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AeroMat 2004 June 10, 2004 Ralph Tapphorn and Don Ulmer David Grimmett, Boeing-Rocketdyne Linus Thomas-Ogbuji, NASA-GRC AeroMat 2004 June 10, 2004 Ralph.

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Presentation on theme: "AeroMat 2004 June 10, 2004 Ralph Tapphorn and Don Ulmer David Grimmett, Boeing-Rocketdyne Linus Thomas-Ogbuji, NASA-GRC AeroMat 2004 June 10, 2004 Ralph."— Presentation transcript:

1 AeroMat 2004 June 10, 2004 Ralph Tapphorn and Don Ulmer David Grimmett, Boeing-Rocketdyne Linus Thomas-Ogbuji, NASA-GRC AeroMat 2004 June 10, 2004 Ralph Tapphorn and Don Ulmer David Grimmett, Boeing-Rocketdyne Linus Thomas-Ogbuji, NASA-GRC Kinetic Metallization Application of Oxidation/Corrosion Resistant Coatings to Rocket Engine Combustion Chamber Liners Application of Oxidation/Corrosion Resistant Coatings to Rocket Engine Combustion Chamber Liners

2 Introduction to Kinetic Metallization Application Oxidation/Blanching Resistant Coatings for Combustion Chamber Liners Coating Properties Tensile Properties Thermal Conductivity Oxidation Test Results TGA Cyclic Oxidation Summary/Future Work Introduction to Kinetic Metallization Application Oxidation/Blanching Resistant Coatings for Combustion Chamber Liners Coating Properties Tensile Properties Thermal Conductivity Oxidation Test Results TGA Cyclic Oxidation Summary/Future Work Overview

3 Impact Consolidation Process Feed-stock: fine powder Accelerant: inert light gas Solid-state Consolidation No Bulk Melting No Liquid Chemicals Environmentally Innocuous No Particle or Hazardous Gas Emission Impact Consolidation Process Feed-stock: fine powder Accelerant: inert light gas Solid-state Consolidation No Bulk Melting No Liquid Chemicals Environmentally Innocuous No Particle or Hazardous Gas Emission Kinetic Metallization

4 Powder fluidized using pressurized He gas (PFU) Powder/gas mix thermally conditioned to improve deposition efficiency (TCU) Deposition nozzle produces highly collimated spray pattern Area coverage using X-Y rastering of nozzle and/or rotation of substrate Powder fluidized using pressurized He gas (PFU) Powder/gas mix thermally conditioned to improve deposition efficiency (TCU) Deposition nozzle produces highly collimated spray pattern Area coverage using X-Y rastering of nozzle and/or rotation of substrate Process Flow He PFU TCU Deposition Nozzle Deposition Nozzle Substrate

5 Coating Development System Desk sized Production unit Same footprint Remove spray enclosure Coating Development System Desk sized Production unit Same footprint Remove spray enclosure KM–CDS First KM-CDS Shipped!! Buyer: US Naval Academy Located: NAVSEA-Carderock First KM-CDS Shipped!! Buyer: US Naval Academy Located: NAVSEA-Carderock

6 MCC liner life in LOX/H 2 engine limited by thermal ratcheting failure initiated by cyclic oxidation/ reduction (“blanching”) of copper alloy liner Desire high conductivity coating that forms adherent, self healing oxide that is stable in H 2 Candidate coatings include Cu- xCr, where x = 20 to 30 vol.% Study initiated to select optimum composition of Cu-XCr based on mechanical properties and oxidation resistance MCC liner life in LOX/H 2 engine limited by thermal ratcheting failure initiated by cyclic oxidation/ reduction (“blanching”) of copper alloy liner Desire high conductivity coating that forms adherent, self healing oxide that is stable in H 2 Candidate coatings include Cu- xCr, where x = 20 to 30 vol.% Study initiated to select optimum composition of Cu-XCr based on mechanical properties and oxidation resistance Application SSME Main Combustion Chamber (MCC) SSME Main Combustion Chamber (MCC)

7 Advantages KM vs. Thermal Spray Eliminates: Porosity Oxygen pickup Interlayer bond coats Vacuum chamber KM vs. Thermal Spray Eliminates: Porosity Oxygen pickup Interlayer bond coats Vacuum chamber

8 Coating Properties Thermal Expansion Specimens Thermal Expansion Specimens Tensile Specimens Tensile Specimens Thermal Conductivity Specimens Thermal Conductivity Specimens Copper Substrate Copper Substrate KM Cu-Cr Deposit KM Cu-Cr Deposit Bulk Cu-Cr specimens machined from 10-mm thick KM deposits Tensile Thermal Conductivity Three Cu-Cr compositions evaluated: Cu-20vol.%Cr Cu-25vol.%Cr Cu-30vol.%Cr Bulk Cu-Cr specimens machined from 10-mm thick KM deposits Tensile Thermal Conductivity Three Cu-Cr compositions evaluated: Cu-20vol.%Cr Cu-25vol.%Cr Cu-30vol.%Cr

9 Tensile Properties KM Cu-Cr tensile properties equivalent to wrought Strength increases (ductility decreases) with increasing Cr content KM Cu-Cr tensile properties equivalent to wrought Strength increases (ductility decreases) with increasing Cr content Wrought KM

10 Fractography Ductile, microvoid coalescence observed at room temperature

11 Thermal Conductivity KM Cu-Cr thermal conductivity equivalent to wrought Conductivity decreases with increasing Cr content KM Cu-Cr thermal conductivity equivalent to wrought Conductivity decreases with increasing Cr content

12 Oxidation Behavior Evaluation of KM Cu-Cr coated GRCop-84 TGA coupons included: Coating Adhesion Static Oxidation Cyclic Oxidation Three Cu-Cr compositions evaluated: Cu-20vol.%Cr Cu-25vol.%Cr Cu-30vol.%Cr Evaluation of KM Cu-Cr coated GRCop-84 TGA coupons included: Coating Adhesion Static Oxidation Cyclic Oxidation Three Cu-Cr compositions evaluated: Cu-20vol.%Cr Cu-25vol.%Cr Cu-30vol.%Cr KM Cu-Cr Coated GRCop- 84 TGA Coupons KM Cu-25vol.%Cr GRCop-84

13 Coating Adhesion Coating adhesion improved by post-deposition heat treatment Note: Arrows indicate failure in epoxy

14 Static Oxidation Formation of continuous Cr 2 O 3 layer underneath external CuO slows oxidation rate Oxidation rate decreases with increasing Cr content Formation of continuous Cr 2 O 3 layer underneath external CuO slows oxidation rate Oxidation rate decreases with increasing Cr content Cu-Cr coating CuO Cr 2 O 3 20Cr 25Cr

15 Cyclic Oxidation Cyclic Temperature 77 ºK to 1023 ºK Best oxidation resistance Cu-Cr Coating with 25vol% Cr Spalling observed Cyclic Temperature 77 ºK to 1023 ºK Best oxidation resistance Cu-Cr Coating with 25vol% Cr Spalling observed 25.0 Cr 20.0 Cr Cu-25vol.%Cr Cu-20vol.%Cr 650ºC 750ºC

16 Summary Kinetic Metallization achieves high density, adherent Cu-Cr coatings Eliminates need for interlayer bond coat Eliminates oxygen pickup during spray process Best balance of oxidation protection and mechanical properties offered by Cu- 25vol.%Cr Kinetic Metallization achieves high density, adherent Cu-Cr coatings Eliminates need for interlayer bond coat Eliminates oxygen pickup during spray process Best balance of oxidation protection and mechanical properties offered by Cu- 25vol.%Cr

17 Future Work NASA initiated new program to evaluate KM NiCrAlY coatings for next-generation LOX/kerosene engines Preliminary work has shown that low porosity, well- adherent KM NiCrAlY coatings can be applied to GRCop-84 No grit blasting surface preparation required No interlayer bond coat required NASA initiated new program to evaluate KM NiCrAlY coatings for next-generation LOX/kerosene engines Preliminary work has shown that low porosity, well- adherent KM NiCrAlY coatings can be applied to GRCop-84 No grit blasting surface preparation required No interlayer bond coat required KM NiCrAlY


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