Multilayered Yttria-Stabilized Zirconia Coating for Improved Thermal Abrasion Resistance

Currently, there is a need for a thermal barrier coating (TBC) that will improve gas turbine efficiency by allowing for maximum inlet temperature and/or reducing the amount of cooling air required for airfoils. New ceramic top-coat and metallic bond coat chemistries for TBCs that are stronger and more temperature-resistant than current 8YSZ TBC systems will improve turbine efficiency. This will ultimately increase energy savings and reduce costs. As a solution to the current problem, yttria-stabilized-zirconia (YSZ) containing thermally insulating microballoons for controlled porosity, temperature resistance, and abrasion resistance will be used as a TBC. The goal is to develop a film that transitions from a top layer of strong, thermally insulating YSZ to a bottom layer of bond metal that will be adhered to the turbine blade as a protective, insulating layer. Commercial Applications and Other Benefits: Almost all electrical power on Earth is produced by a turbine of some type. Because this product improves turbine efficiency, it will be useful in aerospace applications, automotive applications, and power plants, all of which require the use of turbines.