Erosion-Resistant Conformal Coatings Using HiPIMS + Positive Kick PVD for Large-Diameter IBR and Lift-Fan Blade Manufacturing

This SBIR project aims to demonstrate a manufacturing process for erosion-resistant coatings for large-diameter IBR and lift-fan blades using an advancement PVD. High-Power Impulse Magnetron Sputtering employing a “Positive Kick” is a new PVD technique that imparts controlled ion energy into the growing film for densification, adhesion, stress control/relief, smoothness and composite metal/ceramic layering. The positive voltage reversal in the presence of dense HiPIMS plasma leads to quasi-conformal sheath coverage on substrates for deposition onto 3D structures and shapes with a single processing system—ideal for the 3D complex IBR and lift-fan structure. Extremely thick multilayer nanocomposite stacks in excess of 100um have been deposited with improved smoothness, lubricity, fracture toughness and ultra-hardness with corrosion resistance. This new technique mitigates the macroparticle problems of cathodic arc, allows deposition of insulating materials with energetic ion control, increases deposition rate and allows stress control. Phase I will demonstrate production of prototype materials for basic functionality testing with pathway for manufacturing scale up in Phase II using large sputtering cathodes for IBRs and lift fan blades.