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At least 1,603 records · Page 89

Thermal conductivity model for nanofiber networks

Understanding thermal transport in nanofiber networks is essential for their applications in thermal management, which are used extensively as mechanically sturdy thermal insulation or high thermal conductivity materials. In this study, using the statistical theory and Fourier's law of heat conduction while accounting for both the inter-fiber contact thermal resistance and the intrinsic thermal resistance of nanofibers, an analytical model is developed to predict the thermal conductivity of nanofiber networks as a function of their geometric and thermal properties. A scaling relation between the thermal conductivity and the geometric properties including volume fraction and nanofiber length of the network is revealed. This model agrees well with both numerical simulations and experimental measurements found in the literature. This model may prove useful in analyzing the experimental results and designing nanofiber networks for both high and low thermal conductivity applications.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

A Comprehensive Numerical and Experimental Study for the Passive Thermal Management in Battery Modules and Packs

Cooling plates in battery packs of electric vehicles play critical roles in passive thermal management systems to reduce risks of catastrophic thermal runaway. In this work, a series of numerical simulations and experiments are carried out to unveil the role of cooling plates (both between cells and a bottom plate parallel to the cell stack) on the thermal behavior of battery modules and packs under nail penetrations. First, we investigated the role of side cooling plates on the thermal runaway propagation mitigation in battery modules (1S3P) and packs (3S3P) by varying the key parameters of the side cooling plates, such as plate thicknesses, thermal contact resistances, and materials. Then, three important factors for passive thermal management systems are identified: (i) thermal mass of side cooling plates, (ii) interfacial thermal contact resistances, and (iii) the effective heat transfer coefficients at exterior surfaces. The roles of bottom cooling plates on thermal runaway propagation mitigation in 1S3P and 1S5P battery modules are numerically investigated by comparing the thermal behavior of the modules with only side cooling plates and with both side and bottom cooling plates.

25 ENERGY STORAGE↗

Chapter 3 - Harvesting Thermal Energy with Ferroelectric Materials

Thermal energy is considered the ubiquitous form of energy as all other forms of energy ultimately degrade to thermal energy. Thermal to electrical energy conversion is currently an important method for electricity generation. The traditional power cycles, however, become technically and economically unviable when heat source temperature reduces below 100 °C. Thermal energy harvesting has been proposed as a viable alternative for low-grade thermal to electrical energy conversion. Thermal energy harvesting is a method of generating electricity using temperature-induced variations in material properties. It is particularly useful when the heat sources are available free-of-cost, either in the form of natural heat or waste heat. While there are several thermal energy harvesting techniques, pyroelectricity is the most promising as it can be used in situations where spatial thermal gradients are difficult to establish or the temperature of the heat source is changing. Despite the fact that the pyroelectric effect in ferroelectric materials has been known for past several decades, thermal energy harvesting using ferroelectric materials has not been much explored in the literature. In this chapter, we would explore various aspects of thermal energy harvesting using ferroelectric materials. We have first established the physics behind ferroelectricity, then provided a detailed description on ferroelectric thermal energy harvesting, discussed various ferroelectric thermodynamic cycles and devices proposed in the literature, and finally described various other emerging applications of ferroelectricity.

DIRECT ENERGY CONVERSION,MATERIALS SCIENCE,OTHER I↗

Identification and characterization of the dominant thermal resistance in lithium-ion batteries using operando 3-omega sensors

Poor thermal transport within lithium-ion batteries fundamentally limits their performance, safety, and lifetime, in spite of external thermal management systems. All prior efforts to understand the origin of batteries' mysteriously high thermal resistance have been confined to ex situ measurements without understanding the impact of battery operation. Here, we develop a frequency-domain technique that employs sensors capable of measuring spatially resolved intrinsic thermal transport properties within a live battery while it is undergoing cycling. Our results reveal that the poor battery thermal transport is due to high thermal contact resistance between the separator and both electrode layers and worsens as a result of formation cycling, degrading total battery thermal transport by up to 70%. We develop a thermal model of these contact resistances to explain their origin. These contacts account for up to 65% of the total thermal resistance inside the battery, leading to far-reaching consequences for the thermal design of batteries. Finally, our technique unlocks new thermal measurement capabilities for future battery research.

25 ENERGY STORAGE↗

THE SWIFT BURST ALERT TELESCOPE PERSPECTIVE ON NON-THERMAL EMISSION IN HIFLUGCS GALAXY CLUSTERS

The search for diffuse non-thermal, inverse Compton (IC) emission from galaxy clusters at hard X-ray energies has been underway for many years, with most detections being either of low significance or controversial. In this work, we investigate 14-195 keV spectra from the Swift Burst Alert Telescope (BAT) all-sky survey for evidence of non-thermal excess emission above the exponentially decreasing tail of thermal emission in the flux-limited HIFLUGCS sample. To account for the thermal contribution at BAT energies, XMM-Newton EPIC spectra are extracted from coincident spatial regions so that both thermal and non-thermal spectral components can be determined simultaneously. We find marginally significant IC components in six clusters, though after closer inspection and consideration of systematic errors we are unable to claim a clear detection in any of them. The spectra of all clusters are also summed to enhance a cumulative non-thermal signal not quite detectable in individual clusters. After constructing a model based on single-temperature fits to the XMM-Newton data alone, we see no significant excess emission above that predicted by the thermal model determined at soft energies. This result also holds for the summed spectra of various subgroups, except for the subsample of clusters with diffuse radio emission. For clusters hosting a diffuse radio halo, a relic, or a mini-halo, non-thermal emission is initially detected at the {approx}5{sigma} confidence level-driven by clusters with mini-halos-but modeling and systematic uncertainties ultimately degrade this significance. In individual clusters, the non-thermal pressure of relativistic electrons is limited to {approx}< 10% of the thermal electron pressure, with stricter limits for the more massive clusters, indicating that these electrons are likely not dynamically important in the central regions of clusters.

79 ASTRONOMY AND ASTROPHYSICS↗

Spectral near-field thermal emission extraction by optical waveguides

As far-field thermal emission is limited by blackbody radiation, the significant enhancement of thermal radiation in the near-field plays a vital role in a variety of applications such as infrared sensing, radiation cooling, and thermophotovoltaics. Yet the techniques of exporting the near-field signal to the far field are still not mature, typically relying on complex instrumentation capable of being applied only to the surfaces of model systems and structures. Here we develop an efficient method of extracting near-field thermal radiation to the far field by integrating a nanoscale thermal emitter with a high-index optical waveguide. By directly depositing the emitter onto the optical waveguide, it requires no vacuum gap and enables efficient coupling of near-field thermal radiation into propagating wave-guided modes. A single-mode planar waveguide incorporated with an indium-tin oxide (ITO) film as a thermal emitter is theoretically investigated to prove the feasibility of thermal extraction. The Wiener-chaos expansion method is applied to directly calculate the thermal radiation from the emitter-waveguide system. We experimentally demonstrate the fidelity of the optical-waveguide-assisted near-field thermal extraction by measuring the emission spectrum of an ITO-coated optical fiber and comparing with theoretical predictions. Our experimental demonstration in conjunction with the direct simulation paves the way for effectively extracting near-field thermal radiation with applications in chemical sensing, infrared imaging, and near-field thermal energy management.

36 MATERIALS SCIENCE↗

Diffuson-driven ultralow thermal conductivity in amorphous N b 2 O 5 thin films

Niobium pentoxide (Nb 2 O 5 ) has been extensively reported for applications of electrochemical energy storage, memristors, solar cells, light emitting diodes (LEDs), and electrochromic devices. The thermal properties of Nb 2 O 5 play a critical role in device performance of these applications. However, very few studies on the thermal properties of Nb 2 O 5 have been reported and a fundamental understanding of heat transport in Nb 2 O 5 is still lacking. The present work closes this gap and provides the first study of thermal conductivity of amorphous Nb 2 O 5 thin films. Ultralow thermal conductivity is observed without any size effect in films as thin as 48 nm, which indicates that propagons contribute negligibly to the thermal conductivity and that the thermal transport is dominated by diffusons. Density-function-theory (DFT) simulations combined with a diffuson-mediated minimum-thermal-conductivity model confirms this finding. Additionally, the measured thermal conductivity is lower than the amorphous limit (Cahill model), which proves that the diffuson model works better than the Cahill model to describe the thermal conduction mechanism in the amorphous Nb 2 O 5 thin films. Additionally, the thermal conductivity does not change significantly with oxygen vacancy concentration. This stable and low thermal conductivity facilitates excellent performance for applications such as memristors.

36 MATERIALS SCIENCE↗

Theoretical Expressions for the Ascent Rate of Moist Deep Convective Thermals

An approximate analytic expression is derived for the ratio λ of the ascent rate of moist deep convective thermals and the maximum vertical velocity within them; λ is characterized as a function of two nondimensional buoyancy-dependent parameters y and h and is used to express the thermal ascent rate as a function of the buoyancy field. The parameter y characterizes the vertical distribution of buoyancy within the thermal, and h is the ratio of the vertically integrated buoyancy from the surface to the thermal top and the vertical integral of buoyancy within the thermal. Theoretical λ values are calculated using values of y and h obtained from idealized numerical simulations of ascending moist updrafts and compared to λ computed directly from the simulations. The theoretical values of [Formula: see text] 0.4–0.8 are in reasonable agreement with the simulated λ (correlation coefficient of 0.86). These values are notably larger than the [Formula: see text] from Hill’s (nonbuoyant) analytic spherical vortex, which has been used previously as a framework for understanding the dynamics of moist convective thermals. The relatively large values of λ are a result of net positive buoyancy within the upper part of thermals that opposes the downward-directed dynamic pressure gradient force below the thermal top. These results suggest that nonzero buoyancy within moist convective thermals, relative to their environment, fundamentally alters the relationship between the maximum vertical velocity and the thermal-top ascent rate compared to nonbuoyant vortices. Implications for convection parameterizations and interpretation of the forces contributing to thermal drag are discussed.

54 ENVIRONMENTAL SCIENCES↗

Extremes of heat conduction-Pushing the boundaries of the thermal conductivity of materials

Thermal conductivity is a familiar property of materials: silver conducts heat well, and plastic does not. In recent years, an interdisciplinary group of materials scientists, engineers, physicists, and chemists have succeeded in pushing back long-established limits in the thermal conductivity of materials. Carbon nanotubes and graphene are at the high end of the thermal conductivity spectrum due to their high sound velocities and relative lack of processes that scatter phonons. Unfortunately, the superlative thermal properties of carbon nanotubes have not found immediate application in composites or interface materials because of difficulties in making good thermal contact with the nanotubes. At the low end of the thermal conductivity spectrum, solids that combine order and disorder in the random stacking of two-dimensional crystalline sheets, so-called "disordered layered crystals," show a thermal conductivity that is only a factor of 2 larger than air. The cause of this low thermal conductivity may be explained by the large anisotropy in elastic constants that suppresses the density of phonon modes that propagate along the soft direction. Low-dimensional quantum magnets demonstrate that electrons and phonons are not the only significant carriers of heat. Near room temperature, the spin thermal conductivity of spin-ladders is comparable to the electronic thermal conductivities of metals. Our measurements of nanoscale thermal transport properties employ a variety of ultrafast optical pump-probe metrology tools that we have developed over the past several years. We are currently working to extend these techniques to high pressures (60 GPa), high magnetic fields (5 T), and high temperatures (1000 K).

Cahill, DG↗

Do Cover Crops and Corn Residue Removal Affect Soil Thermal Properties?

Soil thermal properties govern the transport and storage of heat in the soil. How management practices such as crop residue removal and cover crop (CC) use affect these soil properties is not well understood. For example, CCs could provide physical cover and improve soil properties after main crop residue removal and thus ameliorate the negative effects of residue removal on soil thermal properties. We measured changes in soil thermal properties including soil thermal conductivity, thermal diffusivity, volumetric heat capacity, and related properties under corn (Zea mays L.) residue removal with and without winter cereal rye (Secale cereale L.) under a 6-yr irrigated no-till continuous corn experiment on a silt loam in south central Nebraska. Cover crops did not affect thermal properties, but corn residue removal reduced field thermal conductivity by 12 to 41% and volumetric heat capacity by 6 to 49% during the growing season for the 0- to 5-cm depth. Residue removal also reduced laboratory thermal conductivity by 19% at –0.03-MPa and by 28% at –1.5-MPa matric potential. Residue removal also reduced volumetric heat capacity in the laboratory by 23% at both matric potentials in the 0- to 10-cm depth. Neither residue removal nor CC affected thermal diffusivity. Thermal conductivity was more strongly correlated with soil water content than with bulk density and soil organic C. Altogether, CC had no effect on thermal properties, but corn residue removal could reduce the soil’s ability to conduct heat relative to no removal.

54 ENVIRONMENTAL SCIENCES↗

Development and Validation of SAM Multi-dimensional Flow Model for Thermal Mixing and Stratification Modeling

Thermal mixing and stratification in large pools or enclosures are very important phenomena that are critical to nuclear reactor safety. Because of the wide ranges of time and length scales associated with such phenomena, accurate modeling and simulation of thermal mixing and stratification remain as the key unresolved, challenging problems for reactor transient analyses. In traditional system analysis codes, simplified zero-dimensional (0-D) models are widely used for their high numerical efficiency, but they generally suffer from very limited prediction accuracies or range of applicability. Like traditional system analysis codes, the current version of the SAM code has implemented such simplified 0-D and one-dimensional mixing models. On the other hand, high-resolution Computational Fluid Dynamics (CFD) tools are often used to model complex thermal mixing and stratification phenomena. They are, however, generally numerically expensive, and they require large amounts of computational resources. It is therefore desirable to implement advanced and efficient thermal mixing and stratification modeling capabilities embedded in a system analysis code. This approach will improve the accuracy of reactor safety analyses when thermal mixing and stratification are involved, and also avoid using the large computational resources needed for high-resolution CFD analysis. Currently, with the support of the U.S. DOE Office of Nuclear Energy’s Nuclear Energy Advanced Modeling and Simulation program, an effort has been launched to develop and implement a multi-dimensional flow model in the system analysis code SAM, and demonstrate its applications to model thermal mixing and stratification phenomena in large enclosures. The main outcomes of this research and development activity are summarized in this report, which presents an attempt to include a built-in advanced multi-dimensional flow model in a system analysis code with the focus on overcoming the simulation challenges of thermal mixing and stratification phenomena. In this report, we start with the introduction of existing SAM code capabilities to simulate thermal mixing and stratification phenomena, which is followed by a short summary of the multi-dimensional model implemented in the SAM code, including both the physical model and the Finite Element Method code implementation. In this study, two options were implemented in the SAM code to model turbulent flows: a relatively simple built-in turbulence model and an interface to accept externally computed turbulent viscosities (e.g., from a high- resolution CFD simulation). Code validation studies on this newly added capability were then carried out to compare SAM simulation results with experimental data from the SUPERCAVNA facility, which was designed to study the complex flow recirculation and thermal stratification phenomena relevant to sodium fast reactor designs. In this study, one transient and two steady-state test cases were used for code validation. Different approaches have been used to model the complex turbulence flow fields in the SUPERCAVNA facility. A highly simplified zero-equation turbulence model was first used, but it was determined that it is too simple to capture the complex turbulence flow fields in these test cases. Subsequently, the code validation continued with the use of turbulent viscosity data from high-resolution STAR-CCM+ CFD simulations to improve the accuracy of the results. Using this approach, the SAM simulation results showed very good agreement with both the SUPERCAVNA experimental data and STAR-CCM+ simulation results. In this report, we demonstrate the development, implementation, and successful validation of a multi-dimensional flow model in the SAM code, which aims to improve the simulation accuracy for complex thermal mixing and stratification phenomena. Lessons have also been learned, including that in cases where the flow fields are not well predicted by the zero-equation model, the iinput of turbulent viscosities from an external source can enhance the overall predictive capabilities needed to accurately capture complex thermal-hydraulic phenomena. Therefore, future research will be needed to further improve the code’s capabilities, such as by developing a more efficient and robust approach to capture the turbulence effects in the SAM code.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Effects of thermal cycling on graphie-fiber-reinforced 6061 aluminum

Graphite-reinforced aluminum alloy metal-matrix composites are among materials being considered for structural components in dimensionally stable space structures. This application requires materials with low values of thermal expansions and high specific stiffnesses. They must remain stable during exposures to the space environment for periods extending to 20 years. The effects of thermal cycling on the thermal expansion behavior and mechanical properties of Thornel P100 graphite 6061 aluminum composites, as fabricated and after thermal processing to eliminate thermal strain hysteresis, have been investigated. Two groups of composites were studied: one was fabricated by hot roll bonding and the other by diffusion bonding. Processing significantly reduced strain hysteresis during thermal cycling in both groups and improved the ultimate tensile strength and modulus in the diffusion-bonded composites. Thermal cycling stabilized the as-fabricated composites by reducing the residual fabrication stress and increased the matrix strength by metallurgical aging. Thermal expansion behavior of both groups after processing was insensitive to thermal cycling. Data scatter was too large to determine effects of thermal cycling on the mechanical properties. The primary effects of processing and thermal cycling can be attributed to changes in the metallurgical condition and stress state of the matrix.

Dries, G. A.↗

Thermal studies of Martian channels and valleys using Termoskan data: New results

The Termoskan instrument onboard the Phobos '88 spacecraft acquired the highest-spatial-resolution thermal data ever obtained for Mars. Included in the thermal images are 2 km/pixel midday observations of several major channel and valley systems, including significant portions of Shalbatana Vallis, Ravi Vallis, Al-Qahira Vallis, Ma'adim Vallis, the channel connecting Valles Marineris with Hydraotes Chaos, and channel material in Eos Chasma. Termoskan also observed small portions of the southern beginnings of Simud, Tiu, and Ares Valles and some channel material in Gangis Chasma. Simultaneous broad band visible data were obtained for all but Ma'adim Vallis. We find that most of the channels and valleys have higher inertias than their surroundings, consistent with Viking IRTM-based thermal studies of Martian channels. We see for the first time that thermal inertia boundaries closely match all flat channel floor boundaries. Combining Termoskan thermal data, relative observations from Termoskan visible channel data, Viking absolute bolometric albedos, and a thermal model of the Mars surface, we have derived lower bounds on channel thermal inertias. Lower bounds on typical channel thermal inertias range from 8.4 to 12.5 (10(exp -3) cal cm(exp -2) s(exp -1/2)K(exp -1)) (352 to 523 in SI units). Lower bounds on inertia differences with the surrounding heavily cratered plains range from 1.1 to 3.5 (46 to 147 in SI units). Atmospheric and geometric effects are not sufficient to cause the inertia enhancements. We agree with previous researchers that localized, dark, high inertia areas within channels are likely eolian in nature. However, the Temloskan data show that eolian deposits do not fill the channels, nor are they responsible for the overall thermal inertia enhancement. Thermal homogeneity and strong correlation of thermal boundaries with the channel floor boundaries lead us to favor noneolian overall explanations.

Betts, B. H.↗

Thermal Performance of Composite Flexible Blanket Insulations for Hypersonic Aerospace Vehicles

This paper describes the thermal performance of a Composite Flexible Blanket Insulation (C.F.B.I.) considered for potential use as a thermal protection system or thermal insulation for future hypersonic vehicles such as the National Aerospace Plane (N.A.S.P.). Thermophysical properties for these insulations were also measured including the thermal conductivity at various temperatures and pressures and the emissivity of the fabrics used in the flexible insulations. The thermal response of these materials subjected to aeroconvective heating from a plasma arc is also described. Materials tested included two surface variations of the insulations, and similar insulations coated with a Protective Ceramic Coating (P.C.C.). Surface and backface temperatures were measured in the flexible insulations and on Fibrous Refractory Composite Insulation (F.R.C.I.) used as a calibration model. The uncoated flexible insulations exhibited good thermal performance up to 35 W/sq cm. The use of a P.C.C. to protect these insulations at higher heating rates is described. The results from a computerized thermal analysis model describing thermal response of those materials subjected to the plasma arc conditions are included. Thermal and optical properties were determined including thermal conductivity for the rigid and flexible insulations and emissivity for the insulation fabrics. These properties were utilized to calculate the thermal performance of the rigid and flexible insulations at the maximum heating rate.

Kourtides, Demetrius A.↗

Integrated Modeling Tools for Thermal Analysis and Applications

Integrated modeling of spacecraft systems is a rapidly evolving area in which multidisciplinary models are developed to design and analyze spacecraft configurations. These models are especially important in the early design stages where rapid trades between subsystems can substantially impact design decisions. Integrated modeling is one of the cornerstones of two of NASA's planned missions in the Origins Program -- the Next Generation Space Telescope (NGST) and the Space Interferometry Mission (SIM). Common modeling tools for control design and opto-mechanical analysis have recently emerged and are becoming increasingly widely used. A discipline that has been somewhat less integrated, but is nevertheless of critical concern for high precision optical instruments, is thermal analysis and design. A major factor contributing to this mild estrangement is that the modeling philosophies and objectives for structural and thermal systems typically do not coincide. Consequently the tools that are used in these discplines suffer a degree of incompatibility, each having developed along their own evolutionary path. Although standard thermal tools have worked relatively well in the past. integration with other disciplines requires revisiting modeling assumptions and solution methods. Over the past several years we have been developing a MATLAB based integrated modeling tool called IMOS (Integrated Modeling of Optical Systems) which integrates many aspects of structural, optical, control and dynamical analysis disciplines. Recent efforts have included developing a thermal modeling and analysis capability, which is the subject of this article. Currently, the IMOS thermal suite contains steady state and transient heat equation solvers, and the ability to set up the linear conduction network from an IMOS finite element model. The IMOS code generates linear conduction elements associated with plates and beams/rods of the thermal network directly from the finite element structural model. Conductances for temperature varying materials are accommodated. This capability both streamlines the process of developing the thermal model from the finite element model, and also makes the structural and thermal models compatible in the sense that each structural node is associated with a thermal node. This is particularly useful when the purpose of the analysis is to predict structural deformations due to thermal loads. The steady state solver uses a restricted step size Newton method, and the transient solver is an adaptive step size implicit method applicable to general differential algebraic systems. Temperature dependent conductances and capacitances are accommodated by the solvers. In addition to discussing the modeling and solution methods. applications where the thermal modeling is "in the loop" with sensitivity analysis, optimization and optical performance drawn from our experiences with the Space Interferometry Mission (SIM), and the Next Generation Space Telescope (NGST) are presented.

Milman, Mark H.↗

Thermal Analysis Methods for an Earth Entry Vehicle

Thermal analysis of a vehicle designed to return samples from another planet, such as the Earth Entry vehicle for the Mars Sample Return mission, presents several unique challenges. The Earth Entry Vehicle (EEV) must contain Martian material samples after they have been collected and protect them from the high heating rates of entry into the Earth's atmosphere. This requirement necessitates inclusion of detailed thermal analysis early in the design of the vehicle. This paper will describe the challenges and solutions for a preliminary thermal analysis of an Earth Entry Vehicle. The aeroheatina on the vehicle during entry would be the main driver for the thermal behavior. and is a complex function of time, spatial position on the vehicle, vehicle temperature, and trajectory parameters. Thus. the thermal analysis must be closely tied to the aeroheating analysis in order to make accurate predictions. Also, the thermal analysis must account for the material response of the ablative thermal protection system TPS. For the exo-atmospheric portion of the mission, the thermal analysis must include the orbital radiation fluxes on the surfaces. The thermal behavior must also be used to predict the structural response of the vehicle (the thermal stress and strains) and whether they remain within the capability of the materials. Thus, the thermal analysis requires ties to the three-dimensional geometry, the aeroheating analysis, the material response analysis, the orbital analysis. and the structural analysis. The goal of this paper is to describe to what degree that has been achieved.

Amundsen, Ruth M.↗

Thermal Analysis Methods For Earth Entry Vehicle

Thermal analysis of a vehicle designed to return samples from another planet, such as the Earth Entry vehicle for the Mars Sample Return mission, presents several unique challenges. The Earth Entry Vehicle (EEV) must contain Martian material samples after they have been collected and protect them from the high heating rates of entry into the Earth's atmosphere. This requirement necessitates inclusion of detailed thermal analysis early in the design of the vehicle. This paper will describe the challenges and solutions for a preliminary thermal analysis of an Earth Entry Vehicle. The aeroheating on the vehicle during entry would be the main driver for the thermal behavior, and is a complex function of time, spatial position on the vehicle, vehicle temperature, and trajectory parameters. Thus, the thermal analysis must be closely tied to the aeroheating analysis in order to make accurate predictions. Also, the thermal analysis must account for the material response of the ablative thermal protection system (TPS). For the exo-atmospheric portion of the mission, the thermal analysis must include the orbital radiation fluxes on the surfaces. The thermal behavior must also be used to predict the structural response of the vehicle (the thermal stress and strains) and whether they remain within the capability of the materials. Thus, the thermal analysis requires ties to the three-dimensional geometry, the aeroheating analysis, the material response analysis, the orbital analysis, and the structural analysis. The goal of this paper is to describe to what degree that has been achieved.

Amundsen, Ruth M.↗

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.↗