Design Framework for Optimized Multifunctional Coatings

AlphaSTAR Corporation proposes to enhance the ICME (Integrated Computational Material Engineering) and lifing model in support of the Design Framework for Optimized Multifunctional Coatings for high temperature thermal/environmental Barrier Coatings (TBC/EBC)) with extended durability/reliability and life. A multiphysics-based multi-objective topology optimization methodology, and virtual design of experiment (DOE), random sampling methodology will be developed to design multifunctional materials including high temperature special technology coatings for use in engine/aircraft high temperature exhaust regions. The innovation centers around: 1) Material Modeling of Coating and Substrate, predicting material performance (strength, stiffness, conductivity) Vs. temperature considering the effect of defects; 2) Structural Analysis and Durability and Damage Tolerance, predicting coating and substrate failure type such as spallation, oxidation/corrosion during thermo-mechanical in-service loading; 3) Thermal Modeling (Zero Order Model), predicting material thermal history profile, voids and densities for each layer of the TBC during coating process for Plasma Spraying and Electron Beam-Physical Vapor Deposition (EB-PVD) ; and 4) Single or Multiple Objective Topology Optimizations to maximize durability, minimize residual stress, and enhance coating life. Verification, validation and accreditation will be performed using existing test data and planned rig testing of TBC/EBC coating systems on metallic and ceramic materials.