SBIR Phase I: Thick Thermal Barrier Coatings

这个小企业创新研究第一阶段项目建议开发一种非视线工艺，用于厚（1毫米）热障涂层（tbc）的纳米层化，该工艺可以提高耐久性，降低导热性。包括交通运输、发电和石油天然气在内的各个行业都希望提高工作温度，以提高效率和性能，但在一定程度上受到现有建筑材料的高温性能（如蠕变、磨损和腐蚀）的限制。克服这些限制的一个途径是通过热障涂层，陶瓷基涂层保护和绝缘高温组件，从而允许更高的工作温度。a)较低的导热系数(k)和b)较大的涂层厚度提高了TBC的绝缘效率。不幸的是，新兴的低钾陶瓷和较厚的tbc都会导致耐久性降低。研究表明，纳米层合既可以降低k值，又可以提高材料的耐久性；然而，目前还没有一种工艺能够将纳米层化tbc应用到上述部门遇到的复杂几何形状上，从而具有成本竞争力。因此，该项目的目标是应用我们创新的电化学沉积工艺来开发纳米层化陶瓷-金属复合材料，以获得卓越的热障涂层性能。热障涂层的市场价值超过37.5亿美元，这些结构被用于各种细分市场，包括柴油和燃气发动机，航空航天和陆基涡轮发动机，以及航空航天结构应用。除了对这些行业产生重大影响外，该技术如果成功，将对环境保护和防腐涂层产生影响，并为国家的基础设施带来好处。第一阶段的研究计划包括与普渡大学和华盛顿大学（UW）的合作，并将有助于建立无与伦比的灵活性，以生产新的TTBC结构，允许研究人员定制厚TBC结构，以实验验证结构-性能模型，并进一步了解高温材料的本构行为。最后，该项目将允许来自UW的理工科本科生作为实习生参与该项目。这些实习将充分利用西澳大学的人才库，为学生提供独特的学习体验。学生将接触到材料合成和测试方法，并将有机会实质性地影响我们正在进行的研究，开发和生产工作。

This Small Business Innovation Research Phase I project proposes to develop a non-line-of-sight process for nanolamination of thick ( 1 mm) thermal barrier coatings (TBCs) with both a) improved durability and b) reduced thermal conductivity. Diverse sectors including transportation, power generation, and oil & gas desire increased operating temperatures for improved efficiency and performance, but are limited in part by the high temperature behavior (e.g. creep, wear, and corrosion) of available materials of construction. One route to overcoming these limitations is through thermal barrier coatings, ceramic-based coatings which protect and insulate high temperature components thereby allowing higher operating temperatures. The insulating efficacy of a TBC improves with a) lower thermal conductivity (k) and b) greater coating thickness. Unfortunately, both emergent low-k ceramics and thicker TBCs result in reduced durability. Research indicates that both low-k and improved durability can be achieved through nanolamination; however, no process is currently capable of cost-competitive application of nanolaminated TBCs onto the complex geometries encountered in the above sectors. This project's objectives are therefore to apply our innovative electrochemical deposition process to develop nanolaminated ceramic-metal composites to achieve superior thermal barrier coating performance.The market for thermal barrier coatings is over $3.75 billion, with these structures being used in a variety of market segments, including diesel and gas engines, aerospace and land based turbine engines, and aerospace structure applications. In addition to having a substantial impact in these sectors, the proposed technology, if successful, would have impact as an environmental protection and anti-corrosion coating, with concomitant benefits to the nation's infrastructure. This Phase I research plan includes collaborations with both Purdue University and the University of Washington (UW), and will help establish unrivaled flexibility for producing novel TTBC architectures, allowing researchers to customize thick TBC architectures for experimentally validating structure-property models and furthering the understanding of high temperature materials' constitutive behavior. Finally, this project will allow undergraduate science and engineering students from UW to participate in the project as interns. These internships will take advantage of the talent pool available at UW, in addition to providing a unique learning experience for the students themselves. Students will gain exposure to materials synthesis and testing methods, and will have the opportunity to substantially impact our ongoing research, development, and production efforts.