Gas Turbine Application of Carbon Fiber Nanocomposite with Fabric Reinforced Protective Coating

New carbon materials and composites with 1-10 nm crystallite sizes are low-cost, lightweight, and scalable, and have unique wear and high temperature characteristics. These materials have been incorporated in newly-developed coatings, which have been applied to gas turbine components (nozzles, vanes, liners, and blades) to improve performance. This project will develop a new carbon-fiber/nano-carbon matrix composite ¿ coated with a fabric-reinforced, nanostructured, oxidation protective layer ¿ which will enhance the performance and life span of high temperature gas turbines. The new composite will be lightweight; have high surface hardness; withstand high temperature; be wear-, shock-, and vibration-resistant; and be shaped into stiff or flexible structures with equal success. Phase I will conduct experiments to prove feasibility in stator turbine applications. Phase II will demonstrate: (1) the engineering scale-up of the proposed carbon nanocomposite ceramic under its nanostructured coating, and (2) its applicability for high temperature turbine stator and rotor components. Commercial Applications and other Benefits as described by the awardee: The new ceramic matrix composites should prevent cracking and delamination, and enhance the efficiency of gas turbines and energy efficiency. Potential applications include high temperature gas turbine nozzles, vanes, liners, and blades, as well as non-lubricated sliding fits, rotors and cases. Other commercial and defense applications include: (1) heat shields and boost motor components, (2) internal combustion and jet engines (as a replacement for steel and other metallic components), and (3) coating of components with very high surface hardness (since the method will increase surface hardness up to 10 on the Mohs scale, the hardness of diamond).