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

这个小型企业创新研究项目将为先进的航空航天和燃气轮机发动机系统中的部件开发高度工程化、抗氧化和耐用的基于NZP的热障涂层。下一代航天推进和发电系统必须满足更高的效率、更高的燃油经济性和更长的寿命的要求。需要更高的燃烧温度和更好的绝缘性来提高发动机效率和此类系统中部件的寿命。由于(1)氧化问题，(2)较低的热化学稳定性，(3)使用中的微观结构变化，以及(4)较低的应变耐受性，基于部分稳定的氧化钇(YPSZ)的最先进的热障涂层(TBC)不能满足这些温度和寿命要求。至少有两篇作文，即。Ba1.25Zr4P5.5Si0.5O24(BS-25)和Ca0.5Sr0.5Zr4P6O24(CS-50)属于NZP陶瓷家族，是先进热障涂层的理想材料。这些材料具有极高的熔化温度(1800℃)、高的热循环稳定性、极低的导热系数(~1.0W/MK)、优异的抗热震性和低的氧离子导电率。此外，它们的热膨胀系数很低。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。成功开发后，这项技术也将有利于汽车和冶金行业。NZP陶瓷基热障涂层可以立即实现的具体商业应用包括：喷气发动机和燃气轮机中的涡轮叶片、燃烧室衬里、定子叶片等；以及柴油发动机中的活塞、气门头、排气口和气缸。其他商业应用包括：(1)热交换器，(2)燃烧器喷嘴，(3)热气风扇和过滤器，(4)腐蚀性环境中的泵和阀门衬里。NZP基热障涂层，热喷涂，功能梯度，先进燃气轮机，低导热系数，抗氧化

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