Design and Processing of Low-Cost, High-Performance Plasma Sprayed Thermal Barrier Coatings that are Resistant to CMAS Attack

ReliaCoat Technologies, LLC, a Stony Brook University based spin-off, in conjunction with program partner Prof. Nitin Padture of Brown University and collaborators GE Aviation and Sulzer Metco, proposes to develop innovative and cost effective approaches for design and processing of high performance plasma sprayed TBC coatings that are resistant to CMAS attack. The proposed two-layer TBC architecture consists of a 7YSZ inner layer and an outer layer with a microstructure of 7YSZ matrix with dispersed micro-dispersoids of second phase Al2O3+TiO2 or Y2O3 oxide to mitigate CMAS attack while maintaining the desirable attributes of t"YSZ composition including low conductivity, high toughness, erosion resistance, foreign object damage resistance and excellent stability with the thermally grown oxide. The core idea is that the arrest of CMAS penetration will occur in the outer layer via precipitation of crystalline phases of anorthite and/or apatite. Through the multiphase SBIR program, the team will demonstrate both laboratory and manufacturing production-capable multi-composition new TBC powder along with the process and coating optimization via Integrated Computational Materials Engineering process-property modeling.