SBIR Phase II: Cubic Phase-Stabilized Zirconia Thermal Barrier Coatings Applied via a Novel Chemical Vapor Deposition Route

This Small Business Innovation Research (SBIR) Phase II project will seek to develop a novel technique for applying thermal barrier coatings (TBCs) to turbine (jet) engine components. The use of low thermal conductivity TBCs has enabled higher temperatures and longer component life to be achieved, along with more efficient engine operation. Application of the state-of-the-art coating compositions via chemical vapor deposition (CVD) has the potential for an order-of-magnitude reduction in processing cost over the conventional technique employed. In addition, CVD is a non-line-of-sight technique capable of coating components and/or regions of components not possible by any other means The next-generation TBC system to be developed in this project will provide superior reduction in actual part temperature and oxidation resistance compared with state-of-the-art coatings. In addition to the increased engine efficiency realized from the higher temperature operation these coatings will allow, this application method has the potential for an 80-90% reduction in cost. Improved TBCs will have wide application to commercial and military propulsion and power generation systems, including turbine and reciprocating engines.