SBIR Phase I: Thick Thermal Barrier Coatings

这个小型企业创新研究第一阶段项目建议开发一种非视距工艺，用于厚(1 Mm)热障涂层(TBC)的纳米分层，同时具有a)更高的耐用性和b)更低的导热系数。包括交通、发电和油气在内的不同行业都希望提高工作温度，以提高效率和性能，但部分受限于可用建筑材料的高温行为(如蠕变、磨损和腐蚀)。克服这些限制的一种方法是通过热障涂层，即保护和绝缘高温部件的陶瓷涂层，从而允许更高的工作温度。通过a)较低的导热系数(K)和b)较大的涂层厚度，TBC的绝缘效率提高。不幸的是，新出现的低K陶瓷和较厚的热障涂层都会导致耐用性降低。研究表明，通过纳米层化可以实现低K和提高耐久性；然而，目前还没有一种工艺能够将纳米层化的热障涂层应用到上述部门遇到的复杂几何形状上，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陶瓷-金属复合材料，以实现优异的热障涂层性能。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，包括柴油和天然气发动机、航空航天和陆基涡轮发动机以及航空航天结构应用。除了在这些领域产生重大影响外，拟议中的技术如果成功，还将作为一种环境保护和防腐涂层产生影响，并伴随着对国家基础设施的好处。这一第一阶段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来生产新型TTBC结构，使研究人员能够定制厚TBC结构，用于实验验证结构-性能模型，并进一步了解高温材料的本构行为。最后，该项目将允许来自密歇根大学的理工科本科生以实习生的身份参与该项目。这些实习除了为学生本身提供独特的学习体验外，还将利用威斯康星大学现有的人才库。学生将接触到材料合成和测试方法，并将有机会对我们正在进行的研究、开发和生产工作产生重大影响。

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.