during or after these tests.

Fry, J.↗
NASA NTRS1973

Effects of diffusion on aluminum depletion and degradation of NiAl coatings

Experiments were performed to critically demonstrate the effects of diffusion on the aluminum depletion and degradation of NiAl coatings on superalloys. Pack aluminized IN 100 and Mar-M200 were diffusion annealed in 0.0005 torr vacuum at 1100 C for 300 hours. Aluminum losses due to oxidation and vaporization were minimal. Metallographic and electron microprobe analyses showed considerable interdiffusion of the coating with the substrate, which caused a large decrease in the original aluminum level of the coating. Subsequent cyclic furnace oxidation tests were performed at 1100 C using 1 hour cycles on pre-diffused and as-coated specimens. The pre-diffusion treatment decreased the oxidation protection for both alloys, but more dramatically for IN 100. Identical oxidation tests of bulk NiAl, where such diffusion effects are precluded, showed no signs of degradation at twice the time needed to degrade the coated superalloys.

Smialek, J. L.↗
NASA NTRS1973

Reliability and effective thermal conductivity of three metallic-ceramic composite insulating coatings on cooled hydrogen-oxygen rockets

An experimental investigation of the structural integrity and effective thermal conductivity of three metallic-ceramic composite coatings was conducted. These coatings were plasma sprayed onto the combustion side of water-cooled, 12.7-centimeter throat diameter, hydrogen-oxygen rocket thrust chambers operating at 2.07 to 4.14 meganewtons per square meter chamber pressure. The metallic-ceramic composites functioned for six to 17 cycles and for as long as 213 seconds of rocket operations and could have probably provided their insulating properties for many additional cycles. The effective thermal conductivity of all the coatings was in the range of 0.7472 to 4.483 w/(m)(K), which makes the coatings a very effective thermal barrier. Photomicrographic studies of cross-sectioned coolant tubes seem to indicate that the effective thermal conductivity of the coatings is controlled by contact resistance between the particles, as a result of the spraying process, and not the thermal conductivity of the bulk materials.

Price, H. G., Jr.↗
NASA NTRS1974

High-velocity-oxidation performance of metal-chromium-aluminum (MCrAl), cermet, and modified aluminide coatings on IN-100 and type VIA alloys at 1093 C

Cermet, MCrAl, and modified aluminide types of coatings applied to IN-100 and NASA-TRW-VIA alloy specimens were cyclically oxidation tested in a high velocity (Mach 1) gas flame at 1093 C. Several coating compositions of each type were evaluated for oxidation resistance. The modified aluminide coating, Pt-Al, applied to alloy 6A proved to be the best, providing oxidation protection to approximately 750 hours based on weight change measurements. The second best, a CoCrAlY coating applied to 6A, provided protection to 450 hours. The third best was a cermet + aluminide coating on 6A with a protection time to 385 hours.

Deadmore, D. L.↗