SEARCH · Engineering Papers

Results for “Multi-layer coating”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 19 records

All sources NASA NTRS DOE OSTI

DOE OSTI2025

Improved damage tolerance of SiC-based nuclear fuel cladding with novel multi-layered SiC coating design at 1200 °C

Continuous SiC fibre reinforced SiC matrix composites (SiC f -SiC m ) with monolithic SiC outer coatings are considered as a damage-tolerant cladding design for loss of coolant accident (LOCA) conditions in light water reactors. However, monolithic SiC coatings are brittle and prone to catastrophic failure. In this study, a SiC f -SiC m cladding with a novel multi-layer SiC outer coating (11 sub-layers, ∼260 µm in total thickness) was investigated under C-ring compression at room temperature and 1200 °C in argon environment. Real-time synchrotron X-ray computed tomography (XCT) was employed to capture crack initiation and propagation processes. Compared to conventional monolithic SiC outer coatings, the multi-layer coating structure facilitated crack deflection and bifurcation enhancing its damage tolerance at both temperatures. Despite pre-existing surface cracks, claddings exhibited stable mechanical-performance at both temperatures. These initial cracks did not critically affect the failure processes as they were not aligned with the maximum stress direction. Furthermore, the microstructure, distribution of residual stresses, and local properties of individual components in the material were thoroughly characterized, and compared with open literature on conventional claddings with monolithic outer coatings. These results provide new insights into the failure mechanisms of multi-layer SiC coatings and offer guidance for the future design of accident-tolerant nuclear fuel claddings.

36 - MATERIALS SCIENCE↗

DOE OSTI2026

Understanding spectral dependance of laser-induced damage precursors in dielectric materials (Abbreviated report_23-ERD-006)

High peak and average power laser systems are typically limited by the handling fluence of the optical components. In particular, the multilayer dielectric coatings are known to be much lower operational fluence than the more ideal bulk materials. In this project we proposed and succeeded in probing different established classes of damage prone precursors at different wavelengths to understand their fundamental laser damage response as a function of wavelength. This study helped to shed light on the fundamental physics of the non-linear precursors that govern laser damage phenomena for ns-regime pulsed laser damage. In this study, we utilized the onsite coating capabilities (VPL, IBS coating lab) to purposefully generate laser damage-prone precursors in hafnia-based coatings (both single and multi-layer coatings). Specifically, we engineered coatings with craze lines initiated by nodules, generated coatings with our xenon-based coating process to suppress nanobubble formation and generated hafnia coatings under controlled oxygen flow conditions to study hafnia sub-oxides and oxygen flow dependance. In these studies we found that craze lines are rife with precursors that are sensitive to ultra-violet light but not to infrared light; we found that the removal of nanobubbles helps with all wavelengths tested, but is most impactful for ultra-violet light; we also found that ultra-violet laser damage performance of hafnia is closely matched to oxygen flow rate, while the infrared performance may be slightly better at lower flow rates. During this LDRD we also successfully stood up a new laser damage testing capability, namely a wavelength agile damage test station to study the spectral response of known laser-induced damage precursors. This is a unique and important capability for Lawrence Livermore National Lab, allowing us to understand the spectral response of materials under high intensity irradiation and damage. This is a vital tool to understand non-linear optical response at wavelengths that we have previously been unable to test at.

36 MATERIALS SCIENCE↗

NASA NTRS1978

A facility for the simulation of environmental parameters and qualification of flight thermal coatings

There is a continuing interest and need for investigation and development of, various paints, coatings, multi-layer insulation, and electrically conductive paints and coatings used for thermal control and electrical discharge of spacecraft surfaces. Degradation of these surfaces by solar-wind energy particles and ultraviolet irradiation, as well as contamination by the outgassing of materials used in conjunction or close proximity to these surfaces, continues to be a matter of concern. The following is a description of a facility with the capability of evaluating the synergistic effects encountered in the space environment. Actual flight qualification programs are also described.

Paczkowski, F. N.↗

NASA NTRS1992

Multi-layer light-weight protective coating and method for application

A thin, light-weight, multi-layer coating is provided for protecting metals and their alloys from environmental attack at high temperatures. A reaction barrier is applied to the metal substrate and a diffusion barrier is then applied to the reaction barrier. A sealant layer may also be applied to the diffusion barrier if desired. The reaction barrier is either non-reactive or passivating with respect to the metal substrate and the diffusion barrier. The diffusion barrier is either non-reactive or passivating with respect to the reaction barrier and the sealant layer. The sealant layer is immiscible with the diffusion barrier and has a softening point below the expected use temperature of the metal.

Wiedemann, Karl E.↗

NASA NTRS1994

Low Earth orbit durability evaluation of protected silicone for advanced refractive photovoltaic concentrator arrays

The need for efficient, cost effective sources of electrical power in space has led to the development of photovoltaic power systems which make use of novel refractive solar concentrators. These concentrators have been conceived in both point-focus and linear-focus designs. Current concentrator lenses are fabricated from flexible silicones with Fresnel facets along their inside surface. To insure the efficient operation of these power systems, the concentrator lenses must be durable and the silicone material must remain specularly transmitting over a reasonable lifetime in low Earth orbit (LEO) and other space environments. Because of the vulnerability of silicones to atomic oxygen and ultraviolet radiation in LEO these lenses have been coated with a multi-layer metal oxide protective coating. The objective of this research was to evaluate the LEO durability of the multilayer coated silicone for advanced refractive photovoltaic concentrator arrays with respect to optical properties and microstructure. Flat metal oxide coated silicone samples were exposed to ground-laboratory and in-space atomic oxyqen for durability evaluation.

Degroh, Kim K.↗

DOE OSTI2025

Corrosion Behavior of Hydrophobic Coatings in Aqueous CO2 Environments

Internal corrosion is caused by gas impurities such as CO2, moisture, and H2S, leading to material degradation. To combat this, the National Energy Technology Laboratory (NETL) developed a novel hydrophobic coating to reduce surface hydrophobicity and enhance the corrosion resistance of steel. NETL’s approach uses multi-layer hydrophobic coatings, a novel and promising coating that could potentially revolutionize the industry's approach to internal corrosion mitigation. This work aims to investigate the corrosion performance of the hydrophobic coating and determine the water uptake. Electrochemical corrosion experiments were carried out on bare X65 carbon steel without and with coating in 3.5 wt.% NaCl saturated with CO2 at 20 °C to follow the water uptake as a function of exposure time. Linear polarization resistance (LPR) was used to determine the corrosion rate for carbon steel immersed in a NaCl electrolyte saturated with CO2. Electrochemical impedance spectroscopy (EIS) of uncoated and coated bare carbon steel was investigated. The analyses of impedance models and water uptake behaviors of hydrophobic coatings were studied for 200 hours during the corrosion process. The water uptake was estimated using the Brasher and Kingsbury relation. The results showed that the superhydrophobic coating that was developed used innovative nano-based materials to act as protection layers on the surface of metallic parts against mechanical aggressors, corrosion, and fouling agents.

corrosion behavior↗

DOE OSTI2026

Influence of Oxygen Flow and Stoichiometry on Optical Properties and Damage Resistance of Hafnium Oxide Thin Films

Hafnium oxide (HfO 2 ) is predominantly used as a high-index material in multi-layer dielectric coatings for high-peak- and high-average-power lasers, but laser damage often initiates within the HfO 2 layers despite their wide bandgap. Oxygen deficiency during deposition can introduce vacancy-related sub-bandgap states and absorptive defects, lowering damage resistance. This study investigates how oxygen flow during HfO 2 deposition with ion beam sputtering (IBS) affects its stoichiometry, defect formation, and nanosecond laser-induced damage threshold (LIDT) and whether single-layer trends predict multilayer performance. Single layers were deposited at varying oxygen flows, characterized for optical and structural properties, and tested for the LIDT at 1064 nm and 355 nm. Increasing oxygen flow drove the layer toward near-stoichiometric HfO 2 , reduced the refractive index, and altered the density of surface pinhole-like features. The single-layer LIDT at 355 nm increased with oxygen, whereas the 1064 nm LIDT was comparatively less sensitive to oxygen flow, consistent with the wavelength-dependent roles of absorptive precursors and microstructural defects. In contrast, a HfO 2 -based high-reflector (HR) showed a higher LIDT at lower oxygen flow, indicating that the family of damage precursors changes between single layers and multilayers; in stacks, structural properties such as stress, gas entrapment and thermal dissipation may outweigh the isolated absorptive defects found in single layers. These results demonstrate that the optimal oxygen flow condition depends on both LIDT wavelength and film architecture. We identified, for single layers, a 15–35 sccm window for maximizing the 1064 nm LIDT and a high-flow optimum (45 sccm) for the 355 nm LIDT and, for 355 nm HR stacks, a distinct lower-flow regime (~10 sccm).

Optics and optical instruments↗

NASA NTRS1992

Design of a pressurized lunar rover

A pressurized lunar rover is necessary for future long-term habitation of the moon. The rover must be able to safely perform many tasks, ranging from transportation and reconnaissance to exploration and rescue missions. Numerous designs were considered in an effort to maintain a low overall mass and good mobility characteristics. The configuration adopted consists of two cylindrical pressure hulls passively connected by a pressurized flexible passageway. The vehicle has an overall length of 11 meters and a total mass of seven metric tons. The rover is driven by eight independently powered two meter diameter wheels. The dual-cylinder concept allows a combination of articulated frame and double Ackermann steering for executing turns. In an emergency, the individual drive motors allow the option of skid steering as well. Two wheels are connected to either side of each cylinder through a pinned bar which allows constant ground contact. Together, these systems allow the rover to easily meet its mobility requirements. A dynamic isotope power system (DIPS), in conjunction with a closed Brayton cycle, supplied the rover with a continuous supply of 8.5 kW. The occupants are all protected from the DIPS system's radiation by a shield of tantalum. The large amount of heat produced by the DIPS and other rover systems is rejected by thermal radiators. The thermal radiators and solar collectors are located on the top of the rear cylinder. The solar collectors are used to recharge batteries for peak power periods. The rover's shell is made of graphite-epoxy coated with multi-layer insulation (MLI). The graphite-epoxy provides strength while the thermally resistant MLI gives protection from the lunar environment. An elastomer separates the two materials to compensate for the thermal mismatch. The communications system allows for communication with the lunar base with an option for direct communication with earth via a lunar satellite link. The various links are combined into one signal broadcast in the S-band at 2.3 GHz. The rover is fitted with a parabolic reflector disk for S-band transmission, and an omnidirectional antenna for local extravehicular activity (EVA) communication. The rover's guidance, navigation, and control subsystem consists of an inertial guidance system, an orbiting lunar satellite, and an obstacle avoidance system. In addition, the rover is equipped with a number of external fixtures including two telerobotic arms, lights, cameras, EVA storage, manlocks, a docking fixture, solar panels, thermal radiators, and a scientific airlock. In conclusion, this rover meets all of the design requirements and clearly surpasses them in the areas of mobility and maneuverability.

Bhardwaj, Manoj↗

NASA NTRS1992

Degradation of electro-optic components aboard LDEF

Re-measurement of the properties of a set of electro-optic components exposed to the low earth orbital environment aboard the Long Duration Exposure Facility (LDEF) indicates that most components survived quite well. Typical components showed some effects related to the space environment unless well protected. The effects were often small but significant. Results for semiconductor infrared detectors, lasers, LED's, filter, mirrors, and black paints will be presented. Semiconductor detectors and emitters were scarred but reproduced their original characteristics. Spectral characteristics of multi-layer dielectric filters and mirrors were found to be altered and degraded. Increased absorption in black paints indicates an increase in absorption sites, giving rise to enhanced performance as coatings for baffles and sunscreens. We find plastics and multi-layer dielectric coatings to be potentially unstable. Semiconductor devices, metal, and glass are more likely to be stable.

Blue, M. D.↗

NASA NTRS1993

Laser damage of HR, AR-coatings, monolayers and bare surfaces at 1064 nm

Laser induced damage thresholds and morphologies were investigated in a variety of uncoated and coated surfaces, including monolayers and multi-layers of different chemical compositions. Both antireflective (AR) and highly reflective (HR) were tested. Testing was done at 1064 nm with 25 picosecond and 8 nanosecond YAG/Nd laser single pulses. Spot diameter in the experiments varied from 0.09 to 0.22 mm. The laser damage measurement procedure consisted of 1-on-1 (single laser pulse in the selected site) and N-on-1 experiments including repeated irradiation by pulses of the same fluence and subsequently raised from pulse to pulse fluence until damage occurred. The highest picosecond damage thresholds of commercially available coatings averaged 12 - 14 J/sq cm, 50 percent less than thresholds obtained in bare fused silica. Some coatings and bare surfaces revealed a palpable preconditioning effect (an increase in threshold of 1.2 to 1.8 times). Picosecond and nanosecond data were compared to draw conclusions about pulse width dependence. An attempt was made to classify damage morphologies according to the type of coating, class of irradiating, and damage level.

Garnov, S. V.↗

NASA NTRS1989

Sequentially evaporated thin Y-Ba-Co-O superconducting films on microwave substrates

The development of high T sub c superconducting thin films on various microwave substrates is of major interest in space electronic systems. Thin films of YBa2Cu3O(7-Delta) were formed on SrTiO3, MgO, ZrO2 coated Al2O3, and LaAlO3 substrates by multi-layer sequential evaporation and subsequent annealing in oxygen. The technique allows controlled deposition of Cu, BaF2 and Y layers, as well as the ZrO buffer layers, to achieve reproducibility for microwave circuit fabrication. The three layer structure of Cu/BaF2/Y is repeated a minimum of four times. The films were annealed in an ambient of oxygen bubbled through water at temperatures between 850 C and 900 C followed by slow cooling (-2 C/minute) to 450 C, a low temperature anneal, and slow cooling to room temperature. Annealing times ranged from 15 minutes to 5 hrs. at high temperature and 0 to 6 hr. at 450 C. Silver contacts for four probe electrical measurements were formed by evaporation followed with an anneal at 500 C. The films were characterized by resistance-temperature measurements, energy dispersive X-ray spectroscopy, X-ray diffraction, and scanning electron microscopy. Critical transition temperatures ranged from 30 K to 87 K as a function of the substrate, composition of the film, thicknesses of the layers, and annealing conditions. Microwave ring resonator circuits were also patterned on these MgO and LaAlO3 substrates.

Valco, G. J.↗

DOE OSTI2025

Pulse duration dependent effects of ultrafast laser induced damage on a 1030 nm multi-layer dielectric mirror for high repetition rate, high average power laser systems

High repetition rate, high peak, and average power laser systems are crucial for next-generation particle accelerators, inertial confinement fusion, and secondary particle sources. These applications demand durable laser optics, particularly interference coatings on optics lasting millions of shots at high fluence. This study focuses on designing, testing, and simulating multi-layer dielectric (MLD) mirrors for pulse durations of 260 fs, 77 fs, and 25 fs at 1030 nm wavelength and 45-degree incidence angle with p -polarization. S-on-1 laser-induced damage thresholds (LIDT) for varying pulse numbers were determined, with single-shot LIDT values of 0.98 Jcm -2 , 1.63 Jcm -2 , and 2.3 Jcm -2 for 25 fs, 77 fs, and 260 fs respectively. A strong correlation between blister shape and local fluence was observed, implying that the layer expansion in a blister depends on local fluence. We have also examined mechanisms responsible for laser-induced stress generation and energy release rates in blister formation. Damage mechanisms are further explored by finite-difference time-domain (FDTD) simulations, incorporating Keldysh strong field ionization, whose predictions were in excellent agreement with the onset of damage determined experimentally. These findings offer insights for enhancing MLD coating technology, promising more efficient and resilient laser systems for diverse scientific and industrial applications.

Noor, Mohamed Yaseen (ORCID:000000021036644X)↗

NASA NTRS1990

Thermal analysis of a strongback structure for a high-frequency microwave antenna concept in geosynchronous orbit

The effects of the geosynchronous thermal environment on the performance of a tetrahedral truss strongback structure for a high-frequency microwave antenna concept for earth science monitoring have been studied. Two orbit conditions (an equinox orbit with a 72-minute eclipse and a solstice orbit with no eclipse) and a range of thermal control approaches were investigated under steady state and transient conditions. The thermal control approaches included aluminum surface coatings with high and low solar-absorptivity-to-infrared-emissivity ratios, multi-layer insulation, a sun shield, and various truss element materials. The effects of both earth shadowing and shadowing by the antenna reflector on temperatures were also examined. Temperatures and corresponding structural distortion results are presented.

Farmer, Jeffery T.↗

NASA NTRS1990

Hazards protection for space suits and spacecraft

A flexible multi-layered covering article for protection against the hazards of exposure to the environment of outer space is disclosed. The covering includes an outer layer section comprising an outermost lamina of woven expanded tetrafluoroethylene yarns (Gore Tex) for protecting against abrasion and tearing, an underlying weave of meta-aramid yarns (Nomex) and para-aramid yarns (Kevlar) for particle impart protection, and electrostatic charge dissipation and control system incorporated therein, and a chemical contaminants control barrier applied as a coating. A middle section includes a succession of thermal insulating layers of polymeric thermoplastic or thermoforming material, each of which is coated with a metal deposit of high infra-red emissivity and low solar radiation absorption characteristics and separated from adjacent insulating layers by a low thermal conductance material. The covering further includes a radiation attenuating layer of a tungsten-loaded polymeric elastomer binder for protecting against bremsstrahlung radiation and an inner layer of rip-stop polyester material for abrasion protection. A chloroprene coating may be supplied the polyester-material for added micrometeroid protection. Securing means of low heat conductance material secures the multi-layers together as a laminar composite.

Kosmo, Joseph J.↗

NASA NTRS1995

Space qualification of IR-reflecting coverslides for GaAs solar cells

Improvements to GaAs solar array performance, from the use on solar cell coverslides of several reflecting coatings that reject unusable portions of the solar spectrum, are quantified. Blue-red-rejection (BRR) coverslides provide both infrared reflection (IRR) and ultraviolet rejection (UVR). BRR coverslides were compared to conventional antireflection (AR) and ultraviolet (UV) coated coverslides. A 2% improvement in peak-power output, relative to that from Ar-coated coverslides, is seen for cells utilizing BRR coverslides with the widest bandpass. Coverslide BRR-filter bandpass width and covered-solar-cell short-circuit current is a function of incident light angle and the observed narrower-bandpass filters are more sensitive to change in angle from the normal than are wide-bandpass filters. The first long-term (3000 hours) UV testing of unirradiated and 1 MeV electron-irradiated GaAs solar cells, with multilayer-coated coverslides to reduce solar array operating temperature, has indicated that all multilayer coatings on coverslides and solar cells will experience degradation from the space environment (UV and/or electrons). Five types of coverslide coatings, designed for GaAs solar cells, were tested as part of a NASA-sponsored space-flight qualification for BRR, multi-layer-coated, coverslides. The reponse to the different radiations varied with the coatings. The extent of degradation and its consequences on the solar cell electrical characteristics depend upon the coatings and the radiation. In some cases, an improved optical coupling was observed during long-term UV exposure to the optical stack. The benefits of multi-layered solar cell optics may depend upon both the duration and the radiation environment of a mission.

Meulenberg, Andrew↗

NASA NTRS1993

Degradation of electro-optic components aboard LDEF

Remeasurement of the properties of a set of electro-optic components exposed to the low-earth environment aboard the Long Duration Exposure Facility (LDEF) indicates that most components survived quite well. Typical components showed some effects related to the space environment unless well protected. The effects were often small but significant. Results for semiconductor infrared detectors, lasers, and LED's, as well as filters, mirrors, and black paints are described. Semiconductor detectors and emitters were scarred but reproduced their original characteristics. Spectral characteristics of multi-layer dielectric filters and mirrors were found to be altered and degraded. Increased absorption in black paints indicates an increase in absorption sites, giving rise to enhanced performance as coatings for baffles and sunscreens.

Blue, M. D.↗

NASA NTRS1994

Analysis of selected materials flown on interior locations of the Long Duration Exposure Facility

This report documents the post-flight condition of selected hardware taken from interior locations on the Long Duration Exposure Facility (LDEF). This hardware was generally in excellent condition. Outgassing data is presented for heat shrink tubing and fiberglass composite shims. Variation in total mass loss (TML) values for heat shrink tubing were correlated with location. Nylon grommets were evaluated for mechanical integrity; slight embrittlement was observed for flight specimens. Multi-layer insulation blankets, wire bundles, and paints in non-exposed interior locations were all in visibly good condition. Silicon-containing contaminant films were observed on silver-coated hex nuts at the space- and Earth-end interior locations.

Smith, H. A.↗

NASA NTRS1993

Beta cloth durability assessment for Space Station Freedom (SSF) Multi-Layer Insulation (MLI) blanket covers

MLI blankets for the Space Station Freedom (SSF) must comply with general program requirements and recommendations for long life and durability in the low-Earth orbit (LEO) environment. Atomic oxygen and solar ultraviolet/vacuum ultraviolet are the most important factors in the SSF natural environment which affect materials life. Two types of Beta cloth (Teflon coated woven glass fabric), which had been proposed as MLI blanket covers, were tested for long-term durability in the LEO environment. General resistance to atomic oxygen attack and permeation were evaluated in the high velocity atomic oxygen beam system at Los Alamos National Laboratories. Long-term exposure to the LEO environment was simulated in the laboratory using a radio frequency oxygen plasma asher. The plasma asher treated Beta cloth specimens were tested for thermo-optical properties and mechanical durability. Space exposure data from the Long Duration Exposure Facility and the Intelsat Solar Array Coupon were also used in the durability assessment. Beta cloth fabricated to Rockwell specification MBO 135-027 (Chemglas 250) was shown to have acceptable durability for general use as an MLI blanket cover material in the LEO environment while Sheldahl G414500 should be used only in locations which are protected from direct Ram atomic oxygen.

Koontz, Steven L.↗