High-Temperature Environmental Barrier Coating for Silicon Carbide Composites

Advanced thermal/environmental barrier coating (T/EBC) systems are desired to protect Si-based ceramics in high temperature, water vapor containing environments. In this work, we will use novel coating synthesis techniques that enable the economical deposition of enhanced T/EBCs having higher temperature capability, improved durability and better erosion resistance than that of current state-of-the-art T/EBC systems (based on silicon/mullite + barium strontium aluminosilicate (BSAS)/BSAS). In the proposed Phase I effort, DVTI will team with UC Santa Barbara to identify T/EBC systems that are anticipated to meet the performance goals at both current and future engine operating temperatures and demonstrate the feasibility of applying these coatings using advanced processing approaches will enable enhanced coating microstuctural control and adhesion. The successful completion of the Phase I work will lead to a follow-on Phase II program focused on down-selecting candidate material(s) and applying the new coating onto complex Si-based components (including those having non line-of-sight regions) for testing using DVTIs production scale coating equipment. Success in this objective will offer the military a pathway toward production implementation of the advanced EBC systems developed in this work and the new deposition processing capabilities required for applying coatings of this type onto complex engine components. BENEFIT: This research is anticipated to result in a thermal/environmental barrier coating system that provides higher temperature capability, improved durability and better erosion resistance than current coatings. These advancements will enable the use of Si-based ceramics in a range of high temperature applications such a gas turbine engines and heat exchangers. These advances will not only benefit military engines, but also commercial and industrial engines requiring greater performance.)