SBIR Phase I: Chemically Bonded Ceramic Exhaust Coating

该小型企业创新研究（SBIR）第一阶段项目将集中开发一种新型化学结合非晶陶瓷网络（CBACN），用作下一代发动机排气热管理系统的热涂层。 涂层将允许性能、价格和加工参数的组合优于当前可用的技术上级。 拟议工作的潜在成果将是一种低成本、易于应用的热障涂层，该涂层与排气部件结合，减少从排气到周围部件的净热损失。 热排气涂层可提高发动机和催化效率，降低发动机罩下温度，并减轻车辆重量。 对消费者的净效果是提高效率、减少温室气体排放、减少污染、提高安全性和降低成本。 汽车制造商的净结果将是更高的企业平均燃油经济性（CAFE）分数，简化的制造工艺，以及每辆车估计节省20美元的成本。 目前的陶瓷排气涂层对于原始设备制造商（OEM）来说太昂贵。 拟议的研究的潜在成果是一个陶瓷排气涂层的热管理系统中使用的OEM use.The智力的优点，该项目来自低成本的进步，易于应用，化学键合陶瓷到市场目前难以应用等离子喷涂陶瓷涂层。 这些涂层的目标特性包括热导率低于5 W/m-K、发射率低于0.3、与排气级不锈钢的附着力、热稳定性、耐磨性、耐化学性以及易于涂覆和集成到车辆制造供应链中。 CBACN可以配制成具有在烧结陶瓷系统中无法获得的宽范围的物理性质。 已经开发了相关的CBACN涂层，其在400系列排气不锈钢上具有足够的粘附性和柔韧性，以经受围绕10 mm心轴的35度弯曲。 独立地，CBACN涂层已被开发为具有低于0.2的发射率和低于1 W/m-K的热导率，尽管没有开发出同时具有所有期望特性的单一涂层。 本项目将侧重于实现这种材料系统所需的材料合成和评估任务。

This Small Business Innovation Research (SBIR) Phase I project will center on the development of a new chemically-bonded amorphous ceramic network (CBACN) for use as a thermal coating in next-generation engine exhaust thermal management systems. The coating will permit a combination of performance, price and processing parameters superior to currently available technologies. The potential outcome of the proposed work will be a low-cost, easy to apply, thermal barrier coating that bonds to exhaust components, reducing the net heat loss from the exhaust to the surrounding components. Thermal exhaust coatings offer improved engine and catalytic efficiency, lower under-hood temperature, and reduce vehicle weight. The net effect for the consumer is improved efficiency, reduced greenhouse gas emissions, reduced pollution, improved safety, and lower cost. The net outcome for automobile manufacturers will be higher corporate average fuel economy (CAFE) scores, a simplified manufacturing process, and an estimated cost savings of $20 per vehicle. Current ceramic exhaust coatings are too costly for use by original equipment manufacturers (OEMs). The potential outcome of the proposed research is a ceramic exhaust coating for use in a thermal management system appropriate for OEM use.The intellectual merit of this project derives from the advancement of low-cost, easy to apply, chemically-bonded ceramics into a market currently occupied by difficult-to-apply plasma sprayed ceramic coatings. Target features for these coatings include thermal conductivity less than 5 W/m-K, emissivity below 0.3, adhesion to exhaust-grade stainless steel, thermal stability, wear resistance, chemical resistance, and ease of coating and integration into the vehicle manufacture supply chain. CBACNs may be formulated with a wide range of physical properties not obtainable in a sintered ceramic system. Related CBACN coatings have been developed with enough adhesion and flexibility on 400 series exhaust stainless steel to survive a 35 degree bend around a 10 mm mandrel. Independently, CBACN coatings have been developed with emissivity below 0.2 and with thermal conductivity below 1 W/m-K, although no single coating has been developed with all the desired properties simultaneously. This project will focus on the material synthesis and evaluation tasks needed to realize such a material system.