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Discuss overview of LME branch current thrusts, processing and testing capabilities, and technical caps. Presentation focusses on Environmental Barrier Coatings (EBCs) development, extreme high temperature environments testing, and new high temperature materials opportunities.
Fourteen foam insulation specimens were tested. Some were plain foam while others contained flame retardants, chopped fiberglass reinforcement and/or vapor barriers. The thermal performance of the insulation was determined by measuring the rate at which LH2 boiled from an aluminum tank insulated with the test material. The test specimens were approximately 50 mm (2 in.) thick. They were structurally scaled so that the test cycle would duplicate the maximum thermal stresses predicted for the thicker insulation of an aircraft liquid hydrogen fuel tank during a typical subsonic flight. The simulated flight cycle of approximately 10 minutes duration heated the other insulation surface to 316 K (110 F) and cooled it to 226 K (20 F) while the inner insulation surface remained at liquid hydrogen temperature of 20 K (-423 F). Two urethane foam insulations exceeded the initial life goal of 2400 simulated flight cycles and sustained 4400 cycles with only minor damage. The addition of fiberglass reinforcement of flame retardant materials to an insulation degraded thermal performance and/or the life of the foam material. Installation of vapor barriers enhanced the structural integrity of the material but did not improve thermal performance. All of the foams tested were available materials; none were developed specifically for LH2 service.
Thermal barrier and environmental barrier coatings (TBCs and EBCs) will play a crucial role in future advanced gas turbine engines because of their ability to significantly extend the temperature capability of the ceramic matrix composite (CMC) engine components in harsh combustion environments. In order to develop high performance, robust coating systems for effective thermal and environmental protection of the engine components, appropriate test approaches for evaluating the critical coating properties must be established. In this paper, a laser high-heat-flux, thermal gradient approach for testing the coatings will be described. Thermal cyclic behavior of plasma-sprayed coating systems, consisting of ZrO2-8wt%Y2O3 thermal barrier and NASA Enabling Propulsion Materials (EPM) Program developed mullite+BSAS/Si type environmental barrier coatings on SiC/SiC ceramic matrix composites, was investigated under thermal gradients using the laser heat-flux rig in conjunction with the furnace thermal cyclic tests in water-vapor environments. The coating sintering and interface damage were assessed by monitoring the real-time thermal conductivity changes during the laser heat-flux tests and by examining the microstructural changes after the tests. The coating failure mechanisms are discussed based on the cyclic test results and are correlated to the sintering, creep, and thermal stress behavior under simulated engine temperature and heat flux conditions.
Alumina as a sublimation suppression barrier for a Zintl thermoelectric material in a thermoelectric power generation device operating at high temperature, e.g. at or above 1000K, is disclosed. The Zintl thermoelectric material may comprise Yb.sub.14MnSb.sub.11. The alumina may be applied as an adhesive paste dried and cured on a substantially oxide free surface of the Zintl thermoelectric material and polished to a final thickness. The sublimation suppression barrier may be finalized by baking out the alumina layer on the Zintl thermoelectric material until it becomes substantially clogged with ytterbia.
Flame sprayed ceramic aluminum and zinc coatings for corrosion prevention of tantalum containment vessel in nuclear reactor
Oxides having magnetoplumbite structure are promising candidate materials for applications as high temperature thermal barrier coatings because of their high thermal stability, high thermal expansion, and low thermal conductivity. In this study, powders of LaMgAl11O19, GdMgAl11O19, SmMgAl11O19, and Gd0.7Yb0.3MgAl11O19 magnetoplumbite oxides were synthesized by citric acid sol-gel method and hot pressed into disk specimens. The thermal expansion coefficients (CTE) of these oxide materials were measured from room temperature to 1500 C. The average CTE value was found to be approx.9.6x10(exp -6)/C. Thermal conductivity of these magnetoplumbite-based oxide materials was also evaluated using steady-state laser heat flux test method. The effects of doping on thermal properties were also examined. Thermal conductivity of the doped Gd0.7Yb0.3MgAl11O19 composition was found to be lower than that of the undoped GdMgAl11O19. In contrast, thermal expansion coefficient was found to be independent of the oxide composition and appears to be controlled by the magnetoplumbite crystal structure. Thermal conductivity testing of LaMgAl11O19 and LaMnAl11O19 magnetoplumbite oxide coatings plasma sprayed on NiCrAlY/Rene N5 superalloy substrates indicated resistance of these coatings to sintering even at temperatures as high as 1600 C.
The thermal protection system installed on the SRB frustrums incurs the formation of debonds between the MSA-2 TPS material and the substrate. The debonds can lead to surface penetrating cracks, called 'smileys' near sealed fasteners and other surface discontinuities. The study concluded that the 'smileys' were caused as the result of stress risers caused by excess fastener sealant (PR-1422) and weakly bonded surfaces. Once the debond occurs, 'smileys' form when the debond area is sufficiently large. The loading for the debond and 'smiley' formation is seen to be depressurization at the vacuum conditions near the end of powered boost. The porous nature of the MSA-2 material covered by a vapor barrier paint provides internal pressure loading of the MSA-2 material. Recommendations for eliminating the problem include elimination of excess PR-1422 sealant and improved attention to bonding surface preparation.
Robotic systems provide a means of performing many of the operations required to establish and maintain a lunar base. They form a synergistic system when properly used in concert with human activities. This paper discusses the various areas where robotics and automation may be used to enhance lunar base operations. Robots are particularly well suited for surface operations (exterior to the base habitat modules) because they can be designed to operate in the extreme temperatures and vacuum conditions of the Moon (or Mars). In this environment, the capabilities of semi-autonomous robots would surpass that of humans in all but the most complex tasks. Robotic surface operations include such activities as long range geological and mineralogical surveys with sample return, materials movement in and around the base, construction of radiation barriers around habitats, transfer of materials over large distances, and construction of outposts. Most of the above operations could be performed with minor modifications to a single basic robotic rover. Within the lunar base habitats there are a few areas where robotic operations would be preferable to human operations. Such areas include routine inspections for leakage in the habitat and its systems, underground transfer of materials between habitats, and replacement of consumables. In these and many other activities, robotic systems will greatly enhance lunar base operations. The robotic systems described in this paper are based on what is realistically achievable with relatively near term technology. A lunar base can be built and maintained if we are willing.
The High-Speed Research (HSR) Airfoil Alloy program developed fourth-generation single-crystal superalloys with up to an 85 F increase in creep rupture capability over current production airfoil alloys. Recent results have been generated at the NASA Glenn Research Center on these fourth-generation alloys, but in coated form, for subsonic turbine blade applications under NASA's Ultra-Efficient Engine Technology (UEET) Program. One goal for UEET is to optimize the airfoil alloy/thermal barrier coating system for 3100 F turbine inlet temperatures. The state-of-the art turbine blade airfoil system consists of a superalloy single crystal that provides the basic mechanical performance of the airfoil. A thermal barrier coating is used to reduce the temperature of the base superalloy, and a bondcoat is deposited between the base material and the thermal barrier coating. The bondcoat improves the oxidation and corrosion resistance of the base superalloy and improves the spallation resistance of the thermal barrier coating. A commercial platinum aluminide bondcoat was applied to the HSR-developed alloys, and a diffusion zone developed as a result of interaction between the bondcoat and the superalloy. Optimized strength is obtained for superalloys when the refractory element content is high and the limits of microstructural stability are approached or exceeded slightly. For fourthgeneration alloys, instability leads to the formation of topologically close packed (TCP) phases, which form internally in the superalloy, and a secondary reaction zone (SRZ), which forms under the diffusion zone. There was a concern that excessive quantities of either TCP or SRZ might decrease the mechanical properties of the superalloy, with SRZ thought to be particularly detrimental and its formation unpredictable. Thus, an SRZreduction effort was initiated in the NASA UEET Program so that methods developed during the HSR project could be optimized further to reduce or eliminate the SRZ. An SRZ is a three-phase constituent composed of TCP and stringers of gamma phase in a matrix of gamma prime. An incoherent grain boundary separates the SRZ from the gammagamma prime microstructure of the superalloy. The SRZ is believed to form as a result of local chemistry changes in the superalloy due to the application of the diffusion aluminide bondcoat. Locally high surface stresses also appear to promote the formation of the SRZ. Thus, techniques that change the local alloy chemistry or reduce surface stresses have been examined for their effectiveness in reducing SRZ. These SRZ-reduction steps are performed on the test specimen or the turbine blade before the bondcoat is applied. Stressrelief heat treatments developed at NASA Glenn have been demonstrated to reduce significantly the amount of SRZ that develops during subsequent high-temperature exposures. Stress-relief heat treatments reduce surface stresses by recrystallizing a thin surface layer of the superalloy. However, in alloys with very high propensities to form SRZ, stress relief heat treatments alone do not eliminate SRZ entirely. Thus, techniques that modify the local chemistry under the bondcoat have been emphasized and optimized successfully at Glenn. One such technique is carburization, which changes the local chemistry by forming submicron carbides near the surface of the superalloy. Detailed characterizations have demonstrated that the depth and uniform distribution of these carbides are enhanced when a stress relief treatment and an appropriate surface preparation are employed in advance of the carburization treatment. Even in alloys that have the propensity to develop a continuous SRZ layer beneath the diffusion zone, the SRZ has been completely eliminated or reduced to low, manageable levels when this combination of techniques is utilized. Now that the techniques to mitigate SRZ have been established at Glenn, TCP phase formation is being emphasized in ongoing work under the UEET Program. The limitsf stability of the fourth-generation alloys with respect to TCP phase formation are currently being defined along with high-temperature creep rupture properties. In addition, a regression model is being developed at Glenn for the prediction of the presence of TCP phase in the microstructure and SRZ under the diffusion zone. The model is based on a design-of-experiments methodology with emphasis on the potential synergistic effects of alloying elements.
The Apollo and subsequent spacecraft have had highly effective radiation barriers; made of aluminized polymer film, they bar or let in heat to maintain consistent temperatures inside. Tech 2000, formerly Quantum International Corporation used the NASA technology in its insulating materials, Super "Q" Radiant Barrier, for home, industry and mobile applications. The insulation combines industrial aluminum foil overlaid around a core of another material, usually propylene or mylar. The outer layer reflects up to 97 percent of heat; the central layer creates a thermal break in the structure and thus allows low radiant energy emission. The Quantum Cool Wall, used in cars and trucks, takes up little space while providing superior insulation, thus reducing spoilage and costs. The panels can also dampen sound and engine, exhaust and solar heat.
A technique based on accelerating positive nitrogen ions onto an aluminum layer has been demonstrated to be effective in forming thin (<2 nm thick) layers of aluminum nitride (AlN(x)) for use as tunnel barriers in Nb/Al-AlN(x)/Nb superconductor/insulator/ superconductor (SIS) Josephson junctions. AlN(x) is the present material of choice for tunnel barriers because, to a degree greater than that of any other suitable material, it offers the required combination of low leakage current at high current density and greater thermal stability. While ultra-thin AlN films with good thickness and stoichiometry control are easily formed using techniques such as reactive molecular beam epitaxy and chemical vapor deposition, growth temperatures of 900 C are necessary for the dissociative adsorption of nitrogen from either nitrogen (N2) or ammonia (NH3). These growth temperatures are prohibitively high for the formation of tunnel barriers on Nb films because interfacial reactions at temperatures as low as 200 to 300 C degrade device properties. Heretofore, deposition by reactive sputtering and nitridation of thin Al layers with DC and RF nitrogen plasmas have been successfully used to form AlN barriers in SIS junctions. However, precise control over critical current density Jc has proven to be a challenge, as is attaining adequate process reproducibility from system to system. The present ion-beam technique is an alternative to the plasma or reactive sputtering techniques as it provides a highly controlled arrival of reactive species, independent of the electrical conditions of the substrate or vacuum chamber. Independent and accurate control of parameters such as ion energy, flux, species, and direction promises more precise control of film characteristics such as stoichiometry and thickness than is the case with typical plasma processes. In particular, the background pressure during ion-beam nitride growth is 2 or 3 orders of magnitude lower, minimizing the formation of compounds with contaminants, which is critical in devices the performance of which is dictated by interfacial characteristics. In addition, the flux of incoming species can be measured in situ using ion probes so that the dose can be controlled accurately. The apparatus used in the present ion-beam technique includes a vacuum chamber containing a commercial collimated- ion-beam source, a supply of nitrogen and argon, and an ion probe for measuring the ion dose. Either argon or nitrogen can be used as the feed gases for the ion source, depending on whether cleaning of the substrate or growth of the nitride, respectively, is desired. Once the Nb base electrode and Al proximity layer have been deposited, the N2 gas line to the ion beam is vented and purged, and the ion-source is turned on until a stable discharge is obtained. The substrate is moved over the ion-beam source to expose the Al surface layer to the ion beam (see figure) for a specified duration for the formation of the nitride tunnel barrier. Next, the Nb counter-electrode layer is deposited on the nitride surface layer. The Nb/Al- AlN(x)/Nb-trilayer-covered substrate is then patterned into individual devices by use of conventional integrated-circuit processing techniques.
Material systems and processes for the development of effective and durable thermal barriers for heavy duty diesel engines were investigated. Seven coating systems were evaluated for thermal conductivity, erosion resistance, corrosion/oxidation resistance, and thermal shock resistance. An advanced coating system based on plasma sprayed particle yttria stabilized zirconia (PS/HYSZ) was judged superior in these tests. The measured thermal conductivity of the selected coating was 0.893 W/m C at 371 C. The PS/HYSZ coating system was applied to the piston crown, fire deck and valves of a single cylinder low heat rejection diesel engine. The coated engine components were tested for 24 hr at power levels from 0.83 MPa to 1.17 MPa brake mean effective pressure. The component coatings survived the engine tests with a minimum of distress. The measured fire deck temperatures decreased 86 C (155 F) on the intake side and 42 C (75 F) on the exhaust side with the coating applied.
Hypersonic and space flight applications continue to push material demands of component-level technologies such as high-temperature seals and thermal barriers. NASA Glenn Research Center continues to develop and evaluate materials and coatings as well as thermal barrier designs for these applications. Experimental test data is presented for two different sheath fabrics that were evaluated in full thermal barrier assemblies through compression and wear testing at elevated temperatures, as well as flow testing at ambient temperature.
Diamond is a promising semiconductor material for novel electronic applications because of its chemical stability and inertness, heat conduction properties, and so-called negative electron affinity (NEA). When a surface has NEA, electrons generated inside the bulk of the material are able to come out into the vacuum without any potential barrier (work function). Such a material would have an extremely high secondary electron emission coefficient o, very high photoelectron (quantum) yield, and would probably be an efficient field emitter. Chemical-vapor-deposited (CVD) polycrystalline diamond films have even more advantages than diamond single crystals. Their fabrication is relatively easy and inexpensive, and they can be grown with high levels of doping--consequently, they can have relatively high conductivity. Because of these properties, diamond can be used for cold cathodes and photocathodes in high-power electronics and in high-frequency and high-temperature semiconductor devices.
Design concepts, based on use of graphite as a thermal barrier for regeneratively cooled FLOX-methane thrust chambers, have been screened and concepts selected for detailed thermodynamic, stress, and fabrication analyses. A single design employing AGCarb-101, a fibrous graphite composite material, for a thermal barrier liner and an electroformed nickel structure with integral coolant passages was selected for fabrication and testing. The fabrication processes and the test results are described and illustrated.
The aluminized polymer film used in spacecraft as a radiation barrier to protect both astronauts and delicate instruments has led to a number of spinoff applications. Among them are aluminized shipping bags, food cart covers and medical bags. Radiant Technologies purchases component materials and assembles a barrier made of layers of aluminized foil. The packaging reflects outside heat away from the product inside the container. The company is developing new aluminized lines, express mailers, large shipping bags, gel packs and insulated panels for the building industry.
A method of applying a physical barrier to suppress thermal decomposition near a surface of a thermoelectric material including applying a continuous metal foil to a predetermined portion of the surface of the thermoelectric material, physically binding the continuous metal foil to the surface of the thermoelectric material using a binding member, and heating in a predetermined atmosphere the applied and physically bound continuous metal foil and the thermoelectric material to a sufficient temperature in order to promote bonding between the continuous metal foil and the surface of the thermoelectric material. The continuous metal foil forms a physical barrier to enclose a predetermined portion of the surface. Thermal decomposition is suppressed at the surface of the thermoelectric material enclosed by the physical barrier when the thermoelectric element is in operation.
The materials technologies studied included thermal barrier coatings for turbine airfoils, turbine disks, cases, turbine vanes and engine and nacelle composite materials. The cost/benefit of each technology was determined in terms of Relative Value defined as change in return on investment times probability of success divided by development cost. A recommended final ranking of technologies was based primarily on consideration of Relative Values with secondary consideration given to changes in other economic parameters. Technologies showing the most promising cost/benefits were thermal barrier coated temperature nacelle/engine system composites.