Novel Coating Methods for Unique TBC/Bond Coat Architectures for Elevated Temperature Operation

Concerns over the use of domestic energy supplies and the desire to reduce CO2 emissions have motivated increased interest in the use of alternative fuels (such as coal ¿syngas¿) and alternative engine cycles. This interest has led to the increased use of an Integrated Gasification Combined Cycle (IGCC) engine, which turns coal into syngas and then removes impurities from the coal gas before it is combusted. To achieve desired efficiencies, higher temperature operation will be required. At these higher temperatures, thermal barrier coatings (TBC) will be needed to reduce the thermal exposure of metallic turbine engine components. This project will develop an advanced TBC coating system (both materials and architecture) for use in IGCC engines, along with the advanced manufacturing methods required for application onto large turbine airfoil components. Commercial Applications and other Benefits as described by the awardee: An economical approach for applying advanced, high temperature TBCs onto turbine components should lead to cheaper, cleaner power production. The coating would be provided as a service to gas turbine manufacturers. Other potential users include the airline industry (as the advanced TBCs also would benefit aero-based gas turbines) and operators of small gas turbines for electric power (i.e. hospitals, hotels, refrigerated warehouses, etc.).