Development and testing of high temperature coatings for the Integrated Solar Upper Stage thermal energy storage system

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Fullerenes And Related Materials, Chemical Vapor Deposition, Other Heat And Thermomechanical Treatments, Thermal Stability, Thermal Effects, Other Nonelectronic Physical Properties

Scientific paper

Key components within the Integrated Solar Upper Stage (ISUS) bimodal system must be able to operate at temperatures as high as 2500 K within both hard vacuum and hot hydrogen environments. Graphite has been selected as the primary thermal energy storage device for ISUS system level and engine ground demonstration testing. The selection of graphite dictated the need for development and testing of high temperature coatings to identify a candidate that can maintain structural integrity at elevated temperatures, be compatible with graphite, and mitigate carbon loss from the graphite. This paper presents the methodology and test results that led to selection of rhenium as the coating material. Vacuum and hydrogen flow tests conducted between 2000 K and 2600 K on rhenium coated graphite coupons indicate mass loss reductions as much as one order of magnitude lower than unprotected graphite under similar temperatures, pressures, hydrogen flowrates, and exposure durations. The durability of rhenium coatings up to 0.381 mm thick was also demonstrated.

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