tech details

Thermal Barrier Coating System

Opportunity

Research is active on the development and application of thermal barrier bond coatings for enhanced substrate oxidative resistance. Several patented and patent pending technologies are available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.


Overview

The realization of high-efficiency, near-zero emission turbine power systems depends on the advancement of the thermal protection of turbine componentry. Current technology for protecting components, such as airfoils, relies primarily on the combined effects of a thermal barrier coating (TBC) and convective cooling. However, state-of-the-art development in both TBC materials and cooling technologies is insufficient to meet the thermal-mechanical demands imposed by hot gas with elevated turbine-inlet-temperatures. Advances in turbine cooling effectiveness, as well as TBC performance and durability are required to adequately address the problems posed by these operating conditions.

These inventions relate to a thermal barrier bond coating system for use on gas turbine components to enhance protection from high temperatures and corrosive environments. Disclosed in these patents are processes for more efficiently interfacing superalloy substrates with metallic-ceramic overlay coatings. The use of these bond coating systems significantly improves oxidative stability of the base metal substrate when compared to current commercial state-of-the-art diffusion aluminide bond coat systems. These systems also promote the adherence of the bond coating with the metal-ceramic yttria-stabilized zirconia overlay forming a functionally graded oxidative-resistant architecture. The novel bond coatings can be applied at production scale at greatly reduced cost using a wet spray


Significance

  • Improved high-temperature oxidative resistance of superalloys
  • Extended functional lifespan of turbine components
  • Bond coatings can be applied using a low-cost wet spray system


Applications

  • Bond coating of nickel-based superalloys used in power generation turbines and aerospace engines


Related Patents

U.S. Patent No. 7,740,948, titled "Thermal Barrier Coatings" issued June 22, 2010.

Inventor: Mary Anne Alvin

U.S. Non-provisional Patent No. 14/864,935, titled “Method of Fabricating a Bond-Coated Article Having a Thermal Barrier Coating" filed September 25, 2015.

Inventors: Mary Anne Alvin


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