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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1985

Thermal barrier coating life prediction model

This is the first report of the first phase of a 3-year program. Its objectives are to determine the predominant modes of degradation of a plasma sprayed thermal barrier coating system, then to develop and verify life prediction models accounting for these degradation modes. The first task (Task I) is to determine the major failure mechanisms. Presently, bond coat oxidation and bond coat creep are being evaluated as potential TBC failure mechanisms. The baseline TBC system consists of an air plasma sprayed ZrO2-Y2O3 top coat, a low pressure plasma sprayed NiCrAlY bond coat, and a Rene'80 substrate. Pre-exposures in air and argon combined with thermal cycle tests in air and argon are being utilized to evaluate bond coat oxidation as a failure mechanism. Unexpectedly, the specimens pre-exposed in argon failed before the specimens pre-exposed in air in subsequent thermal cycles testing in air. Four bond coats with different creep strengths are being utilized to evaluate the effect of bond coat creep on TBC degradation. These bond coats received an aluminide overcoat prior to application of the top coat to reduce the differences in bond coat oxidation behavior. Thermal cycle testing has been initiated. Methods have been selected for measuring tensile strength, Poisson's ratio, dynamic modulus and coefficient of thermal expansion both of the bond coat and top coat layers.

Hillery, R. V.↗
NASA NTRS1994

Powder-Curtain Feeder For Coating Filament Tow

Continuous fiber web receives powder coat first on one side, then on other. Vibrating helical screw mechanism in powder feeder provides even flow of powder to form powder curtain that descends onto moving web. Small amount of powder that falls to side or through web recovered easily. Powder-curtain feeder part of apparatus similar to one described in "System Applies Polymer Powder to Filament Tow" (LAR-14231).

Baucom, Robert M.↗
NASA NTRS2017

Coatings for Oxidation and Hot Corrosion Protection of Disk Alloys

Increasing temperatures in aero gas turbines is resulting in oxidation and hot corrosion attack of turbine disks. Since disks are sensitive to low cycle fatigue (LCF), any environmental attack, and especially hot corrosion pitting, can potentially seriously degrade the life of the disk. Application of metallic coatings are one means of protecting disk alloys from this environmental attack. However, simply the presence of a metallic coating, even without environmental exposure, can degrade the LCF life of a disk alloy. Therefore, coatings must be designed which are not only resistant to oxidation and corrosion attack, but must not significantly degrade the LCF life of the alloy. Three different Ni-Cr coating compositions (29, 35.5, 45wt. Cr) were applied at two thicknesses by Plasma Enhanced Magnetron Sputtering (PEMS) to two similar Ni-based disk alloys. One coating also received a thin ZrO2 overcoat. The coated samples were also given a short oxidation exposure in a low PO2 environment to encourage chromia scale formation. Without further environmental exposure, the LCF life of the coated samples, evaluated at 760C, was less than that of uncoated samples. Hence, application of the coating alone degraded the LCF life of the disk alloy. Since shot peening is commonly employed to improve LCF life, the effect of shot peening the coated and uncoated surface was also evaluated. For all cases, shot peening improved the LCF life of the coated samples. Coated and uncoated samples were shot peened and given environmental exposures consisting of 500 hrs of oxidation followed by 50 hrs of hot corrosion, both at 760C). The high-Cr coating showed the best LCF life after the environmental exposures. Results of the LCF testing and post-test characterization of the various coatings will be presented and future research directions discussed.

LCF life↗
NASA NTRS2019

LCF Life of As-Deposited and Annealed NiCr-Y Coatings for Oxidation and Hot Corrosion Protection of Disk Alloys

Increasing temperatures in aero gas turbines is resulting in oxidation and hot corrosion attack of turbine disks. Since disks are sensitive to low cycle fatigue (LCF), any environmental attack, and especially hot corrosion pitting, can seriously degrade the life of the disk. Application of metallic coatings is one means of protecting disk alloys from this environmental attack. However, the presence of a metallic coating can degrade the LCF life of a disk alloy. Therefore, coatings must be designed which are not only resistant to oxidation and corrosion attack, but do not significantly degrade the LCF life of the alloy.Three different NiCr-Y coating compositions (29, 35.5, 44 wt.% Cr, all with 0.1 wt.% Y) were applied at two thicknesses by Plasma Enhanced Magnetron Sputtering (PEMS) to two similar Ni-based disk alloys. One Ni-35.5Cr-0.1Y coating also received a thin ZrO2 overcoat. The coated samples were also given a short thermal anneal in a low PO2 environment to encourage bonding of the coating and substrate as well as initiating formation of a chromia scale. Without further environmental exposure, the LCF life of coated and uncoated samples was evaluated at 760°C in air. The LCF lifetime of all coated samples was less than that of uncoated samples. The LCF life scaled with the Cr content and the high-Cr, thin coating showed the highest LCF life. Pre and post-test characterization of the various coatings, including identification of crack initiation sites, will be presented and the effect of the coating on the LCF life discussed.

low cycle fatigue↗
NASA NTRS2020

LCF Life of NiCr-Y Coated Disk Alloys After Shot Peening, Oxidation and Hot Corrosion

In a prior companion study (Ref. 1), three different Ni-Cr coating compositions (29, 35.5, 45 wt% Cr) were applied at two thicknesses by Plasma Enhanced Magnetron Sputtering (PEMS) to two similar Ni-based disk alloys. One coating also received a thin ZrO2 overcoat. The low cycle fatigue (LCF) life of each coating was determined at 760 °C and was less than that of the uncoated specimens. In this followon effort, shot peening was examined as a means to improve the as-deposited coating morphology as well as impart a residual compressive stress in the near-surface region. After evaluating the effect of the shot peening on the LCF life, the effectiveness of the shot-peened coating in protecting the disk alloy from oxidation and hot corrosion attack was evaluated. This evaluation was accomplished by exposing coated and shot-peened specimens to 500 h of oxidation followed by 50 h of hot corrosion, both at 760 °C in air. These exposed specimens were then tested in fatigue and compared to similarly treated and exposed uncoated specimens. For all cases, shot peening improved the LCF life of the coated specimens. More specifically, the highest Cr coating showed the best LCF life of the coated specimens after shot peening, as well as after the environmental exposures. Characterization of the coatings after shot peening, oxidation, hot corrosion and LCF testing is presented and discussed.

James A Nesbitt↗
NASA NTRS1998

Thermal High- and Low-Cycle Fatigue Behavior of Thick Thermal Barrier Coating Systems

Ceramic thermal barrier coatings have received increasing attention for advanced gas turbine and diesel engine applications because of their ability to provide thermal insulation to engine components. However, the durability of these coatings under the severe thermal cycling conditions encountered in a diesel engine (ref. 1) still remains a major issue. In this research at the NASA Lewis Research Center, a high-power laser was used to investigate the thermal fatigue behavior of a yttria-stabilized zirconia coating system under simulated diesel engine conditions. The mechanisms of fatigue crack initiation and propagation, and of coating failure under complex thermal low-cycle fatigue (LCF, representing stop/start cycles) and thermal high-cycle fatigue (HCF, representing operation at 1300 rpm) are described. Continuous wave and pulse laser modes were used to simulate pure LCF and combined LCF/HCF, respectively (ref. 2). The LCF mechanism was found to be closely related to the coating sintering and creep at high temperatures. These creep strains in the ceramic coating led to a tensile stress state during cooling, thus providing the major driving force for crack growth under LCF conditions. The combined LCF/HCF tests induced more severe coating surface cracking, microspallation, and accelerated crack growth than did the pure LCF test. HCF thermal loads also facilitated lateral crack branching and ceramic/bond coat interface delaminations. HCF is associated with the cyclic stresses originating from the high-frequency temperature fluctuation at the ceramic coating surface. The HCF thermal loads act on the crack by a wedging mechanism (ref. 1), resulting in continuous crack growth at temperature. The HCF stress intensity factor amplitude increases with the interaction depth and temperature swing, and decreases with the crack depth. HCF damage also increases with the thermal expansion coefficient and the Young's modulus of the ceramic coating (refs. 1 and 3).

Miller, Robert A.↗
NASA NTRS2004

Reading Through Paint

Two-dimensional data matrix symbols, which contain encoded letters and numbers, are permanently etched on items for identification. They can store up to 100 times more information than traditional bar codes. While the symbols provide several advantages over bar codes, once they are covered by paint they can no longer be read by optical scanners. Since most products are painted eventually, this presents a problem for industries relying on the symbols for identification and tracking. In 1987, NASA s Marshall Space Flight Center began studying direct parts marking with matrix symbols in order to track millions of Space Shuttle parts. Advances in the technology proved that by incorporating magnetic properties into the paints, inks, and pastes used to apply the matrix symbols, the codes could be read by a magnetic scanner even after being covered with paint or other coatings. NASA received a patent for such a scanner in 1998, but the system it used for development was not portable and was too costly. A prototype was needed as a lead-in to a production model. In the summer of 2000, NASA began seeking companies to build a hand-held scanner that would detect the Read Through Paint data matrix identification marks containing magnetic materials through coatings.

Source record↗
NASA NTRS1988

Auger analysis of a fiber/matrix interface in a ceramic matrix composite

Auger electron spectroscopy (AES) depth profiling was used to characterize the fiber/matrix interface of an SiC fiber, reaction bonded Si3N4 matrix composite. Depth profiles of the as received double coated fiber revealed concentration oscillations which disappeared after annealing the fiber in the environment used to fabricate the composite. After the composite was fractured, the Auger depth profiles showed that failure occurred in neither the Beta-SiC fiber body nor in the Si3N4 matrix but, concurrently, at the fiber coating/matrix interface and within the fiber coating itself.

Honecy, Frank S.↗
NASA NTRS1988

Auger analysis of a fiber/matrix interface in a ceramic matrix composite

Auger electron spectroscopy (AES) depth profiling was used to characterize the fiber/matrix interface of an SiC fiber, reaction bonded Si3N4 matrix composite. Depth profiles of the as received double coated fiber revealed concentration oscillations which disappeared after annealing the fiber in the environment used to fabricate the composite. After the composite was fractured, the Auger depth profiles showed that failure occurred in neither the Beta-SiC fiber body nor in the Si3N4 matrix but, concurrently, at the fiber coating/matrix interface and within the fiber coating itself.

Honecy, Frank S.↗
NASA NTRS2016

Design and Deployment of a Multichroic Polarimeter Array on the Atacama Cosmology Telescope

We present the design and the preliminary on-sky performance with respect to beams and pass bands of a multichroic polarimeter array covering the 90 and 146 GHz cosmic microwave background bands and its enabling broad-band optical system recently deployed on the Atacama Cosmology Telescope (ACT). The constituent pixels are feedhorn-coupled multichroic polarimeters fabricated at NIST. This array is coupled to the ACT telescope via a set of three silicon lenses incorporating novel broad-band metamaterial anti-reflection coatings. This receiver represents the first multichroic detector array deployed for a CMB experiment and paves the way for the extensive use of multichroic detectors and broad-band optical systems in the next generation of CMB experiments.

passbands↗
NASA NTRS2005

Very Tough, Erosion-Resistant Turbine Airfoil Thermal Barrier Coatings Developed

Ceramic thermal barrier coatings (TBCs) are receiving increased attention for advanced gas turbine engine applications. These coatings are considered to be technologically important because of their ability to further increase engine operating temperatures and reduce cooling requirements, thus achieving higher engine efficiency, lower emissions, and increased performance goals. To take full advantage of the capabilities of these coatings, researchers need to use an aggressive design approach whenever possible--one that allows greater temperature reductions through the coating systems and less cooling air to the components. Advanced TBCs that have significantly lower thermal conductivity and better thermal stability than current coatings have been developed for future ultra-efficient, low-emission engine systems. Multicomponent-doped, defect-clustered TBCs have been shown to offer the low conductivity and high stability required for future high-temperature engine applications.

Zhu, Dong-Ming↗
NASA NTRS1996

Tensile Strength and Microstructural Characterization of Uncoated and Coated HPZ Ceramic Fibers

Tensile strengths of as-received HPZ fiber and those surface coated with BN, BN/SiC, and BN/Si3N4 have been determined at room temperature using a two-parameter Weibull distribution. Nominally approx. 0.4 micron BN and 0.2 micron SiC or Si3N4 coatings were deposited on the fibers by chemical vapor deposition using a continuous reactor. The average tensile strength of uncoated HPZ fiber was 2.0 +/- 0.56 GPa (290 +/- 81 ksi) with a Weibull modulus of 4.1. For the BN coated fibers, the average strength and the Weibull modulus increased to 2.39 +/- 0.44 GPa (346 +/- 64 ksi) and 6.5, respectively. The HPZ/BN/SiC fibers showed an average strength of 2.0 +/- 0.32 GPa (290 +/- 47 ksi) and Weibull modulus of 7.3. Average strength of the fibers having a dual BN/Si3N4 surface coating degraded to 1.15 +/- 0.26 GPa (166 +/- 38 ksi) with a Weibull modulus of 5.3. The chemical composition and thickness of the fiber coatings were determined using scanning Auger analysis. Microstructural analysis of the fibers and the coatings was carried out by scanning electron microscopy and transmission electron microscopy. A microporous silica-rich layer approx. 200 nm thick is present on the as-received HPZ fiber surface. The BN coatings on the fibers are amorphous to partly turbostratic and contaminated with carbon and oxygen. Silicon carbide coating was crystalline whereas the silicon nitride coating was amorphous. The silicon carbide and silicon nitride coatings are non-stoichiometric, non-uniform, and granular. Within a fiber tow, the fibers on the outside had thicker and more granular coatings than those on the inside.

Bansal, Narottam P.↗
NASA NTRS1973

Passivation of pigment particles for thermal control coatings

Five powders were received for plasma calcining during this report period. The particle size using a fluid energy mill, and obtained pigments that could be plasma calcined. Optimum results are obtained in the plasma calcining of zinc orthotitanate when finely dispersed particles are subjected to a calculated plasma temperature of 1670 C. Increasing the plasma calcining time by using multiple passes through the plasma stabilized the pigment to vacuum UV irradiation was evidenced by the resulting ESR spectra but slightly decreased the whiteness of the pigment. The observed darkening is apparently associated with the formation of Ti(+3) color centers.

Farley, E. P.↗
NASA NTRS1989

Compatibility of molten salts with advanced solar dynamic receiver materials

Metal-coated graphite fibers are being considered as a thermal conductivity enhancement filler material for molten salts in solar dynamic thermal energy storage systems. The successful metal coating chosen for this application must exhibit acceptable wettability and must be compatible with the molten salt environment. Contact angle values between molten lithium fluoride and several metal, metal fluoride, and metal oxide substrates have been determined at 892 C using a modification of the Wilhelmy plate technique. Reproducible contact angles with repeated exposure to the molten LiF indicated compatibility.

Jaworske, D. A.↗
NASA NTRS2000

Raman Study of Uncoated and p-BN/SiC-Coated Hi-Nicalon Fiber-Reinforced Celsian Matrix Composites: Distribution and Nanostructure of Different Phases - Part 1

Hi-Nicalon fiber reinforced celsian matrix composites were characterized by Raman spectroscopy and imaging, using several laser wavelengths. Composite #1 is reinforced by as-received fibers while coatings of p-BN and SiC protect the fibers in composite #2. The matrix contains traces of the hexagonal phase of celsian, which is concentrated in the neighborhood of fibers in composite #1. Some free silicon was evident in the coating of composite #2 which might involve a {BN + SiC yields BNC + Si} "reaction" at the p-BN/SiC interface. Careful analysis of C-C peaks revealed no abnormal degradation of the fiber core in the composites.

Gouadec, Gwenael↗
NASA NTRSDate not supplied

The Completion of a Geosynchronous Earth Orbit Survey with the Eugene Stansbery-Meter Class Autonomous Telescope

The Eugene Stansbery-Meter Class Autonomous Telescope (ES-MCAT) is the primary optical sensor used by the NASA Orbital Debris Program Office (ODPO) to statistically characterize the geosynchronous Earth orbit (GEO) debris environment and support future Orbital Debris Engineering Model (ORDEM) releases. The ES-MCAT completed its first optical survey of the GEO region from 2020 to 2022. The primary goal of this survey was to autonomously collect and process GEO data with calculated photometric and astrometric uncertainties. A pointing plan was developed to provide uniform sampling within the region of interest (ROI) while accounting for predicted downtime due to insufficient observing conditions. Detections are autonomously correlated to the Space Surveillance Network (SSN) catalog to determine if objects are correlated targets (CTs) or uncorrelated targets (UCTs), the latter of which are of interest for modeling the GEO orbital debris environment. To assess the size detection sensitivity over time and monitor the general performance of the telescope’s optics and software, the optical throughput of the system and limiting magnitudes are evaluated on a routine basis. While the telescope’s ability to operate autonomously and remotely allowed for the GEO survey to continue throughout the COVID-19 pandemic, travel restrictions hampered routine cleaning of the optics during this time, and the primary mirror degraded enough to require recoating. The mirror was removed in 2022, concluding the first GEO survey. The primary mirror received a new coating designed to be more robust against the harsh environment surrounding the ES-MCAT’s location on Ascension Island, accounting for experience gained during operations over the first GEO survey. In early 2023, the recoated primary mirror was reinstalled, and the second GEO survey was initiated. The primary goal of the second GEO survey is to characterize the evolving GEO debris environment with updated optics, software, and pointing strategies while allowing for the inclusion of non-GEO regimes or those that are outside of the ROI. While the pointing method implemented in the first survey allowed for adequate coverage of the ROI over two years, it has been improved to include pointings that avoid the Moon’s position and the galactic plane to reduce software processing time and maximize the detection capabilities of fainter objects. This method also accounts for the changing weather patterns throughout the year and reduces coverage gaps in the ROI. Provided the success of the first two-year GEO survey using autonomous operations, the ODPO is actively collaborating with the United States Space Force (USSF) to make the ES-MCAT a contributing sensor to the SSN. This paper presents results from the first GEO survey including magnitude distributions and orbital parameters for CTs and UCTs. Details are provided for the automated processing pipeline and the optical system throughput for the previous and current primary mirror coatings. In addition, an updated strategy for the second GEO survey to optimize coverage over the ROI is discussed, as are preliminary results from the ongoing second survey.

Corbin Cruz↗
NASA NTRSDate not supplied

The Completion of a Geosynchronous Earth Orbit Survey with the Eugene Stansbery-Meter Class Autonomous Telescope

The Eugene Stansbery-Meter Class Autonomous Telescope (ES-MCAT) is the primary optical sensor used by the NASA Orbital Debris Program Office (ODPO) to statistically characterize the geosynchronous Earth orbit (GEO) debris environment and support future Orbital Debris Engineering Model (ORDEM) releases. The ES-MCAT completed its first optical survey of the GEO region from 2020 to 2022. The primary goal of this survey was to autonomously collect and process GEO data with calculated photometric and astrometric uncertainties. A pointing plan was developed to provide uniform sampling within the region of interest (ROI) while accounting for predicted downtime due to insufficient observing conditions. Detections are autonomously correlated to the Space Surveillance Network (SSN) catalog to determine if objects are correlated targets (CTs) or uncorrelated targets (UCTs), the latter of which are of interest for modeling the GEO orbital debris environment. To assess the size detection sensitivity over time and monitor the general performance of the telescope’s optics and software, the optical throughput of the system and limiting magnitudes are evaluated on a routine basis. While the telescope’s ability to operate autonomously and remotely allowed for the GEO survey to continue throughout the COVID-19 pandemic, travel restrictions hampered routine cleaning of the optics during this time, and the primary mirror degraded enough to require recoating. The mirror was removed in 2022, concluding the first GEO survey. The primary mirror received a new coating designed to be more robust against the harsh environment surrounding the ES-MCAT’s location on Ascension Island, accounting for experience gained during operations over the first GEO survey. In early 2023, the recoated primary mirror was reinstalled, and the second GEO survey was initiated. The primary goal of the second GEO survey is to characterize the evolving GEO debris environment with updated optics, software, and pointing strategies while allowing for the inclusion of non-GEO regimes or those that are outside of the ROI. While the pointing method implemented in the first survey allowed for adequate coverage of the ROI over two years, it has been improved to include pointings that avoid the Moon’s position and the galactic plane to reduce software processing time and maximize the detection capabilities of fainter objects. This method also accounts for the changing weather patterns throughout the year and reduces coverage gaps in the ROI. Provided the success of the first two-year GEO survey using autonomous operations, the ODPO is actively collaborating with the United States Space Force (USSF) to make the ES-MCAT a contributing sensor to the SSN. This paper presents results from the first GEO survey including magnitude distributions and orbital parameters for CTs and UCTs. Details are provided for the automated processing pipeline and the optical system throughput for the previous and current primary mirror coatings. In addition, an updated strategy for the second GEO survey to optimize coverage over the ROI is discussed, as are preliminary results from the ongoing second survey.

Corbin Cruz↗