Hung D. Nguyen, Gynelle C. Steele, and Jessica R. Morris

Glenn Research Center, Cleveland, Ohio

An Overview of 2014 SBIR Phase I and Phase II

Materials Structures for Extreme Environments

NASA/TM—2015-218917

November 2015
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Hung D. Nguyen, Gynelle C. Steele, and Jessica R. Morris

Glenn Research Center, Cleveland, Ohio

An Overview of 2014 SBIR Phase I and Phase II

Materials Structures for Extreme Environments

NASA/TM—2015-218917

November 2015

National Aeronautics and

Space Administration

Glenn Research Center

Cleveland, Ohio 44135
Available from

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NASA/TM—2015-218917 iii

Contents

Abstract ......................................................................................................................................................................1

Robust High Temperature Environmental Barrier Coating System.....................................................................3

A Simple, Robust, Lightweight Microscopy and Sample Processing System for Scientific and 

Commercial Research on the International Space Station.............................................................................4

Self-lubricating Hard Coatings for Extreme Environments.................................................................................5

Development of Hermetic Sealing Glasses for Solid Oxide Fuel Cells...............................................................6

Simulating Nonlinear Dynamics of Deployable Space Structures ......................................................................7

Improved Attachment Design for Ceramic Turbine Blades via Hybrid Concepts ..............................................8

Lightweight, Advanced Sorbent-based Device to Collect and Pressurize CO2 from Martian Atmospheres.......9

Microfluidic System for CO2 Reduction to Hydrocarbons in Microgravity......................................................10

Cavitation Peening of Aerospace Bearings........................................................................................................11

NASA/TM—2015-218917 1 

An Overview of 2014 SBIR Phase I and Phase II

Materials Structures for Extreme Environments 

Hung D. Nguyen, Gynelle C. Steele, and Jessica R. Morris1

National Aeronautics and Space Administration 

Glenn Research Center 

Cleveland, Ohio 44135 

Abstract 

NASA’s Small Business Innovation Research (SBIR) program focuses on technological innovation by 

investing in development of innovative concepts and technologies to help NASA mission directorates address 

critical research needs for Agency programs.

This report highlights nine of the innovative SBIR 2014 Phase I and Phase II projects that emphasize one of 

NASA Glenn Research Center’s six core competencies—Materials and Structures for Extreme Environments. The 

technologies cover a wide spectrum of applications such as high temperature environmental barrier coating 

systems, deployable space structures, solid oxide fuel cells, and self-lubricating hard coatings for extreme 

temperatures. Each featured technology describes an innovation, technical objective, and highlights NASA 

commercial and industrial applications. 

This report provides an opportunity for NASA engineers, researchers, and program managers to learn how 

NASA SBIR technologies could help their programs and projects, and lead to collaborations and partnerships 

between the small SBIR companies and NASA that would benefit both. 

 

1 Lewis’ Educational and Research Collaborative Internship Project (LERCIP). 

NASA/TM—2015-218917 3

Robust High Temperature 

Environmental Barrier Coating 

System

For ceramic matrix composite gas turbine components using 

affordable processing approach

This Phase I project demonstrates the use of advanced manufacturing techniques 

to enable the affordable application of multifunctional thermal/environmental 

barrier coatings (TBCs/EBCs) having enhanced resistance to high temperature 

combustion environments. Thermal/environmental barrier coatings 

(TBCs/EBCs) have potential for enhanced resistance to high temperature 

combustion environments. Current TBC/EBC systems are stable up to 2400 °F, 

but become unstable at 2700 °F. To improve the performance at these high 

temperatures, multi-layered T/EBC designs are proposed. To improve 

capability, a multiple layered T/EBC system will be employed using a physical 

vapor deposition based processing approach. This deposition approach enables 

improved coating adhesion and advanced coating, architectural, compositional, 

and microstructural control, as well as non-line-of-sight (NLOS) deposition. 

TheTBC/EBC bond coats will then be deposited onto gas turbine engine 

components for full high temperature capable systems. This work aids in 

incorporating Si-based ceramic components in gas turbine engines, thus 

reducing weight and increasing operating temperatures of the engines. 

Applications 

NASA

► Coating for components of future 

aircraft engines that operate at 

high temperature, including:

o Turbine blades

o Combustion liners

o Exhaust components

o Gas turbine engines

► Increased turbine engine 

performance for the ARMD 

Subsonic Fixed Wing Project 

Commercial

► Reduced costs for coating onto 

commercial engine components

► Other functional coating systems such 

as:

o Thermal barrier coatings

o Wear- and corrosion-resistant 

coatings

o Thin film batteries

o Damping coatings

Phase I Objectives

► Demonstrate feasibility of using 

advanced plasma activation 

techniques

► Demonstrate scaled up 

processing approach

► Perform metallographic analysis, 

thermal cycle testing. 

Benefits

► Reduced fuel consumption 

► Increased operating 

temperatures

► Improved turbine efficiency 

► Robust bond coat protects 

component surface from ceramic 

recession 

► Coats interior portions of 

components

Firm Contact

Balvinder Gogia

Direct Vapor Technologies International, Inc.

2 Boars Head Lane

Charlottesville, VA, 22903-4605

PHONE: (434) 977-1405

Proposal number: A3.07-8783
NASA/TM—2015-218917 4

A Simple, Robust, Lightweight 

Microscopy and Sample 

Processing System for Scientific 

and Commercial Research on the 

International Space Station

A light-weight, user-friendly, algorithmically- or remotelycontrolled microscope for easy-access light microscopy 

The need for high-quality microscopy in space is expected to intensify in 

colloid physics, particle suspensions, biomolecule crystal growth, and basic 

life sciences. An algorithmically- or remotely-controlled digital microscope 

coupled to high-throughput fluid sample processing and sample changing 

systems is proposed as a solution. The Techshot microscope is an easyaccess light microscope consisting of a novel illuminator-condenser with no 

moving parts, fluid sample processing capabilities, a remotely controlled 

translating stage using hollow slides, a high-definition color video camera, 

and available multi-parameter image processing analysis. Its simplicity is 

expected to further increase interest in light microscopy experiments aboard 

the ISS.

Applications 

NASA

► Use within the International 

Space Station—National 

Laboratory by NASA 

investigators

Commercial

► Can be incorporated into other 

spaceflight service programs for 

government agencies

► Industrial research on the dynamics 

of colloids and particle suspensions 

found in food, cosmetic, paint, 

pharmaceutical, and composite 

industries 

Phase I Objectives

► Defining requirements

► Building a prototype dynamic 

microscopy system

► Testing in a laboratory setting by real 

users under conditions worthy of a final 

TRL-5 designation

Benefits

► High-throughput, lightweight 

microscopy system 

► Novel-illuminator-condenser with no 

moving parts

► Fluid sample processing capabilities

► Remotely controlled translating stage 

using hollow slides

► High-definition color video camera

► Multiparameter image processing and 

analysis

► Expected to increase the level of 

interest in light microscopy experiments 

aboard the ISS

Firm Contact

Rich Boling

Techshot, Inc.

7200 Highway 150

Greenville, IN, 47124-9515

PHONE: (812) 728-8136

FAX: (812) 923-9598

Proposal number: H10.02-8875
NASA/TM—2015-218917 5

Self-lubricating Hard Coatings for 

Extreme Environments

Low-friction hard coatings for lubricating mechanical and 

tribological components 

This program will develop low friction hard coatings for lubricating 

mechanical and tribological components used for exploring Mars, the 

Moon, asteroids, comets, and other small bodies. This SBIR program will 

build on MesoCoat’s extensive prior experience in developing dense, hard 

friction-free coatings. 

Applications 

NASA

► Rovers

► Motor and pump shaft and 

seals

► Deployable structures

► Latching mechanisms 

Commercial

► Commercial aircraft engines

► Diesel and turbine engines

► Run-dry industrial linkage 

component applications 

► Metal cutting and forming tools 

and dies

► Mining and excavation equipment 

► Automotive components

► Agricultural equipment

Phase I Objectives

► Verify that self-lubricating hardfacings 

can meet life and lubrication 

requirements of space exploration 

mechanisms

► Prepare nanocomposite self-lubricating 

cermet agglomerated powders 

► Add additional encapsulants and 

additives to produce desired mesostructures in coatings

► Apply to substrates using HVOF 

thermal spray

► Evaluate run-dry friction and wear 

properties

► Analyze results in terms of composition, 

micro- and meso-structure, and coating 

method to guide future down-selection 

Benefits

► Provides wear resistance and 

lubrication in high temperatures and 

severe environments 

► Nano-structured and meso-structured 

coatings that are compatible with steel, 

aluminum, and titanium 

► Low-friction hard coatings for lubricating 

mechanical and tribological

components for exploring lunar and 

Mars surfaces 

Firm Contact

Evelina Vogli

MesoCoat

24112 Rockwell Drive

Euclid, OH, 44117-1329

PHONE: (216) 453-0866

FAX: (216) 481-0781

Proposal number: S4.04-8603
NASA/TM—2015-218917 6

Development of Hermetic Sealing 

Glasses for Solid Oxide Fuel Cells 

Producing seals with the goal of zero or minimal leak rates

Sealing glasses, either rigid glass-ceramics or viscous, non---crystallizing 

compositions, will be developed and sealing processes will be optimized 

based on NASA’s solid oxide fuel cell (SOFC) designs. SOFC design 

constraints will guide compositional development, and these new 

compositions will then be used for long-term (500 hours) material 

compatibility tests under SOFC operational conditions. Prototype seals will 

then be produced and thermally cycled between room temperature and 

850°C to test thermo-mechanical compatibility of the sealing material with 

SOFC components. 

Applications 

NASA

► Reliable, thermally stable, 

hermetic sealing materials for 

SOFCs and SOEs

► High-efficiency power systems

Commercial

► Aid nation’s SOFCs program meet 

its cost and performance targets 

► Achieve reliable SOFC operation for 

extended operating life 

► Enable fuel cell-based near-zero 

emission coal plants that reduce 

water requirements and capability of 

capturing 97% of carbon 

Phase I Objectives

► Identify specific SOFC materials for 

sealing and determine specific 

operational conditions

► Test glass-ceramic seal and/or viscous 

glass seal with NASA specified 

materials and conditions

► Refine the glass compositions and 

processing parameters with the 

requisite thermal and physical 

properties

► Evaluate long-term thermal and 

chemical stability

► Conduct hermetic and thermal cycle 

tests

Benefits

► Capable of thermal cycling under SOFC 

operational conditions (e.g., 

methane/oxygen)

► Thermally and chemically stable, thus 

further developing SOFCs as highefficiency power system

Firm Contact

Cheol-Woon Kim

MO-SCI Corporation

4040 Hy Point North

Rolla, MO, 65401-8277

PHONE: (573) 364-2338

FAX: (573) 364-9589

Proposal number: H8.01-9586

G81

GlassCeramic

YSZ G81

Glass-Ceramic

Excellent wetting and bonding to YSZ 
NASA/TM—2015-218917 7

Simulating Nonlinear Dynamics of 

Deployable Space Structures 

Improved simulation of 3D nonlinear dynamics of future 

large solar array structure systems

This project strengthens validated modeling analysis and simulation 

techniques by developing a vertical application to simulate the nonlinear 

dynamics of the various stages of deployable space structures. Modeling 

complex, flexible-body, nonlinear structures can be time consuming and 

prone to error. Existing nonlinear structural analysis simulation software 

does not effectively simulate structural assemblies with significant motion. 

This project will address the simulation problems by creating a custom 

vertical application for deployable space structures. The software will 

include a dynamic simulation of the rollup, deployment, and maneuvering 

operation of large solar array structures. Additionally, an active, nonlinear 

controller will be developed that will reduce roll-out solar array (ROSA) 

deflection during spacecraft maneuvers.

Applications 

NASA

► Simulation of nonlinear 

dynamics of ROSA structures

► Software applications for 

deployable space structure 

market

► Solar array configurations

► Deployable antennas 

Commercial

► Software application for agencies 

that work with deployable space 

structures

► Deployable flaps and slats on 

aircraft

Phase II Objectives

► Add capabilities to software developed 

in Phase I

► Improve integration of functions, 

including new support of the simulation 

of lanyards and tape strings

► Simulation of additional deployable 

space structures including antennas

Benefits

► Advanced simulation capabilities that 

are more efficient and require less 

specialized knowledge 

► Reduced deflection of a ROSA during 

spacecraft maneuvers

Firm Contact

Brant Ross

MotionPort LLC

473 South River Road, Suite 1-182

Saint George, UT, 84790-2150

PHONE: (435) 703-9195

Proposal number: H5.02-9104
NASA/TM—2015-218917 8

Improved Attachment Design for 

Ceramic Turbine Blades via Hybrid 

Concepts 

A design that exploits the thermal expansion mismatch 

between CMCs and metals to solve the attachment issue 

This project proposes a hybrid metal-CMC turbine blade. A SiC/SiCCMC 

airfoil section will be bonded to a single crystal superalloy root section to 

mitigate risks associated with an all-CMC blade inserted in a superalloy 

disk. The bond between the CMC and single crystal will be primarily 

mechanical, and enhanced with clamping arising from thermal expansion 

mismatch. Two single crystal root sections will be bonded to each other 

using diffusion bonding and/or transient liquid phase bonding at 

temperatures near 2200°F.The single crystals will form a clam shell around 

the CMC. Upon cooling, the metal will shrink around the CMC spar to 

firmly clamp it. Single crystals will resist stress relaxation at an operating 

temperature of 1500°F, thus maintaining clamping loads for long lives. 

Applications 

NASA

► Reliable insertion for ceramic 

matrix composite blades into 

high temperature nickel alloy 

disks 

► Enabling technology for 

meeting future goals of 

achieving SFC gains 

► Turbo engine designs with CMC 

materials resulting in higher 

operating temperatures

Commercial

► Aircraft engines

► Pratt and Whitney 

► Rolls Royce would benefit from a

hybrid blade attachment design

Phase II Objectives

► Demonstrate the manufacturability of 

the single crystal clam shell clamped to 

a CMC spar 

► Demonstrate the single-crystal clam 

shell’s ability to maintain an interference 

fit on the CMC spar during operational 

conditions 

► Determine if a compliant layer is 

required between the CMC spar and 

the single crystal clam shell 

Benefits

► Higher operating temperatures

► Reductions in required cooling

► Reductions in vehicle weight

► Increased durability and/or decreased 

weight of PM disks 

Firm Contact

John Gayda

johngaydajr@yahoo.com

6659 Pearl Road #201

Parma Heights, OH 44130-3821

(440) 845-7020

Proposal number: A3.07-9772
NASA/TM—2015-218917 9

Lightweight, Advanced Sorbentbased Device to Collect and 

Pressurize CO2 from Martian 

Atmospheres 

Development of a high-capacity, high-purity, regenerable 

CO2 adsorbent 

Human exploration of Mars and unmanned sample return missions can 

benefit from use of propellants and life-support consumables produced from 

resources available on Mars. The first step of any in-situ propellant 

production is the acquisition of carbon dioxide from Mars’s atmosphere and 

its compression for further chemical processing. 

TDA Research Inc. has developed a compact, lightweight, advanced 

sorbent-based compressor to recover high-pressure, high-purity CO2 from 

the Martian atmosphere. The system eliminates the need for a mechanical 

pump, increasing the reliability with relatively low power consumption. 

TDA’s system uses a new, high capacity sorbent that selectively adsorbs 

CO2 at 0.1 psia and regenerates by temperature swing, producing a 

continuous, high-purity CO2 flow at pressure (>15 psia). 

Applications 

NASA

► Lightweight, compact, and 

energy efficient adsorbent 

based solid-state CO2 

compressor system to collect 

and pressurize CO2 from the 

Martian atmosphere

► CO2 control system for 

commercial spacecraft cabin 

air revitalization and space 

suits

Commercial

► Removal of CO2 emissions from the 

coal-fired power plants

► Removal of CO2 from

o Biogas

o Natural gas

o Water-gas-shift reaction in 

hydrogen manufacturing 

Phase II Objectives

► Develop a high capacity, regenerable 

CO2 adsorbent that maintains its CO2

capacity and mechanical integrity over 

extended adsorption/desorption cycles

► Optimize the sorbent formulation 

► Conduct at least 100 complete 

adsorption/regeneration cycles for the 

best sorbent formulation 

► Carry out a design of the adsorbentbased CO2 compressor 

► Demonstrate the technical feasibility of 

the concept 

► Quantify the logistics savings

Benefits

► Eliminates the need for a mechanical 

pump

► Increases the reliability with relatively 

low power consumption 

Firm Contact

Ambalavanan Jayaraman

TDA Research, Inc.

12345 West 52nd Avenue

Wheat Ridge, CO, 80033-1916

PHONE: (303) 422-7819

FAX: (303) 422-7763

Proposal number: H1.01-9408
NASA/TM—2015-218917 10

Microfluidic System for CO2

Reduction to Hydrocarbons in 

Microgravity 

Low-cost fabrication of high-efficiency microchannel-plate 

reactors for the electrocatalytic reduction of CO2 to CH4

Electrocatalytic reduction of carbon dioxide to methane and other 

hydrocarbons (HC) will be demonstrated based on the etching of 

microchannel electrodes and copper electrodeposition on the cathodes. The 

copper electrocatalytic efficiency will be enhanced via oxide reduction. A 

high channel density will give high active area in compact form factor while 

avoiding complications of packed-bed reactors. Ionic liquids (ILs) will give 

advantages such as low evaporative loss, high CO2 and low HC solubility, 

and electrochemical inertness. The challenge of gas-liquid separations in 

microgravity will be addressed through a novel centripetal application of an 

established spiral-channel microfluidic concept. The system includes: 1) 

absorber to getter gaseous CO2 using an IL electrolyte, 2) microfluidic 

electroreactor to convert CO2 to HC with O2 as by-product, and 3) spiralchannel gas-liquid separator to remove HC and O2 from the IL for recycling 

to the absorber. 

Applications 

NASA

► Centripetal microchannel 

separators for gas-liquid 

separations in microgravity

► In-situ generation of 

hydrocarbon fuels from CO2

sourced from crew exhalation 

gases or the Martian 

atmosphere 

► Compact form factor of 

stackable-plate will integrate 

readily into NASA space 

vehicles 

Commercial

► Highly efficient chemical reactors 

► Efficient, low-power, in-situ 

conversion of carbon dioxide to 

methane 

► Reduction in anthropogenic 

greenhouse gas emissions 

(including carbon dioxide) 

Phase II Objectives

► Demonstrate and develop a technology 

for production of stackable-plate 

microchannel reactor-separator units for 

CO2 reduction to hydrocarbons to serve 

as a means for in-situ generation of fuel 

during space missions

► Demonstrate the control of copper 

deposit thickness, structure, and 

conformity

► Execute copper layer oxide reduction 

activation process

► Demonstrate electrocatalytic activity of 

activated copper layers 

► Evaluate the feasibility in terms of 

thermal, electrical, and economic 

considerations 

► Develop a simulation and modeling 

argument for feasibility of centripetal 

separation concept 

Benefits

► Robust, high-efficiency microreactor 

systems for conversion of CO2 to CH4

Firm Contact

E. Jennings Taylor

Faraday Technology, Inc

315 Huls Drive

Englewood, OH, 45315-8983

PHONE: (937) 836-7749

FAX: (937) 836-9498

Proposal number: H1.01-9409
NASA/TM—2015-218917 11

Cavitation Peening of Aerospace 

Bearings 

Using bubbles to strengthen metals

High-value bearings are critical for safety, reliability, cost, and performance 

of modern aircraft. A typical passenger jet has 100 to 175 high-value 

bearings, each costing $2,500 to $50,000. Ormond LLC has developed a 

process called cavitation peening that has been shown to enhance bearing 

life which in turn reduces cost and frequency of bearing replacement. The 

process imparts deep, high magnitude residual stresses through use of ultrahigh pressure water jets to generate intense clouds of cavitation bubbles that 

collapse on the work piece generating shock waves that cold work the 

material. The process uses no particles, and thus produces no waste and 

adds no weight to the part, all while enhancing bearing life, reliability, and 

performance.

Applications 

NASA

► Aircraft gas turbines

► Rotating components where 

weight or power consumption is 

an issue, such as

o Motors

o Rotors

o Pumps

o Wheels

► New bearing materials and nonbearing applications, such as

o Airframe structures

o Gears

o Drivetrain components

Commercial

► Automobile fuel economy

► Wind turbine power generation

► Aircraft engine efficiency and 

reliability

► Manufacturing machinery reliability

► Aluminum airframes

► Carburized gears

► Titanium rotors and disks

► Steel structures

Phase II Objectives

► Demonstrate the ability to generate high 

magnitude deep residual stress in 

different kinds of bearing elements and 

different bearing materials with 

cavitation peening 

► Characterize the non-residual stress 

effects of cavitation peening

► Quantify rolling contact fatigue life 

improvement for cavitation-peened 

bearing components and full bearing 

assemblies

► Demonstrate the stability of the 

cavitation peening effects over load 

cycles and temperature cycles to 

simulate aircraft environments 

Benefits

► 100% fatigue improvement 

► Enhances bearing life, reliability, and 

performance 

► No particles are used

► No waste created from process

► Adds no weight to components

► Reduces costs 

Firm Contact

Tom Butler

ORMOND, LLC

4718 B Street Northwest, Suite 104

Auburn, WA, 98001-1750

PHONE: (253) 852-1298

FAX: (253) 852-6940

Proposal number: A3.07-9218