Commercial Applications for Recycled Rare Earth Zirconate Thermal Barrier Coating Materials

This Phase I project seeks to develop a method for the recycling of rare earth zirconate thermal barrier coatings (TBCs).  Thermal barrier coatings are crucial to the function and performance of military aircraft engines, as they influence the operating temperatures and environments for the aircrafts.  There are currently two main types of established thermal barrier coating materials, yttria-stabilized zirconia (YSZ) and gadolinium zirconate (Gd2Zr2O7).  These two coatings materials have been carefully developed and extensively tested for use in both commercial and military applications.  Since these thermal barrier coating materials have become firmly entrenched in the aviation defense supply chain, it is imperative that the methods and materials used in producing these coatings are maintained.  However, the production sources of the rare earth and zirconia raw materials necessary for the manufacture of these coatings are concentrated almost entirely in China.  The limited supply options for the TBC raw materials results in substantial uncertainty regarding the availability of these materials for use in TBCs.  Xylon Technical Ceramics has developed and patented a novel, environmentally friendly technology that is capable of recycling rare earth zirconate wastes into their core chemical components at high purities.  Xylon plans to utilize this process to recycle gadolinium oxide from Gd2Zr2O7 wastes directly back into current commercial thermal barrier coating operations, thereby creating a domestic source of these critical raw materials to benefit military and commercial users.