SBIR Phase I: Development of NZP-Based Advanced Thermal Barrier Coatings

该小型企业创新研究项目将开发高度工程化、抗氧化和耐用的NZP基热障涂层，用于先进航空航天和燃气涡轮机发动机系统的部件。 下一代航空航天推进和发电系统必须满足更高效率、更高燃油经济性和更长寿命的要求。 需要更高的燃烧温度和更好的绝缘来提高发动机效率和这些系统中的部件的寿命。 基于氧化钇部分稳定的氧化锆（YPSZ）的现有技术热障涂层（TBC）不足以满足这些温度和寿命要求，因为：（1）氧化问题，（2）低的热化学稳定性，（3）使用中的微观结构变化，和（4）低的应变公差。属于NZP陶瓷族的Ba1.25Zr4P5.5Si0.5O24（BS-25）和Ca0.5Sr0.5Zr4P6O24（CS-50）至少两种组合物理想地适用于先进的热障涂层。这些组合物的有吸引力的性质包括高熔融温度（180 ℃）、高热循环稳定性、非常低的热导率（~ 1.0W/mK）、优异的耐热冲击性和低氧离子传导性。 此外，它们的热膨胀系数非常低。 将使用功能梯度（FG）设计方法来最大限度地减少热膨胀失配并引入有益的表面压应力。 一旦开发成功，这项技术也将有利于汽车和冶金工业。NZP陶瓷基热障涂层可以立即实现的具体商业应用是：用于涡轮机叶片、燃烧室衬套、定子叶片等，在喷气和燃气涡轮机发动机中;以及在柴油发动机中活塞、阀头、排气口和汽缸。其他商业应用包括：（1）热交换器，（2）燃烧器喷嘴，（3）热气体风扇和过滤器，以及（4）腐蚀环境中的泵和阀衬。NZP基热障涂层，热喷涂，功能梯度，先进燃气轮机，低导热性，抗氧化性

This Small Business Innovation Research project will develop highly engineered, oxidation resistant and durable NZP-based TBCs for components in advanced aerospace and gas turbine engine systems. Next generation aerospace propulsion and power generation systems have to meet requirements of higher efficiencies, greater fuel economy, and longer lifetimes. Higher firing temperatures and better insulation are required to improve engine efficiency and lifetimes of components in such systems. State-of-the art thermal barrier coatings (TBCs) based on yttria partially-stabilized zirconia (YPSZ) are inadequate to meet these temperature and lifetime requirements because of:(1) oxidation problems, (2) low thermo-chemical stability, (3) in-service microstructural changes, and (4) low strain tolerance. At least, two compositions viz. Ba1.25Zr4P5.5Si0.5O24 (BS-25) and Ca0.5Sr0.5Zr4P6O24 (CS-50,) belonging to the NZP ceramics family, are ideally suited for advanced TBCs. Attractive properties of these compositions include high melting temperature ( 1800C), high thermal cycling stability, very low thermal conductivity (~1.0 W/mK), excellent thermal shock resistance, and low oxygen ion conductivity. In addition, their thermal expansion coefficients are very low. Functionally Graded (FG) design approach will be used to minimize thermal expansion mismatches and introduce beneficial surface compressive stresses. When successfully developed, this technology will also be beneficial to automotive and metallurgical industries.Specific commercial applications that could be immediately realized for NZP ceramics-based TBCs are: for turbine blades, combustor liners, stator vanes, etc., in jet and gas turbine engines; and pistons, valve heads, exhaust port, and cylinders in diesel engines. Other commercial applications are in: (1) Heat Exchangers, (2) Burner Nozzles, (3) Hot Gas Fans and Filters, and (4) Pump and Valve Linings in Corrosive Environments.NZP-Based TBCs, Thermal Spray, Functionally Gradient, Advanced Gas Turbines, Low Thermal Conductivity, Oxidation Resistance