SBIR Phase I: High Temperature Corrosion Protection of Copper by the Application of an Aluminum Based Diffusion Coating

这个小型企业创新研究（SBIR）第一阶段项目将评估一种低成本的陶瓷涂层工艺，以保护铜及其合金免受高温腐蚀。铜及其合金的优良导热性、可加工性和相对化学惰性使其成为热水器中热交换器和电加热元件的有吸引力的候选者。不幸的是，铜换热器的高温氧化和冷凝水腐蚀限制了其使用寿命。 为了在这些应用中继续使用铜，需要具有良好导热性的化学惰性高温涂层。该项目的目标是通过定制涂层的成分和工艺变量来获得一系列具有不同导热性能的陶瓷和金属陶瓷涂层。该项目的更广泛影响/商业潜力是开发一种具有广泛适用性的颠覆性低成本陶瓷涂层工艺。该技术适用于腐蚀保护至关重要的消费电器和汽车市场。其中包括家用电器，运输散热器和加热器芯，以及高温工业黄铜和铜热交换器。如果成功，会产生重大的社会影响吗？更有效的热水器设计将导致减少材料消耗和更大程度地将高效加热器模型推广到市场。对于汽车应用，提高能源效率应导致降低能源成本和减少废气排放造成的污染物。

This Small Business Innovation Research (SBIR) Phase I project will evaluate a low cost ceramic coating process to protect copper and its alloys from high temperature corrosion. The excellent thermal conductivity, workability, and relative chemical inertness of copper and its alloys make them attractive candidates for heat exchangers and electrical heating elements in water heating appliances. Unfortunately, high-temperature oxidation and condensate corrosion of copper heat exchangers limits their service life. To continue the use of copper in these applications, chemically inert, high temperature coatings with good thermal conductivity are required. The objective of this project is to achieve a range of ceramic and cermet coatings with varying thermal conductivity behavior through tailoring the composition and process variables of the coating.The broader impact/commercial potential of this project is development of a disruptive, low cost ceramic coating process with wide-ranging applicability. The technology is amenable to a consumer appliance and automotive markets where corrosion protection is critical. These include home appliances, transportation radiators and heater cores, as well high temperature industrial brass and copper heat exchangers. If successful there are some important societal impacts?the more efficient water heater designs should lead to reduced materials consumption and greater diffusion of the high efficiency heater models into the market. For automotive applications, improved energy efficiency should result in reduced energy costs and reduced pollutants from lower exhaust emissions.