Advanced Thermal Barrier Coatings for Next Generation Gas Turbine Engines Fueled by Coal-Derived Syngas Email Page
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Performer:  Brown University in Providence in State of RI Location:  Providence, Rhode Island
Project Duration:  09/01/2012 – 08/31/2015 Award Number:  FE0008933
Technology Area:  University Training and Research Total Award Value:  $324,400
Key Technology:  High Performance Materials DOE Share:  $299,400
Performer Share:  $25,000

Schematic diagrams of APS TBCs cross-sections<br/>with lignite fly ash deposits, before and after<br/>exposure to heat, depicting the interactions:<br/>(A) 7YSZ and (B) Gd<sub>2</sub>Zr<sub>2</sub>O7. Diagrams not to scale.
Schematic diagrams of APS TBCs cross-sections
with lignite fly ash deposits, before and after
exposure to heat, depicting the interactions:
(A) 7YSZ and (B) Gd2Zr2O7. Diagrams not to scale.

Project Description

The overall objective of this proposed research is to elucidate the feasibility of two-layer air plasma-sprayed (APS) thermal barrier coatings (TBCs) for next generation gas-turbine engines fueled by coal-derived syngas. First, optimized two-layer 48YSZ/7YSZ TBCs on bond-coated superalloy substrates will be fabricated and characterized. Then the mechanical and thermal properties of the new TBCs will be measured. After, the high-temperature interactions between lignite coal fly ash and the new TBCs at high temperatures (isothermal conditions) will be investigated. This will be followed by an investigation into the thermal cycling behavior of new TBCs under thermal gradient conditions with spray of lignite coal fly ash and water. The thermo-chemomechanical failure and durability of the new TBCs tested under those conditions will then be modeled. Finally, the technology pertaining to the new TBCs with optimized compositions and microstructures will be transferred to original equipment manufacturers for further development and possible utilization in next generation gas-turbine engines fueled by coal-derived syngas.

Project Benefits

This project will develop (TBCs) for next generation gas turbine engines fueled by coal-derived syngas. These developments can lead to improved durability and reliability, reduced maintenance, fuel flexibility, and lower cost of gas-turbine engines. Overall, improvement to high-temperature advanced-materials will promote the development of advanced power plant designs that can operate at higher temperatures and in the presence of impurities such as coal fly ash, leading to improvements in efficiency and operational flexibility, and resulting in lower capital and operating costs.

Presentations, Papers, and Publications

Contact Information

Federal Project Manager Jason Hissam:
Technology Manager Robert Romanosky:
Principal Investigator Nitin Padture: