High Temperature Oxidation Resistant Alumina Coatings for Advanced Energy and Processing Systems

50304-98-I High Temperature Oxidation Resistant Alumina Coatings for Advanced Energy and Processing Systems--Plasma Processes, Inc., 4914 D Moores Mill Road, Huntsville, AL 35811-1558; (205) 851-7653 Mr. Timothy McKechnie, Principal Investigator Mr. Timothy McKechnie, Business Official DOE Grant No. DE-FG02-98ER82645 Amount: $75,000 High-temperature oxidation protection is essential to improve energy efficiency and reduce the staggering costs of corrosion. Corrosion damage costs 4% of the U.S. Gross National Product each year. In addition, corrosion has a deleterious effect on the environment and can often lead to catastrophic consequences. The resistance to such corrosion is best achieved by the development of adherent stable alumina coatings. Innovative plasma spray and reactive sputter deposition technologies will be used to produce tough adherent alumina coatings that exhibit improved elevated temperature oxidation and corrosion resistance. Alumina coatings will be developed and subjected to high temperature corrosive environments to determine how composition, microstructure, and processing affects coating integrity. More importantly, the use of innovative deposition techniques will allow microstructural manipulation that will lead to important insights regarding alumina adherence and performance. Commercial Applications and Other Benefits as described by the awardee: Immediate commercialization should be realized for alumina-based thermal barrier coatings for turbine blades, combustor liners, stator vanes, etc.; aeronautical and land-based turbine engines; and pistons, valve heads, exhaust ports, and cylinders in diesel engines. Other commercial applications include heat exchangers, burner nozzles, hot gas fans and filters, and pump and valve linings for corrosive environments. _