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

该小型企业创新研究（SBIR）第二阶段项目将进一步开发和优化NZP（磷酸钠锆型）陶瓷基隔热涂层（TBC）技术，用于先进的涡轮机和发电系统。这些先进的系统推动了对更高工作温度的需求，以实现更高的效率，而不影响耐用性。这种要求增加了以下威胁：（i）降低热障有效性的微结构变化;（ii）过早氧化剥落;和（iii）在常规氧化钇稳定的氧化锆（YSZ）基热障涂层中对机械应力的敏感性。一些NZP陶瓷具有非常低的导热率和氧传导率、优异的热循环阻力和高温稳定性，但也具有低的热膨胀。 第一阶段证明了热喷涂简单和功能梯度（以最小化热膨胀失配）的NZP与YSZ的TBC的可行性，其是更好的热障，并且还具有非常好的对1200摄氏度的热循环抗性。第二阶段的主要目标是完成科学和工程开发，以便将基于新西兰的TBC技术商业化。 一个由学术和工业合作者组成的团队将在承诺的最终用户的指导下工作，以实现这一目标。基于NZP的TBC概念的潜在成功开发将使高效发电系统和燃气涡轮机发动机的应用成为可能，特别是涡轮机叶片和叶片，以及燃烧室和加力燃烧室。基于NZP的涂料还可以用作环境屏障涂料（EBC），并可用于柴油发动机和耐磨密封件。基于NZP的涂层的经济效益可能超过1亿美元，这是由于降低了部件维护、燃料和运营成本。

This Small Business Innovation Research (SBIR) Phase II project will further develop and optimize the NZP (sodium zirconium phosphate type) ceramic-based thermal barrier coating (TBC) technology for use in advanced turbine and power generation systems. These advanced systems drive the need for higher operating temperatures to achieve better efficiencies without compromising durability. Such requirements heighten the threat of: (i) microstructural changes which reduce thermal barrier effectiveness; (ii) premature oxidative spalling; and (iii) susceptibility to mechanical stresses in conventional yttria-stabilized zirconia (YSZ)-based TBCs. Some NZP ceramics have very low thermal and oxygen conductivity, excellent thermal cycling resistance and high temperature stability but also have low thermal expansion. Phase I demonstrated the feasibility of thermal spraying simple and functionally graded (to minimize thermal expansion mismatches) TBCs of NZP with YSZ that are better thermal barriers and also have very good thermal cycling resistance to 1200 degrees C. The primary goal for Phase II is to complete the scientific and engineering development in order to commercialize the NZP-based TBC technology. A team of academic and industrial collaborators will work under the guidance of committed end-users to achieve this goal. Potential successful development of the NZP-based TBC concept will enable applications in high efficiency power generating systems and gas turbine engines; specifically, for turbine vanes and blades, and combustors and afterburners. Coatings based on NZP can also double up as environmental barrier coatings (EBCs), and find use in diesel engines and as abradable seals. The financial benefits of the NZP-based coatings could be over $100M arising from reduced component maintenance and fuel and operational costs.