Thermal Barrier Coatings for Titanium and High Temperature Polymeric Composite Components

MicroPhase Coatings Inc (MPCI) will prove the technical feasibility of an innovative thermal barrier coating in response to SBIR topic AF03-115. The technology uses a novel polymer-titanium-silicate matrix that cures at room temperature. It incorporateshollow glass microspheres for additional thermal insulation. The matrix has already been demonstrated in the laboratory--it withstands high temperatures (to 1800F), provides thermal insulation, withstands shock and vibration, and strongly adheres to ametal and composite substrates. We add nano-clays to enhance the ability of the coating to serve as a barrier against moisture diffusion and nano-titanium crystals to scavenge free hydrogen. The dual combined effect, in concert with a relatively benignapplication process, will further inhibit titanium embrittlement. Our solution-cast approach will offer significant operational advantages compared to traditional plasma-deposited ceramics-i.e., low cost, easy application, field repairable, and broadcommercial use. Phase I will confirm adhesion, inter-layer integrity, thermal-mechanical compatibility, thermal conductivity, and absence of embrittlement. We have established a strategic business relationship with Pratt & Whitney to ensure asystem-engineered approach, engine compatibility, and to help with commercialization. The commercialization potential of thermal barrier coatings (TBCs) for engine and aircraft parts is very large. As engine development has continued to spawn hotterengines, stress on components has increased to the point that parts are failing before they reach their design life. With effective TBCs, engineers can design and develop new systems, concurrently considering substrates and coatings as integral subsystems,rather than treating coating as an afterthought. Integrated design approaches can lead to lighter, longer lasting systems, lower maintenance cost, and better performance. MicroPhase Coatings' approach to the Air Force SBIR enhances commercializationpotential by providing a coating that can withstand flame and temperatures to 2000F, thereby allowing the coating to be used with firewalls, exhaust systems, navy ship bulkheads, petro-chemical processing, and other hot manufacturing processes. The coatingcan be applied at room temperature without the need for expensive plasma deposition systems, thus significantly enhancing affordability and cost-effectiveness. MPCI's proposal presents a commercialization strategy that is based on a strong team ofstrategic business partners.