Design and Processing of Low-Cost, High-Performance Plasma Sprayed Thermal Barrier Coatings that are Resistant to CMAS Attack Navy STTR FY2012.A Sol No.: Navy STTR FY2012.A Topic No.: N12A-T019 Topic Title: Design and Processing of Low-Cost, High-Performance Plasma Sprayed Thermal Barrier Coatings that are Resistant to CMAS Attack Proposal No.: N12A-019-0008 Firm: ReliaCoat Technologies, LLC Long Island High Technology Incubator 25 Health Sciences Drive Suite 123 Stony Brook, New York 11790-3350 Contact: Travis Wentz Phone: (631) 739-8818 Web Site: www. reliacoat.com Abstract: ReliaCoat Technologies, LLC, a Stony Brook University based spin-off, in conjunction with program partner Prof. Nitin Padture of Brown University and collaborators GE Aviation and Sulzer Metco, proposes to develop innovative and cost effective approaches for design and processing of high performance plasma sprayed TBC coatings that are resistant to CMAS attack. The proposed two-layer TBC architecture consists of a 7YSZ inner layer and an outer layer with a microstructure of 7YSZ matrix with dispersed micro-dispersoids of second phase Al2O3+TiO2 or Y2O3 oxide to mitigate CMAS attack while maintaining the desirable attributes of t' YSZ composition including low conductivity, high toughness, erosion resistance, foreign object damage resistance and excellent stability with the thermally grown oxide. The core idea is that the arrest of CMAS penetration will occur in the outer layer via precipitation of crystalline phases of anorthite and/or apatite. Through the multiphase SBIR program, the team will demonstrate both laboratory and manufacturing production-capable multi-composition new TBC powder along with the process and coating optimization via Integrated Computational Materials Engineering process-property modeling. Benefits: TBCs are considered to be extremely important to the future of the advanced gas turbine engines. As such the aviation and power generation markets are significant beneficiary of plasma spray technology. Almost 2 million pounds of YSZ materials was thermal-sprayed around the world for both OEM and overhaul applications in aviation and power generation turbines. The current market for TBCs is approximately $200 million annually. As temperature of engines increase, so does the requirement to improve coatings, both from performance and reliability. Research on both aspects is critical to sustained implementation of this advanced technology. The anticipated benefit to the aviation industry, to thermal spray industry (end users, supply chain and research institutions) is significant. Spill-over effects into other segments of TS applications can also be extensive. Return