Demonstration of Non-Line-of-Sight TBC

Advances in turbine materials resulting in high strength and lightweight metallic and ceramic components have allowed for high efficiency, high power density, compactness, and low emissions. Current technology turbine blades are comprised of single crystal nickel superalloys in combination with ceramic thermal barrier coatings (TBC). Typical TBC composition consists of an aluminum rich bond coat, thermally grown oxide (TGO), and yttria stabilized zirconia (YSZ). These coatings have limited durability and constrain peak engine temperatures due to non-uniform coating thickness and susceptibility to crack propagation. Non-uniformities within the thickness are caused by line-of-sight coating applications typical of current industry standards. To address these shortcomings, Mainstream will rely on its expertise in nano-technology and chemical vapor deposition techniques to demonstrate a non-line-of-sight method for producing a strain-tolerant thermal barrier coating. The Phase I effort will characterize the mechanical properties of the nanocomposite coating, demonstrate the feasibility of the inclusion of nanostructures within a ceramic matrix, and validate the strain tolerance via thermal fatigue and thermal shock experiments.