Development of Electrically Mediated Electrophoretic Deposition for Thermal Barrier Coating Systems

78745S The gas turbine engine manufacturing industry is an important aspect of the U.S. commercial economy and critical to both the Departments of Energy and Defense. A novel, low-cost turbine blade coating process is needed to improve thermal barrier coating structures and turbine blade robustness. This project will develop a non-line-of-sight, electrically mediated, elecrophoretic deposition process for coating these turbine blades. In particular, thermal barrier coatings containing yttrium-stabilized zirconia, doped with varying amounts of rare earth elements, will be investigated in an attempt to lower the thermal conductivity of the coating system and enable higher operating temperatures in natural gas and synthesis gas environments. Phase I will: (1) deposit, via electrically mediated electrophoretic deposition, yttria stablized zirconia doped with varying amounts of rare earth elements; (2) assess post-processing methods to create high-performance coatings that will excel in the high-temperature environments of turbine engines; (3) evaluate coating integrity after thermal stability and thermal cycling tests; and (4) determine implementation costs and performances compared to currently practiced techniques. Commercial Applications and other Benefits as described by the awardee: With the application of thermal barrier coatings composed of new materials, higher operating temperatures can be achieved, leading to increased fuel efficiency and reduced waste energy and energy costs.