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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
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NASA NTRS2002

Atmospheric Pressure Spray Chemical Vapor Deposited CuInS2 Thin Films for Photovoltaic Applications

Solar cells have been prepared using atmospheric pressure spray chemical vapor deposited CuInS2 absorbers. The CuInS2 films were deposited at 390 C using the single source precursor (PPh3)2CuIn(SEt)4 in an argon atmosphere. The absorber ranges in thickness from 0.75 - 1.0 micrometers, and exhibits a crystallographic gradient, with the leading edge having a (220) preferred orientation and the trailing edge having a (112) orientation. Schottky diodes prepared by thermal evaporation of aluminum contacts on to the CuInS2 yielded diodes for films that were annealed at 600 C. Solar cells were prepared using annealed films and had the (top down) composition of Al/ZnO/CdS/CuInS2/Mo/Glass. The Jsc, Voc, FF and (eta) were 6.46 mA per square centimeter, 307 mV, 24% and 0.35%, respectively for the best small area cells under simulated AM0 illumination.

Harris, J. D.↗
NASA NTRS2002

Ternary Precursors for Depositing I-III-VI2 Thin Films for Solar Cells via Spray CVD

The development of thin-film solar cells on flexible, lightweight, space-qualified substrates provides an attractive cost solution to fabricating solar arrays with high specific power (W/kg). Thin-film fabrication studies demonstrate that ternary single source precursors (SSP's) can be used in either a hot or cold-wall spray chemical vapour deposition (CVD) reactor, for depositing CuInS2, CuGaS2, and CuGaInS2 at reduced temperatures (400 to 450 C), which display good electrical and optical properties suitable for photovoltaic (PV) devices. X-ray diffraction studies, energy dispersive spectroscopy (EDS), and scanning electron microscopy (SEM) confirmed the formation of the single phase CIS, CGS, CIGS thin-films on various substrates at reduced temperatures.

Banger, K. K.↗
NASA NTRS2003

The Effect of Film Composition on the Texture and Grain Size of CuInS2 Prepared by Spray Pyrolysis

CuInS2 was deposited by spray pyrolysis using single-source precursors synthesized in-house. Films with either (112) or (204/220) preferred orientation always showed Cu-rich and In-rich composition respectively. The In-rich (204/220)-oriented films always contained a secondary phase evaluated as an In-rich compound, and the hindrance of (112)-oriented grain growth was confirmed by glancing angle X-ray diffraction. In conclusion, only the Cu-rich (112)-oriented films with dense columnar grains can be prepared without the secondary In-rich compound. The effect of extra Cu on the grain size and the solar cell results will be also presented.

Jin, Michael H.-C.↗
NASA NTRS2002

Investigation into the Micro-Gravity Effects on Two-Phase Spray Thermophysics

This viewgraph presentation provides information on the effects of microgravity on a spray system being developed for thermal management in aerospace environments. The presentation addresses trends in thermal technology and NASA's thermal technology needs, thermophysics experiments conducted in microgravity, and equipment for the experiments.

Yerkes, Kirk↗
NASA NTRS2003

Microstructure and Properties of Thermally Sprayed Functionally Graded Coatings for Polymeric Substrates

The use of polymer matrix composites (PMCs) in the gas flow path of advanced turbine engines offers significant benefits for aircraft engine performance but their useful lifetime is limited by their poor erosion resistance. High velocity oxy-fuel (HVOF) sprayed polymer/cermet functionally graded (FGM) coatings are being investigated as a method to address this technology gap by providing erosion and oxidation protection to polymer matrix composites. The FGM coating structures are based on a polyimide matrix filled with varying volume fractions of WC-Co. The graded coating architecture was produced using a combination of internal and external feedstock injection, via two computer-controlled powder feeders and controlled substrate preheating. Porosity, coating thickness and volume fraction of the WC-Co filler retained in the coatings were determined using standard metallographic techniques and computer image analysis. The pull-off strength (often referred to as the adhesive strength) of the coatings was evaluated according to the ASTM D 4541 standard test method, which measured the greatest normal tensile force that the coating could withstand. Adhesive/cohesive strengths were determined for three different types of coating structures and compared based on the maximum indicated load and the surface area loaded. The nature and locus of the fractures were characterized according to the percent of adhesive and/or cohesive failure, and the tested interfaces and layers involved were analyzed by Scanning Electron Microscopy.

Ivosevic, M.↗
NASA NTRS2003

Mode I, Mode II, and Mixed-Mode Fracture of Plasma-sprayed Thermal Barrier Coatings at Ambient and Elevated Temperatures

The mixed-mode fracture behavior of plasma-sprayed ZrO2-8 wt% Y2O3 thermal barrier coatings was determined in air at 25 and 1316 C in asymmetric four-point flexure with single edge v-notched beam (SEVNB) test specimens. The mode I fracture toughness was found to be K(sub Ic) = 1.15 plus or minus 0.07 and 0.98 plus or minus 0.13 MPa the square root of m, respectively, at 25 and 1316 C. The respective mode II fracture toughness values were K(sub IIc) = 0.73 plus or minus 0.10 and 0.65 plus or minus 0.04 MPa the square root of m. Hence, there was an insignificant difference in either K(sub Ic or K(sub IIc) between 25 and 1316 C for the coating material, whereas there was a noticeable distinction between K(sub Ic) and K(sub IIc), resulting in K(sub IIc) per K(sub Ic) = 0.65 at both temperatures. The empirical mixed-mode fracture criterion best described the coatings' mixed-mode fracture behavior among the four mixed-mode fracture theories considered. The angle of crack propagation was in reasonable agreement with the minimum strain energy density criterion. The effect of the directionality of the coating material in on K(sub Ic) was observed to be insignificant, while its sintering effect at 1316 C on K(sub Ic) was significant.

Choi, Sung R.↗
NASA NTRS2003

Test Data Analysis of a Spray Bar Zero-Gravity Liquid Hydrogen Vent System for Upper Stages

To support development of a zero-gravity pressure control capability for liquid hydrogen (LH2), a series of thermodynamic venting system (TVS) tests was conducted in 1996 and 1998 using the Marshall Space Flight Center (MSFC) multipurpose hydrogen test bed (MHTB). These tests were performed with ambient heat leaks =20 and 50 W for tank fill levels of 90%, 50%, and 25%. TVS performance testing revealed that the spray bar was highly effective in providing tank pressure control within a 7-kPa band (131-138 Wa), and complete destratification of the liquid and the ullage was achieved with all test conditions. Seven of the MHTB tests were correlated with the TVS performance analytical model. The tests were selected to encompass the range of tank fill levels, ambient heat leaks, operational modes, and ullage pressurants. The TVS model predicted ullage pressure and temperature and bulk liquid saturation pressure and temperature obtained from the TVS model were compared with the test data. During extended self-pressurization periods, following tank lockup, the model predicted faster pressure rise rates than were measured. However, once the system entered the cyclic mixing/venting operational mode, the modeled and measured data were quite similar.

Hedayat, A.↗
NASA NTRS2003

The Effect of Film Composition on the Texture and Grain Size of CuInS2 Prepared by Spray Pyrolysis

Ternary single-source precursors were used to deposit CuInS2 thin films using chemical spray pyrolysis. We investigated the effect of the film composition on texture, secondary phase formation, and grain size. As-grown films were most often In-rich. They became more (204/220)-oriented as indium concentration increased, and always contained a yet unidentified secondary phase. The (112)-prefened orientation became more pronounced as the film composition became more Cu-rich. The secondary phase was determined to be an In-rich compound based on composition analysis and Raman spectroscopy. In addition, as-grown Cu-rich (112)-oriented films did not exhibit the In-rich compound. Depositing a thin Cu layer prior to the growth of CuInS2 increased the maximum grain size from - 0.5 micron to - 1 micron, and prevented the formation of the In-rich secondary phase.

Jin, Michael H.↗
NASA NTRS2003

Combined Mode I and Mode II Fracture of Plasma-Sprayed Thermal Barrier Coatings at Ambient and Elevated Temperatures

The mode I, mode II, and combined mode I-mode II fracture behavior of ZrO2- 8wt%Y2O3 thermal barrier coatings was determined in asymmetric flexure loading at both ambient and elevated temperatures. Precracks were introduced in test specimens using the single-edge-v-notched beam (SEVNB) method incorporated with final diamond polishing to achieve sharp crack tips. A fracture envelope of KI versus KII was determined for the coating material at ambient and elevated temperatures. Propagation angles of fracture as a function of K(sub I)/K(sub II) were also determined. The mixed-mode fracture behaviors of the coating material were compared with those of monolithic advanced ceramics determined previously. The mixed-mode fracture behavior of the plasma-sprayed thermal barrier coating material was predicted in terms of fracture envelope and propagation angle using mixed-mode fracture theories.

Choi, Sung R.↗
NASA NTRS2003

Spray Bar Zero-Gravity Vent System for On-Orbit Liquid Hydrogen Storage

During zero-gravity orbital cryogenic propulsion operations, a thermodynamic vent system (TVS) concept is expected to maintain tank pressure control without propellant resettling. In this case, a longitudinal spray bar mixer system, coupled with a Joule-Thompson (J-T) valve and heat exchanger, was evaluated in a series of TVS tests using the 18 cu m multipurpose hydrogen test bed. Tests performed at fill levels of 90, 50, and 25 percent, coupled with heat tank leaks of about 20 and 50 W, successfully demonstrated tank pressure control within a 7-kPa band. Based on limited testing, the presence of helium constrained the energy exchange between the gaseous and liquid hydrogen (LH2) during the mixing cycles. A transient analytical model, formulated to characterize TVS performance, was used to correlate the test data. During self-pressurization cycles following tank lockup, the model predicted faster pressure rise rates than were measured; however, once the system entered the cyclic self-pressurization/mixing/venting operational mode, the modeled and measured data were quite similar. During a special test at the 25-percent fill level, the J-T valve was allowed to remain open and successfully reduced the bulk LH2 saturation pressure from 133 to 70 kPa in 188 min.

Hastings, L. J.↗
NASA NTRS2003

Analysis of Plasma-Sprayed Thermal Barrier Coatings With Homogeneous and Heterogeneous Bond Coats Under Spatially Uniform Cyclic Thermal Loading

This report summarizes the results of a numerical investigation into the spallation mechanism in plasma-sprayed thermal barrier coatings observed under spatially-uniform cyclic thermal loading. The analysis focuses on the evolution of local stress and inelastic strain fields in the vicinity of the rough top/bond coat interface during thermal cycling, and how these fields are influenced by the presence of an oxide film and spatially uniform and graded distributions of alumina particles in the metallic bond coat aimed at reducing the top/bond coat thermal expansion mismatch. The impact of these factors on the potential growth of a local horizontal delamination at the rough interface's crest is included. The analysis is conducted using the Higher-Order Theory for Functionally Graded Materials with creep/relaxation constituent modeling capabilities. For two-phase bond coat microstructures, both the actual and homogenized properties are employed in the analysis. The results reveal the important contributions of both the normal and shear stress components to the delamination growth potential in the presence of an oxide film, and suggest mixed-mode crack propagation. The use of bond coats with uniform or graded microstructures is shown to increase the potential for delamination growth by increasing the magnitude of the crack-tip shear stress component.

Arnold, Steven M.↗
NASA NTRS2004

Spray Cooling Processes for Space Applications

The present paper reports ongoing work to develop numerical and modeling tools used to design efficient and effective spray cooling processes and to determine characteristic non-dimensional parametric dependence for practical fluids and conditions. In particular, we present data that will delineate conditions towards control of the impingement dynamics of droplets upon a heated substrate germane to practical situations.

Kizito, John P.↗
NASA NTRS2004

Investigation of Enhanced Surface Spray Cooling

Experiments were conducted to study the effects of enhanced surfaces on heat transfer during spray cooling. The surface enhancements consisted of cubic pin fins, pyramids, and straight fins (uniform cross sectional straight fins) machined on the top surface of copper heater blocks. Each had a cross-sectional area of 2.0 square cm. Measurements were also obtained on a heater block with a flat surface for baseline comparison purposes. A 2x2 nozzle array was used with PF-5060 as the working fluid. Thermal performance data was obtained under nominally degassed (chamber pressure of 41.4 kPa ) and gassy conditions (chamber with N2 gas at 101 kPa). The results show that the straight fins had the largest enhancement in heat flow. Critical heat flux (CHF) for this surface showed an increase of 55% in comparison to the flat surface for the nominally degassed condition. The cubic pin finned and pyramid surfaces provided slightly more than half the heat flux enhancement (30% - 40% greater than the flat surface) of the straight fins. The gassy case showed that the straight fins again provided the largest enhancement (48%) in CHF relative to the flat surface. This was followed by the cubic pin fins, and pyramids which had increases of 31% and 18% respectively. No significant effect was observed in the surface temperature at which CHF occurs for either portion of the study.

Silk, Eric A.↗
NASA NTRS2004

Sintering and Fracture Behavior of Plasma-sprayed Thermal Barrier Coatings

Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. There is a need to characterize the fundamental sintering and fracture behavior of the current ZrO2-(7 to 8)wt%Y2O3 coating, in order to fully take advantage of the coating capability. In addition, a thorough evaluation of the coating behavior and temperature limits will be useful for more accurately assessing the benefit gained from future advanced coating systems. In this study, the sintering behavior of plasma-sprayed ZrO2-8wt%Y2O3 coatings was systematically investigated as a function of temperature and time using a dilatometer in the temperature range of 1200-1500 C. The coating sintering kinetics obtained by dilatometry were compared with the coating thermal conductivity increase kinetics, determined by a steady-state laser heat-flux testing approach, under high temperature and thermal gradient sintering conditions. The mode I, mode II, and mixed mode I-mode II fracture behavior of as-processed and sintering-annealed coatings was determined in asymmetric flexure loading at ambient and elevated temperatures in order to evaluate the coating sintering effects on the fracture envelope of K(sub I) versus K(sub II). The coating thermal conductivity cyclic response associated with the interface delamination of the coating systems under simulated engine heat-flux conditions will be discussed in conjunction with the sintering and fracture testing results.

Zhu, Dongming↗
NASA NTRS2005

Synthesis, Characterization and Decomposition Studies of Tris(N,N-dibenzyldithiocarbamato) Indium(III): Chemical Spray Deposition of Polycrystalline CuInS2 on Copper Films

Tris(bis(phenylmethyl)carbamodithioato-S,S ), commonly referred to as tris(N,Ndibenzyldithiocarbamato) indium(III), In(S2CNBz2)3, was synthesized and characterized by single crystal X-ray crystallography. The compound crystallizes in the triclinic space group P1 bar with two molecules per unit cell. The material was further characterized using a novel analytical system employing the combined powers of thermogravimetric analysis, gas chromatography/mass spectrometry and Fourier-Transform infrared spectroscopy to investigate its potential use as a precursor for the chemical vapor deposition (CVD) of thin film materials for photovoltaic applications. Upon heating, the material thermally decomposes to release CS2 and benzyl moieties in to the gas phase, resulting in bulk In2S3. Preliminary spray CVD experiments indicate that In(S2CNBz2)3 decomposed on a Cu substrate reacts to produce stoichiometric CuInS2 films.

Hehemann, David G.↗
NASA NTRS2005

Characterization of Cold Sprayed CuCrAl Coated GRCop-84 Substrates for Reusable Launch Vehicles

An advanced Cu-8(at.%)Cr-4%Nb alloy developed at NASA's Glenn Research Center, and designated as GRCop-84, is currently being considered for use as combustor liners and nozzles in NASA's future generations of reusable launch vehicles (RLVs). Despite the fact that this alloy has superior mechanical and oxidation properties compared to many commercially available copper alloys, it is felt that its high temperature and environmental resistance capabilities can be further enhanced with the development and use of suitable coatings. Several coatings and processes are currently being evaluated for their suitability and future down selection. A newly developed CuCrAl has shown excellent oxidation resistance compared to current generation Cu-Cr coating alloys. Cold spray technology for depositing the CuCrAl coating on a GRCop-84 substrate is currently being developed under NASA's Next Generation Launch Technology (NGLT) Propulsion Research and Technology (PR&T) project. The microstructures, mechanical and thermophysical properties of overlay coated GRCop-84 substrates are discussed.

Raj, S . V.↗