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Completed TRL 3 (started at 2, targeting 3)
Aerosol deposition (AD) is a novel process which allows for the low-cost formation of fully dense, nanocrystalline, ceramic coatings at room temperature. Ceramics are traditionally processed in excess of 1000⁰C prohibiting production of ceramic films on low melting point substrates. By utilizing the AD process, ceramic films may be coated atop polymeric substrates. Aerosol deposited ceramic coatings provide the unique opportunity to form highly protective coatings, especially on ubiquitous polymeric and composite substrates for space applications. In the harsh environment of low earth orbit (LEO) atomic oxygen plays a major role in the degradation of polymeric materials such as polyimide (PI) Kapton® and polyethylene terephthalate (PET) Mylar®. Atomic oxygen attack causes concern to the longevity of these polymers when used as low thickness reflective blankets. Using AD technology, more reliable coatings of SiO2, and SiO2-polytertrafluoroethylene (PTFE) composite coatings may be achieved. The produced nanocrystalline ceramic coatings proposed here would be part of the TA 10.1.3.1 Technological Area Breakdown Structure (TABS) as a nanomaterial barrier coating to prevent degradation and improve longevity of polymeric materials under LEO conditions. This research will serve to find the most efficient parameters in order to use AD to form these coatings and characterize the coatings surface and protective abilities. A key part of the process will be to characterize the powders to be sprayed in the AD chamber. Characterization of the powders morphology and size distribution will be achieved using Frauenhoffer diffraction particle sizing, a scanning electron microscope (SEM), and an X-ray diffractometer (XRD). These powders will be used as spray deposition parameters are varied in a systematic, iterative fashion until optimal deposition is achieved. This process will be aided by my own experience in the field of ceramic AD coatings. The custom-built vacuum AD apparatus at New Mexico Tech (NMT) will be utilized for fabrication of films. A scanning white light, interferometric, optical profilometer will be used to determine film thickness, roughness and defect (pinhole) density. Atomic force microscopy (AFM) will be used to do the same at a smaller surface spatial wavelength. The Visiting Technologists Experience will be an exceptional opportunity not only for my own goals but for furthering the experiment through the possibility of techniques not available at NMT. These include vacuum deposition of a reflective aluminum layer, scratch testing in order to test the adhesion of the AD coatings, and atomic oxygen erosion testing (possibly at the Glenn Research Center). I hope to demonstrate that the coating can extend the life of reflective blankets used in LEO by providing protection against atomic oxygen degradation, in accordance with the 10.1.3 TABS element. However, the benefits of AD ceramic and ceramic composite coatings in space may extend further. This research may also prove applicable to the outer PTFE layer of woven beta cloth for added protection against micrometeoroids. The research may open the way for AD in other NASA application areas including protective coatings of light weight inflatable habitats, space suits, thermal barrier coatings, radiation barrier coatings and in-space repair of thermal barrier re-entry tiles. This technology has the possibility to aid not only in improvements to the longevity of low earth orbiting systems, but as a new technique to be utilized for protection and repair of systems in all space environments, thus accelerating human progress to the moon, Mars, and beyond.
The coating may be able to extend the life of reflective blankets used in LEO by providing protection against atomic oxygen degradation, in accordance with the 10.1.3 TABS element. However, the benefits of AD ceramic and ceramic composite coatings in space may extend further. This research may also prove applicable to the outer PTFE layer of woven beta cloth for added protection against micrometeoroids. The research may open the way for AD in other NASA application areas including protective coatings of light weight inflatable habitats, space suits, thermal barrier coatings, radiation barrier coatings and in-space repair of thermal barrier re-entry tiles. This technology has the possibility to aid not only in improvements to the longevity of low earth orbiting systems, but as a new technique to be utilized for protection and repair of systems in all space environments, thus accelerating human progress to the moon, Mars, and beyond.
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