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

这个小型企业创新研究项目将开发高度工程化、抗氧化和耐用的基于nzp的tbc，用于先进的航空航天和燃气涡轮发动机系统。下一代航空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使用寿命的要求。为了提高发动机效率和延长此类系统部件的使用寿命，需要更高的燃烧温度和更好的绝缘性。基于氧化钇部分稳定氧化锆（YPSZ）的最先进的热障涂层（tbc）由于以下原因无法满足这些温度和寿命要求：(1)氧化问题，(2)低热化学稳定性，(3)使用中的显微组织变化，以及(4)低应变容限。至少有两种成分，即Ba1.25Zr4P5.5Si0.5O24 （BS-25）和Ca0.5Sr0.5Zr4P6O24 (CS-50,)，属于NZP陶瓷家族，是高级tbc的理想选择。这些组合物具有高熔融温度（1800C）、高热循环稳定性、极低导热系数（~1.0 W/mK）、优异的抗热震性和低氧离子电导率等吸引人的特性。此外，它们的热膨胀系数很低。功能梯度（FG）设计方法将用于最小化热膨胀不匹配并引入有益的表面压应力。一旦成功开发，该技术也将有利于汽车和冶金工业。基于NZP陶瓷的tbc可以立即实现的具体商业应用包括：用于喷气和燃气涡轮发动机的涡轮叶片，燃烧室衬垫，定子叶片等；还有活塞、气门头、排气口和柴油发动机的气缸。其他商业应用包括：(1)热交换器，(2)燃烧器喷嘴，(3)热风机和过滤器，(4)腐蚀性环境中的泵和阀门衬里。基于nzp的tbc，热喷涂，功能梯度，先进的燃气轮机，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