Functionally Graded Laminated Metal-Ceramic Thermal Barrier Systems by Low-Cost Electrochemical Processing

New materials are needed to withstand the ever-increasing temperatures and harsher chemical environments of Integrated Gasification Combined Cycle (IGCC) systems. This project will extend a unique alloy manufacturing process to the scalable and low-cost production of functionally graded ceramic-metal thermal barrier coatings (TBCs) that exhibit spatially tailored porosity and chemistry. The proposed thermal barrier systems will possess greater durability through the elimination of interfaces that dominate the failure modes of modern TBC systems. In addition, the new TBCs will have a reduced thermal conductivity (below 0.7 W/mK) and improved thermo-mechanical properties through nano- and micro-scale lamination. Commercial Applications and other Benefits as described by the awardee: In addition to the IGCC application, the technology should have direct commercial applications in industries ranging from oil and gas to aerospace, with potential secondary applications as environmental protective coatings for corrosion prevention in civil and military infrastructure.