Design Framework for Optimized Multifunctional Coatings

In Phase I, AlphaSTAR developed and partially validated an Integrated Computational Material Engineering (ICME): (i) APS Manufacturing Process, (ii) a DOE optimization capability that minimizes thermal conductivity(TC) and residual stress (RS) of metal/TBC thermal protection systems; and (iii) an ICME D&DT tool predicting damage and fracture evolutions that addressed TMF and RUL considering recession, oxidation, thermal growth oxidation (TGO), and debonding. In Phase II, AlphaSTAR will extend the ICME technology to ceramic/EBC including: (1) APS process development with (i) rumpling, (ii) thermodynamic CMAS reactions and (iii) and optimization of TC and RS and (2) D&DT optimization for extended RUL. Objective is to (1) optimize and extend exhaust nozzle remaining useful life (RUL) by maximizing manufacturing Air Plasma Spraying (APS) of environmental/thermal barrier coating (EBC/TBC) material systems; (2) optimize material performance within the substrate, bond/intermediate/top coat; and (3) perform Durability and Damage Tolerance (D&DT) analysis and optimization under thermal mechanical fatigue (TMF) in-service loading. Software will be extensively test validated for Ceramic/EBC and Metal/TBC systems: (a) RS using in-situ-coating properties sensor measurement; (b) Rig testing; TGO measurement, CMAS reactions, and TMF testing. Software will be made available to industry with training, tutorials, baseline/optimized models supported by validated results and material database.