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

该小型企业创新研究(SBIR)二期项目将进一步开发和优化NZP(磷酸锆钠)陶瓷基热障涂层(TBC)技术，用于先进的涡轮机和发电系统。这些先进的系统需要更高的工作温度，以在不影响耐用性的情况下实现更高的效率。这些要求增加了以下威胁：(1)降低热障有效性的微观结构变化；(2)过早的氧化剥落；(3)传统的氧化钇稳定氧化氧化锆(YSZ)基热障涂层对机械应力的敏感性。一些NZP陶瓷具有非常低的导热系数和氧气传导率，优异的耐热循环性能和较高的温度稳定性，但也具有低的热膨胀。第一阶段论证了采用简单和功能梯度(以减少热膨胀失配)的NZP和YSZ热障涂层的可行性，这些热障是更好的隔热层，并且在1200℃下具有非常好的耐热循环性能。第二阶段的主要目标是完成科学和工程开发，以便将基于NZP的热障涂层技术商业化。一个学术和工业合作者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其能够应用于高效率发电系统和燃气轮机发动机，特别是涡轮叶片和叶片，以及燃烧室和加力燃烧室。以NZP为基础的涂料还可以兼作环境屏障涂料(EBCs)，并用于柴油发动机和可磨损的密封件。由于减少了部件维护、燃料和运营成本，基于NZP的涂料的经济收益可能超过1亿美元。

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.