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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

(U)SAXS characterization of porous microstructure of chert: insights into organic matter preservation

This study characterizes the microstructure and mineralogy of 132 (ODP sample), 1000 and 1880 million-year-old chert samples. By using ultra-small-angle X-ray scattering (USAXS), wide-angle X-ray scattering and other techniques, the preservation of organic matter (OM) in these samples is studied. The scarce microstructural data reported on chert contrast with many studies addressing porosity evolution in other sedimentary rocks. The aim of this work is to solve the distribution of OM and silica in chert by characterizing samples before and after combustion to pinpoint the OM distribution inside the porous silica matrix. The samples are predominantly composed of alpha quartz and show increasing crystallite sizes up to 33 ± 5 nm (1σ standard deviation or SD). In older samples, low water abundances (~0.03%) suggest progressive dehydration. (U)SAXS data reveal a porous matrix that evolves over geological time, including, from younger to older samples, (1) a decreasing pore volume down to 1%, (2) greater pore sizes hosting OM, (3) decreasing specific surface area values from younger (9.3 ± 0.1 m 2 g -1 ) to older samples (0.63 ± 0.07 m 2 g -1 , 1σ SD) and (4) a lower background intensity correlated to decreasing hydrogen abundances. The pore-volume distributions (PVDs) show that pores ranging from 4 to 100 nm accumulate the greater volume fraction of OM. Raman data show aromatic organic clusters up to 20 nm in older samples. Raman and PVD data suggest that OM is located mostly in mesopores. Observed structural changes, silica–OM interactions and the hydro­phobicity of the OM could explain the OM preservation in chert.

(U)SAXS↗
DOE OSTI2016

Intermixing and Formation of Cu-Rich Secondary Phases at Sputtered CdS/CuInGaSe 2 Heterojunctions

In this work, the Cu migration behavior in PVD-CdS/PVD-Cu(In,Ga)Se 2 (CIGS) heterojunctions is investigated by high-resolution electron microscopy (HREM) and energy dispersive X-ray spectroscopy (EDS). Incorporation of Cu into the CdS forms Cu-rich domains but has no effect on epitaxy of the CdS. Epitaxy is commonly observed in the CdS studied. Secondary ion mass spectroscopy depth profiles confirm the presence of Cu in the CdS. In some cases, Cd is completely replaced by Cu, resulting in a Cu-S binary compound epitaxially grown on the CIGS and fully coherent with the surrounding CdS. This is most likely to be cubic Cu 2 S, based on lattice spacing measurements from HREM images and EDS elemental quantification. In addition, we find that the buffer layer crystal structure influences the extent of Ga depletion at the CIGS surface, which is more pronounced adjacent to zinc-blende CdS than wurtzite CdS. Density functional theory calculations reveal that Cu clustering and different Ga depletion widths can be attributed to the inherent anisotropy of wurtzite CdS and differences in CIGS point-defect migration barriers. Understanding the influence of these effects on device properties is a critical step in developing more efficient CdS/CIGS-based photovoltaics.

14 SOLAR ENERGY↗
DOE OSTI2018

Superhard Nanostructured Ceramic–Metal Coatings with a Low Macrostress Level

The macrostressed state of (Ti,Al)N–Cu and (Ti,Al)N–Ni ceramic–metal coatings obtained by the arc-PVD method has been studied using X-ray diffraction and by measuring the radius of curvature of a coating–base composite sample (Stoney’s method). It is established that the presence of a tough metal phase favors significant reduction in the level of macrostresses in these structures as compared to those in (Ti,Al)N ceramic coatings, the absolute values of which decrease from 4.7–4.3 to 0.17–0.32 GPa. At the same time, both Ti–Al–Cu–N and Ti–Al–Ni–N coatings retain high hardness of 43 and 51 GPa, respectively, versus 29 GPa for Ti–Al–N coatings. The obtained results give grounds to suppose that the high hardness of the ceramic–metal coatings studied is determined by their nanocrystalline structure rather than by compressive macrostresses.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2015

AREVA Team Enhanced Accident Tolerant Fuels Concepts (Phase 1A Final Report)

In response to the Department of Energy (DOE) funded initiative to develop and deploy lead fuel assemblies (LFAs) of Enhanced Accident Tolerant Fuel (EATF) into a US reactor within 10 years, AREVA put together a team to develop promising technologies for improved fuel performance during off normal operations. This team consisted of the University of Florida (UF) and the University of Wisconsin (UW), Savannah River National Laboratory (SRNL), Duke Energy and Tennessee Valley Authority (TVA). This team brought broad experience and expertise to bear on EATF development. AREVA has been designing; manufacturing and testing nuclear fuel for over 50 years and is one of the 3 large international companies supplying fuel to the nuclear industry. The university and National Laboratory team members brought expertise in nuclear fuel concepts and materials development. Duke and TVA brought practical utility operating experience. This report documents the results from the initial “discovery phase” where the team explored options for EATF concepts that provide enhanced accident tolerance for both Design Basis (DB) and Beyond Design Basis Events (BDB). The main driver for the concepts under development were that they could be implemented in a 10 year time frame and be economically viable and acceptable to the nuclear fuel marketplace. The economics of fuel design make this DOE funded project very important to the nuclear industry. Even incremental changes to an existing fuel design can cost in the range of $100M to implement through to LFAs. If this money is invested evenly over 10 years then it can take the fuel vendor several decades after the start of the project to recover their initial investment and reach a breakeven point on the initial investment. Step or radical changes to a fuel assembly design can cost upwards of $500M and will take even longer for the fuel vendor to recover their investment. With the projected lifetimes of the current generation of nuclear power plants large scale investment by the fuel vendors is difficult to justify. Specific EATF enhancements considered by the AREVA team were; Improved performance in DB and BDB conditions; Reduced release to the environment in a catastrophic accident; Improved performance during normal operating conditions; Improved performance if US reactors start to load follow; Equal or improved economics of the fuel; and Improvements to the fuel behavior to support future transportation and storage of the used nuclear fuel (UNF). In pursuit of the above enhancements, EATF technology concepts that our team considered were; Additives to the fuel pellets which included; Chromia doping to increase fission gas retention. Chromia doping has the potential to improve load following characteristics, improve performance of the fuel pellet during clad failure, and potentially lock up cesium into the fuel matrix; Silicon Carbide (SiC) Fibers to improve thermal heat transfer in normal operating conditions which also improves margin in accident conditions and the potential to lock up iodine into the fuel matrix; Nano-diamond particles to enhance thermal conductivity; Coatings on the fuel cladding; and Nine coatings on the existing Zircaloy cladding to increase coping time and reduce clad oxidation and hydrogen generation during accident conditions, as well as reduce hydrogen pickup and mitigate hydride reorientation in the cladding. To facilitate the development process AREVA adopted a formal “Gate Review Process” (GR) that was used to review results and focus resources onto promising technologies to reduce costs and identify the technologies that would potentially be carried forward to LFAs within a 10 year period. During the initial discovery phase of the project AREVA took the decision to be relatively hands off and allow our university and National Laboratory partners to be free thinking and consider options that would not be constrained by preconceived ideas from the fuel vendor. To counter this and to keep the partners focused, the GR process was utilized. During this GR process each of the team members presented their findings to a board made up of technical experts from utilities, fuel manufacturing experts, fuel technical experts, and fuel research and development (R&D) experts. During the initial 2 years of the project there were several major accomplishments. These accomplishments, along with the implications for successfully implementing EATF, are; The experimental spark plasma sintering process (SPS) process was successfully used to produce fuel pellets containing either 10% SiC whiskers or nano-diamond particles. The ability to use this process enables the thermal margin enhancements of the fuel additives to be realized. Without the SPS process, the conventional process cannot support adding pellet additives in the required quantities; Coatings of Ti2AlC were successfully applied to Zircaloy-4 cladding. Testing of Ti2AlC coatings at Loss of Cooling Accident (LOCA) conditions showed reduced cladding oxidation compared to present un-coated Zircaloy-4 cladding. This achievement allows the presently used cladding system to be retained so that the 10 year schedule can be met. Having to implement a new cladding material will extend the development schedule beyond 10 years; Several documents were produced to support future development, testing, and licensing of EATF, including a design requirements traceability matrix, a draft business plan, a draft test plan, a draft regulatory plan, and the acceptance criteria for lead fuel assembly insertion into a commercial reactor. This preparatory work lays the foundation for ensuring the future development plans address all the areas required to test, license, and manufacture the new EATF; and In addition, the high velocity oxy-fuel and electrophoretic deposition (EPD) coating application processes were dropped from further consideration due to their inability to meet manufacturing criteria. This allows the resources to be focused on the most promising EATF concepts identified. Future development opportunities that were identified during this work include; The use of SiC or diamond requires that a new pellet production technique (Spark Plasma Sintering), be developed. This entails investment in developing, proving and implementing a new commercial pellet production process. Development of the process to apply thinner coatings is required; Coatings cannot be too “thick” or they will displace a significant volume of water in the core resulting in reduced thermal hydraulic characteristics; Application of the coating at high temperature can affect the Zircaloy substrate. This will require the development and implementation of a new cladding coating manufacturing process; and Replace the Cold Spray (CS) cladding coating application with the Physical Vapor Deposition (PVD) process to eliminate duplication of work and provide greater control over coating thicknesses. This can result in a reduction in the final cycle economic penalty of coatings.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Understanding the Effect of Na in Improving the Performance of CuInSe 2 Based Photovoltaics

Cu(In,Ga)Se 2 (CIGS) thin film photovoltaic technology is in the early stages of commercialization with an annual manufacturing capacity over 1 GW and has demonstrated the highest module efficiency of any of the thin film technologies. However there still is a lack of fundamental understanding of the relationship between the material properties and solar cell device operation. It is well known that the incorporation of a small amount of Na into the CIGS film during processing is essential for high efficiency devices. However, there are conflicting explanations for how Na behaves at the atomic scale. This report investigates how Na is incorporated into the CIGS device structure and evaluates the diffusion of Na into CIGS grain boundaries (GBs) and bulk crystallites. Participants: This project was carried out at the Institute of Energy Conversion at the University of Delaware, collaborating with the Rockett group at the University of Illinois Urbana-Champagne. Significant Findings: The significant outcomes of this project for each task include; Task 1.0: Effect of Na in Devices Fabricated on PVD Deposited CIGS; Na diffusion occurs through the Mo back contact via GBs driven by the presence of oxygen; Na reversibly compensates donor defects in CIGS GBs,Task 2.0: Na Incorporation in Single Crystal CIGS; and bulk Na diffusion proceeds rapidly such that grains are Na-saturated immediately following CIGS thin film manufacture. Industry Guidance: The presented results offer interesting concepts for modification of manufacturing processes of CIGS-based PV modules. Possible approaches to improve control of Na uptake and uniformly increase levels in CIGS films are highlighted for processes that employ either soda-lime glass or NaF as the Na source. Concepts include the potential of O 2 or oxidative based treatments of Mo back contacts to improve Na diffusion through the metal film and increase Na uptake into the growing CIGS. This project has also offered fundamental understanding of the behavior of Na in CIGS grains and GBs, particularly the confirmation that CIGS grains will be saturated with Na immediately following manufacture Summary of Results: Most commercially available CIGS modules are fabricated on soda-lime glass coated with Mo as the back electric contact, and Na in the glass diffuses through the Mo layer into the CIGS during film growth. In Task 1 the transport of Na through Mo was evaluated using x-ray photoelectron surface spectroscopy along with diffusion modeling to obtain diffusion coefficients at several temperatures. It was determined that Na diffusion in Mo only occurs along GBs and that oxygen provides an additional driving force to enhance Na transport. Device data revealed that older Mo substrates with a greater amount of surface oxide resulted in slightly higher efficiencies due to enhanced Na incorporation caused by the oxide. This finding shows that Mo substrates could potentially undergo an oxidation treatment prior to CIGS deposition to further improve and control the incorporation of Na. To determine if in-grain Na affects device performance, in Task 1 Na was selectively removed from GBs using heat/rinse cycles. Due to the low temperature of this treatment, Na at GBS remained mobile while diffusion within the bulk was too slow for Na removal from the grain interiors. Changes in electrical properties were evaluated using conductivity and Seebeck coefficient measurements, with both decreasing as Na was removed to reach values similar to Na-free controls samples. This can be explained by the compensation of donor defects by Na, causing an increase in the free carrier concentration. Devices showed a decrease in open-circuit voltage after Na removal confirming that the beneficial effects of GB Na. The findings of this project will provide guidance for rational optimization of Na incorporation procedures in the manufacturing of CIGS solar cells. While it is known that Na segregates at CIGS GBs, the nature and role of Na diffusion into grain interiors was less clear. In Task 2, single crystal CuInSe 2 was used as a model system to represent the grain interiors of CIGS. Crystals processed by two different methods of different compositions and dislocation densities, were evaluated. Diffusion coefficients were obtained at two temperatures after Na diffusion, giving near identical values, ~2x10 11 cm 2 /s and ~6x10 11 cm2/s at 420°C and 480°C, respectively, for each crystal. Characterization confirmed that dislocation densities were too low to significantly impact the effective diffusion coefficient. The Cu-poor crystal had a higher solubility suggesting that Na diffusion is mediated by Cu-vacancies, but was not accompanied by an expected increase in diffusion coefficient. The activation energy for diffusion was similar to values expected for interstitial diffusion, but the large size of Na + ions should result in a solubility that is much lower than what was experimentally measured. A hybrid interstitial-substitutional mechanism is proposed that combines the fast diffusion of interstitial atoms with the high solubility common for substitutional impurities. Lattice diffusion of Na proceeds fast enough that CIGS grain interiors will have Na concentrations near the solubility limit of 1018 cm -3 when manufactured under standard conditions. Na and K treated epitaxial CIS films showed a significant increase in cathodoluminescence emission intensity, indicating a reduction of non-radiative recombination pathways, which is consistent with improvements in CIGS device performance, though the mechanism is not clear. Pathways forward: Despite the success of this project, there are a number of questions remaining related to further the understanding of the chemistry of Na in CIGS films and devices. These include further elucidation of the mechanisms of Na passivation in CIGS GBs, with identification of which defects are involved and confirmation of the possible effects of in-grain Na on device performance. To complete analysis of the cell structure, conformation of the presence and possible chemistries of Na at the CIGS/CdS junction and/or in the front transparent contacts, and its effects on device performance, is needed.

14 SOLAR ENERGY↗
DOE OSTI2018

LDRD 191204: Optimization of Sputtered Aluminum Nitride for the Seeding of Metal Organic Chemical Vapor Deposition Gallium Nitride Films

GaN-on-Si combines the wide bandgap advantages of GaN with the cost and scaling advantages of Si. Sputtered A1N is an attractive nucleation layer material because it reduces Al diffusion into the Si and eliminates a time-intensive preconditioning step in the GaN growth process, but is limited by the poor film quality of PVD A1N films deposited on Si substrates. Sputtering also offers a large degree of control over A1N film properties, including control of the intrinsic stress using substrate biasing. Doping the A1N films with Sc improves the lattice match to A1GaN and GaN films by expanding the a-axis and c-axis lattice parameters. A1N and A1 0.88 Sc 0.12 N films have been grown on silicon, metal, and sapphire substrates and characterized for properties such as stress, grain size, roughness, and film orientation for use as nucleation layers for MOCVD GaN growth.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Capturing the Competing Influence of Thermal and Mechanical Loads on the Strain of Turbine Blade Coatings via High Energy X-rays

This paper presents findings of synchrotron diffraction measurements on tubular specimens with a thermal barrier coating (TBC) system applied by electron beam physical vapor deposition (EB-PVD), having a thermally grown oxide (TGO) layer due to aging in hot air. The diffraction measurements were in situ while applying a thermal cycle with high temperature holds at 1000 °C and varying internal air cooling mass flow and mechanical load. It was observed that, during high temperature holds at 1000 °C, the TGO strain approached zero if no mechanical load or internal cooling was applied. When applying a mechanical load, the TGO in-plane strain (e22) changed to tensile and the out of plane TGO strain (e11) became compressive. The addition of internal cooling induced a thermal gradient, yielding a competing effect, driving the e22 strain to compressive and e11 strain to tensile. Quantifying TGO strain variations in response to competing factors will provide a path to controlling the TGO strain, and further improving the lifetime assessment and durability design strategies for TBC systems.

36 MATERIALS SCIENCE↗
DOE OSTI2023

CMOS-Compatible Ultrathin Superconducting NbN Thin Films Deposited by Reactive Ion Sputtering on 300 mm Si Wafer

We report a milestone in achieving large-scale, ultrathin (~5 nm) superconducting NbN thin films on 300 mm Si wafers using a high-volume manufacturing (HVM) industrial physical vapor deposition (PVD) system. The NbN thin films possess remarkable structural uniformity and consistently high superconducting quality across the entire 300 mm Si wafer, by incorporating an AlN buffer layer. High-resolution X-ray diffraction and transmission electron microscopy analyses unveiled enhanced crystallinity of (111)-oriented δ-phase NbN with the AlN buffer layer. Notably, NbN films deposited on AlN-buffered Si substrates exhibited a significantly elevated superconducting critical temperature (~2 K higher for the 10 nm NbN) and a higher upper critical magnetic field or H c2 (34.06 T boost in H c2 for the 50 nm NbN) in comparison with those without AlN. These findings present a promising pathway for the integration of quantum-grade superconducting NbN films with the existing 300 mm CMOS Si platform for quantum information applications.

36 MATERIALS SCIENCE↗
NASA NTRS1973

Enriched aluminide coatings for dispersion strengthened nickel materials

Improved aluminide/barrier coating combinations for dispersion strengthened nickel materials were investigated. The barrier materials involved alloys with refractory metal content to limit interdiffusion between the coating and the substrate, thereby minimizing void formation. Improved aluminide coatings involved the dispersion of aluminum-rich compounds. Coatings were tested in argon at 1533 K (2300 F) for 100 hours and in cyclic oxidation at 1422 K (2100 F). Two coatings on TDNiCr completed 300 hours of oxidation testing, none on TDNi. Selected coating combinations were evaluated in Mach 1 burner rig testing using JP-4 fuel and air at 1422 K (2100 F) and 1477 K (2200 F) for 350 and 100 hours, respectively. Static oxidation in 1-hour cycles was conducted at 1533 K (2300 F) for 100 hours. For comparison purposes a physical vapor deposition (PVD) NiCrAlY coating was tested concurrently. Only the NiCrA1Y coating survived the 1477 K (2200 F)/100-hour burner rig test and 275 hours of the 350-hour 1422 K (2100 F) test. Elevated temperature exposure reduced room temperature tensile properties but had little effect on elevated temperature properties.

Levinstein, M. A.↗
NASA NTRS1977

Protection of cooled blades of complex internal structure

The problem of general protection of cooled blades of complex internal structure was solved by a method called SF technique which makes possible the protection of both external and internal surfaces, as well as those of the orifices of cooling air, whatever their diameter. The SF method is most often applied in the case of pack process, at controlled or high activity; it can be of use on previously uncoated parts, but also on pieces already coated by a thermochemical, chemical or PVD method. The respective thickness of external and internal coatings may be precisely predetermined, no parasitic particle being liable to remain inside the parts after application of the protecting treatment. Results obtained to date by application of this method are illustrated by the presentation and examination of a various selection of advanced turbo engines.

Glamiche, P.↗
NASA NTRS1984

Thermal barrier coating life prediction model development

Thermal barrier coatings (TBCs) for turbine airfoils in high-performance engines represent an advanced materials technology that has both performance and durability benefits. In order to achieve these benefits, however, the TBC system must be reliable. Prediction of the lives of two types of strain-tolerant and oxidation-resistant TBC systems that are produced by commercial coating suppliers to the gas turbine industry is examined. The plasma sprayed TBC system, composed of a low-pressure plasma spray (LPPS) applied oxidation resistant NiCrAlY bond coating and an air-plasma-sprayed yttria (8 percent) partially stabilized zirconia insulative layer is applied by both Chromalloy and Klock. The second type of TBC is applied by the electron beam-physical vapor depositon (EB-PVD) process by Temescal.

Strangman, T. E.↗
NASA NTRS1986

Thermal barrier coating life-prediction model development

The program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant thermal barrier coating (TBC) systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma-spray (LPPS) or an argon shrouded plasma-spray (ASPS) applied oxidation resistant NiCrAlY or (CoNiCrAlY) bond coating and an air-plasma-sprayed yttria partially stabilized zirconia insulative layer, is applied by both Chromalloy, Klock, and Union Carbide. The second type of TBS is applied by the electron beam-physical vapor deposition (EB-PVD) process by Temescal. The second year of the program was focused on specimen procurement, TMC system characterization, nondestructive evaluation methods, life prediction model development, and TFE731 engine testing of thermal barrier coated blades. Materials testing is approaching completion. Thermomechanical characterization of the TBC systems, with toughness, and spalling strain tests, was completed. Thermochemical testing is approximately two-thirds complete. Preliminary materials life models for the bond coating oxidation and zirconia sintering failure modes were developed. Integration of these life models with airfoil component analysis methods is in progress. Testing of high pressure turbine blades coated with the program TBS systems is in progress in a TFE731 turbofan engine. Eddy current technology feasibility was established with respect to nondestructively measuring zirconia layer thickness of a TBC system.

Strangman, T. E.↗
NASA NTRS1986

Thermal barrier coating life prediction model development

Thermal barrier coatings (TBCs) for turbine airfoils in high-performance engines represent an advanced materials technology with both performance and durability benefits. The foremost TBC benefit is the reduction of heat transferred into air-cooled components, which yields performance and durability benefits. This program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant TBC systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma-spray (LPPS) or an argon shrouded plasma-spray (ASPS) applied oxidation resistant NiCrAlY (or CoNiCrAlY) bond coating and an air-plasma-sprayed yttria (8 percent) partially stabilized zirconia insulative layer, is applied by Chromalloy, Klock, and Union Carbide. The second type of TBC is applied by the electron beam-physical vapor deposition (EB-PVD) process by Temescal.

T E Strangman↗
NASA NTRS1988

Adhesion scratch testing - A round-robin experiment

Six sets of samples, TiN coated by chemical or physical vapor deposition methods (CVD or PVD) onto cemented carbide or high-speed steel (HSS), and TiC coated by CVD onto cemented carbide have been scratch tested using three types of commercially available scratch adhesion tester. With exception of one cemented carbide set, the reproducibility of the critical loads for any given set with a given stylus is excellent, about + or - 5 percent, and is about + or - 20 percent for different styli. Any differences in critical loads recorded for any given sample set can be attributed to the condition of the stylus (clean, new, etc.), the instrument used, the stylus itself (friction coefficient, etc.), and the sample set itself. One CVD set showed remarkably large differences in critical loads for different styli, which is thought to be related to a mechanical interaction between stylus and coating which is enhanced by a plastic deformability in the film related to the coating microstructure. The critical load for TiN on HSS increases with coating thickness, and differences in frictional conditions led to a systematic variation in the critical loads depending on the stylus used.

Perry, A. J.↗
NASA NTRS1991

Novel applications for TAZ-8A

Recent needs in the non-aerospace industrial sector have revitalized interest in high performance alloys. TAZ-8A has a combination of properties that makes it unique: a high temperature strength, oxidation resistance, abrasion resistance, and exceptional thermal shock resistance. The major drawback for the utilization of this alloy is the relatively high cost compared with the more common iron base alloys. Reduced material consumption and lower costs are possible by using coatings of TAZ-8A on a low cost substrate. Coatings were applied using plasma spray techniques developed by NASA as well as modified plasma vapor deposition (PVD) techniques.

Riddlebaugh, Stephen M.↗
NASA NTRS1991

Chemical vapor deposition coatings for oxidation protection of titanium alloys

Results of an experimental investigation of the oxidation protection afforded to Ti-14Al-21Nb and Ti-14Al-23Nb-2V titanium aluminides and Ti-17Mo-3Al-3Nb titanium alloy by aluminum-boron-silicon and boron-silicon coatings are presented. These coatings are applied by a combination of physical vapor deposition (PVD) and chemical vapor deposition (CVD) processes. The former is for the application of aluminum, and the latter is for codeposition of boron and silicon. Coating thickness is in the range of 2 to 7 microns, and coating weights are 0.6 to 2.0 mg/sq cm. Oxidation testing was performed in air at temperatures to 1255 K in both static and hypersonic flow environments. The degree of oxidation protection provided by the coatings is determined from weight change measurements made during the testing and post test compositional analyses. Temperature-dependent total normal emittance data are also presented for four coating/substrate combinations. Both types of coatings provided excellent oxidation protection for the exposure conditions of this investigation. Total normal emittances were greater than 0.80 in all cases.

Cunnington, G. R.↗
NASA NTRS1995

Mechanical properties testing and results for thermal barrier coatings

Thermal Barrier Coatings (TBC's) provide a significant challenge in the evaluation of their mechanical properties in ways that provide data that is not specimen dependent. The paper reviews various developments of the principal author over the past several years for both plasma sprayed and physical vapor deposited (PVD) materials, as well as new data on the fatigue behavior of one material system. The test methods that have been employed address tensile and compressive modulus and ultimate strength, tensile and compressive fatigue strength, and interfacial strength. This testing is now underway. Property testing is especially difficult for TBC's owing to the limitation on fabrication thickness of the coating. Bending tests are not used as these tests do not provide sufficiently uniform states of strain for property evaluations. Test specimens with uniform states of axial stress have been devised for each material system. The results show that the material property results between various experimenters and experimental methods are not yet consistent. However, the results provide critical design data at a suitable level of accuracy for life prediction. The paper will review both tensile and compressive mechanical testing of uniaxial specimens showing property dependencies on material density and temperatures for both material systems. Successful test results for both tensile and compressive fatigue loadings will be given. The test data shows that the fatigue strength of the TBC's is highly stress dependent in both loading conditions and is likely to depend on stress range and not mean stress. The fatigue strength of the plasma sprayed TBC's appears to increase with elevated temperatures in a range of temperatures below the creep activation temperature for the materials. The plasma sprayed TBC materials have been confirmed to have cyclic hysteresis at all temperature levels down to room temperature. Limited failure analysis data for various specimens suggest that the failure modes are driven by normal geometric discontinuities in the TBC's.

Cruse, T. A.↗
NASA NTRS1995

Thermal barrier coating life modeling in aircraft gas turbine engines

Analytical models useful for predicting ceramic thermal barrier coating (TBC) spalling life in aircraft gas turbine engines are presented. Electron beam-physical vapor deposited (EB-PVD) and plasma sprayed TBC systems are discussed. TBC spalling was attributed to a combination of mechanisms such as metal oxidation at the ceramic-metal interface, ceramic-metal interface stress concentrations at free surfaces due to dissimilar materials, ceramic-metal interface stresses caused by local radius of curvature and interface roughness, material properties and mechanical behavior, transient temperature gradients across the ceramic layer and component design features. TBC spalling life analytical models were developed based on observations of TBC failure modes and plausible failure theories. TBC failure was assumed to occur when the imposed stresses exceeded the material strength (at or near the ceramic-metal interface). TBC failure knowledge gaps caused by lack of experimental evidence and analytical understanding are noted. The analytical models are considered initial engineering approaches that capture observed TBC failure trends.

Nissley, D. M.↗