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Glass, sapphire and polymer fibers transparent to visible and infrared electromagnetic frequencies are extensively used in communication and sensing. The lifetimes of these waveguides are extended considerably by suitably coating them. Plastic coated silica waveguides are gradually replacing metal coaxial cables used in communications and they have been used successfully in various types of sensing. Unfortunately plastic coatings cannot withstand very high temperatures. In order to perform contact or invasive sensing in the medium to high temperature range and in harsh environments, other appropriate coating materials have to be used. This thesis examines various refractory materials as candidate coating materials. Coating materials should not react chemically with the waveguide material but should have matching thermal expansion coefficients. Refractory materials are examined in detail for thermodynamic suitability for both sapphire and silica waveguide cores and claddings. The candidate coating materials selected are alumina, silicon carbide, zirconia and metal niobium. Experimental verification of the chemical inertness of these materials with silica and sapphire in very low pressure and at 857°C temperature is studied. The materials found suitable for coating can be coated using the various methods discussed. Fibers suitably coated with these materials would be suitable for high temperature sensing in harsh environments and in situ within advanced high temperature composites. Metal niobium does not react with sodium and is thermodynamically compatible with alumina which is also a very stable refractory material. Multilayer coatings of niobium and alumina on sapphire exposed to harsh environmental conditions can prolong the life of the sapphire waveguide. X-ray diffraction and electron microprobe analyses of the single oxides and carbides, namely, alumina, silicon carbide and zirconia and the metal niobium, were conducted. It was found that sapphire did not react with any of the selected ceramics; the silica fiber underwent structural change in the silicon carbide matrix and the change was macroscopic. Within the restricted environment, the silica fiber appeared not to react with the alumina, zirconia and niobium matrices. This thesis specifically considers the possibility of using the various ceramics as coating materials without analyzing the nature of the phases present. Hence detailed analyses of phases were not made when macroscopic change in fiber structure was observed or as observed during the x-ray analyses and microprobe analyses. / Master of Science

The study addresses the coating selection for a proposed placement of a hydroturbine into the Gulf Stream. The turbine will generate energy in a similar manner to a wind turbine. The effects of biofouling and corrosion in the current project are assessed. A review of different types of traditional paint coatings is given, as well as the option for a copper-nickel alloy. Testing that should be undertaken for the coating selection is described in detail. Coating considerations are offered and discussed. Design considerations and modifications are also offered. / by Andrew Spicer Bak. / Vita. / Thesis (M.S.C.S.)--Florida Atlantic University, 2009. / Includes bibliography. / Electronic reproduction. Boca Raton, Fla., 2009. Mode of access: World Wide Web.

Thesis (MTech (Mechanical Engineering))--Cape Peninsula University of Technology. / For the last few decades, methods to improve the engine efficiency and reduce the fuel consumption of jet engines have received increased attention. One of the solutions is to increase the operating temperature in order to increase the exhaust gas temperature, resulting in an increased engine power. However, this approach can be degrading for some engine parts such as turbine blades, which are required to operate in a very hostile environment (at ≈ 90% of their melting point temperature). Thus, an additional treatment must be carried out to protect these parts from corrosion, oxidation and erosion, as well as to maintain the substrate’s mechanical properties which can be modified by the high temperatures to which these parts are exposed. Coating, as the most known protection method, has been used for the last few decades to protect aircraft engine parts. According to Wolfe and Co-workers [1], 75% of all engine components are now coated. The most promising studies show that the thermal barrier coating (TBC) is the best adapted coating system for these high temperature applications. TBC is defined as a fine layer of material (generally ceramic or metallic material or both) directly deposited on the surface of the part In order to create a separation between the substrate and the environment to reduce the effect of the temperature aggression. However, the application of TBCs on surfaces of components presents a challenge in terms of the consistency of the thickness of the layer. This is due to the nature of the processes used to apply these coatings. It has been found that variations in the coating thickness can affect the thermodynamic performance of turbine blades as well as lead to premature damage due to higher thermal gradients in certain sections of the blade. Thus, it is necessary to optimise the thickness distribution of the coating.

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The tribological properties of cold sprayed Ni-WC metal matrix composite (MMC) coatings were investigated under dry sliding conditions from room temperature (RT) up to 400°C, and during thermal cycling to explore their temperature adaptive friction and wear behavior. Characterization of worn surfaces was conducted using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and Raman spectroscopy to determine the chemical and microstructural evolution during friction testing. Data provided insights into tribo-oxide formation mechanisms controlling friction and wear. It was determined that the steady-state coefficient of friction (CoF) decreased from 0.41 at RT to 0.32 at 400˚C, while the wear rate increased from 0.5×10-4 mm3/N·m at RT to 3.7×10-4 mm3/N·m at 400˚C. The friction reduction is attributed primarily to the tribochemical formation of lubricious NiO on both the wear track and transfer film adhered to the counterface. The increase in wear is attributed to a combination of thermal softening of the coating and a change in the wear mechanism from adhesive to more abrasive. In addition, the coating exhibited low friction behavior during thermal cycling by restoring the lubricious NiO phase inside the wear track at high temperature intervals. Therefore, cold sprayed Ni-WC coatings are potential candidates for elevated temperature and thermally self-adaptive sliding wear applications.

Indiana University-Purdue University Indianapolis (IUPUI) / Zirconia (ZrO2) is an important ceramic material with a broad range of applications. Due to its high melting temperature, low thermal conductivity, and high-temperature stability, zirconia based ceramics have been widely used for thermal barrier coatings (TBCs). When TBC is exposed to thermal cycling during real applications, the TBC may fail due to several mechanisms: (1) phase transformation into yttrium-rich and yttrium-depleted regions, When the yttrium-rich region produces pure zirconia domains that transform between monoclinic and tetragonal phases upon thermal cycling; and (2) cracking of the coating due to stress induced by erosion. The mechanism of erosion involves gross plastic damage within the TBC, often leading to ceramic loss and/or cracks down to the bond coat. The damage mechanisms are related to service parameters, including TBC material properties, temperature, velocity, particle size, and impact angle. The goal of this thesis is to understand the structural and mechanical properties of the thermal barrier coating material, thus increasing the service lifetime of gas turbine engines. To this end, it is critical to study the fundamental properties and potential failure mechanisms of zirconia. This thesis is focused on investigating the structural and mechanical properties of zirconia. There are mainly two parts studied in this paper, (1) ab initio calculations of thermodynamic properties of both monoclinic and tetragonal phase zirconia, and monoclinic-to-tetragonal phase transformation, and (2) image-based finite element simulation of the indentation process of yttria-stabilized zirconia. In the first part of this study, the structural properties, including lattice parameter, band structure, density of state, as well as elastic constants for both monoclinic and tetragonal zirconia have been computed. The pressure-dependent phase transition between tetragonal (t-ZrO2) and cubic zirconia (c-ZrO2) has been calculated using the density function theory (DFT) method. Phase transformation is defined by the band structure and tetragonal distortion changes. The results predict a transition from a monoclinic structure to a fluorite-type cubic structure at the pressure of 37 GPa. Thermodynamic property calculations of monoclinic zirconia (m-ZrO2) were also carried out. Temperature-dependent heat capacity, entropy, free energy, Debye temperature of monoclinic zirconia, from 0 to 1000 K, were computed, and they compared well with those reported in the literature. Moreover, the atomistic simulations correctly predicted the phase transitions of m-ZrO2 under compressive pressures ranging from 0 to 70 GPa. The phase transition pressures of monoclinic to orthorhombic I (3 GPa), orthorhombic I to orthorhombic II (8 GPa), orthorhombic II to tetragonal (37 GPa), and stable tetragonal phases (37-60 GPa) are in excellent agreement with experimental data. In the second part of this study, the mechanical response of yttria-stabilized zirconia under Rockwell superficial indentation was studied. The microstructure image based finite element method was used to validate the model using a composite cermet material. Then, the finite element model of Rockwell indentation of yttria-stabilized zirconia was developed, and the result was compared with experimental hardness data.