Computational design of erosion-resistant, damage-tolerant, galvanically compatible coatings for compressor airfoil leading edges in gas turbine engines Navy SBIR FY2012.1 Sol No.: Navy SBIR FY2012.1 Topic No.: N121-039 Topic Title: Computational design of erosion-resistant, damage-tolerant, galvanically compatible coatings for compressor airfoil leading edges in gas turbine engines Proposal No.: N121-039-0339 Firm: QuesTek Innovations LLC 1820 Ridge Avenue Evanston, Illinois 60201-3621 Contact: Abhijeet Misra Phone: (847) 425-8233 Web Site: www.questek.com Abstract: Turbo-shaft engines operating in desert environments are continuously exposed to erosive media, such as sand particles. This environment leads to compressor airfoil erosion resulting in significant performance loss of the engine, reducing fleet readiness and increasing maintenance costs. Additionally, high-energy particle impact can introduce significant foreign-object damage (FOD) leading to airfoil deformation. Under the proposed SBIR program, QuesTek Innovations LLC, a leader in the field of materials design, in collaboration with Directed Vapor Technologies International (DVTI), proposes to develop novel erosion-resistant, damage-tolerant, and galvanically-compatible coatings for compressor airfoils in turbine engines. QuesTek will lead the SBIR program and will utilize its well established and successful Materials by Designr methodology to design novel functionally-graded hierarchical coating architectures specific to the airfoil substrate material. Multiple strategies capable of achieving the desired combination of erosion resistance, impact damage tolerance and galvanic compatibility with the underlying substrate will be considered in this Phase I program. DVTI will use its proprietary directed vapor deposition (DVD) technique to apply these coatings on compressor airfoils. In the program QuesTek will partner with a leading OEM to define the material requirement matrix, processing requirements, and ultimately lead implementation of new coated airfoils into fielded systems. Benefits: Erosion and FOD-resistant coatings on compressor airfoils will reduce airfoil erosion and deformation thereby reducing engine maintenance costs, while improving fleet readiness and increasing aircraft time on wing (TOW). Improved engine durability will also prolong system life, thereby reducing overall system life-cycle costs. Coatings that are more galvanically compatible will enable compressor airfoils to endure the corrosive environments encountered by carrier-based aircraft. Additionally, current coating solutions being evaluated by NAVAIR are produced through a foreign collaboration, which raises ITAR concerns, whereas the proposed program will enable the development of a domestic technology. Beyond aerospace markets, secondary market applications for improved compressor airfoil coatings may include industrial gas turbines, where the erosion coatings can provide numerous benefits to the industry, including (a) reduced carbon emissions due to higher compressor efficiencies, (b) increased engine power, and (c) increased productivity due to extended engine lifetimes. Return