Development of HEA Bond Coat Compositions for Thermal Barrier Coating Systems

Period of Performance: 01/01/2015 - 12/31/2015


Phase 1 STTR

Recipient Firm

UES Services Inc.
4401 Dayton-Xenia Road Array
Dayton, OH 45432
Firm POC
Principal Investigator

Research Institution

Pennsylvania State University
110 Technology Center Building
University Park, PA 16802
Institution POC


The drive toward higher High-entropy alloys (HEAs) have potential to be used as high temperature materials and in coating material applications due to their combination of strength, ductility, thermal stability, corrosion and wear resistance. We propose to develop new and improved bond coats using selected HEAs. Both cathodic arc evaporation and plasma spray will be used for coating deposition. WHAT IS TO BE DONE IN PHASE I In Phase I, we will initially explore cathodic arc evaporation of a few compositions selected from the design approach introduced by a co-investigator of this proposal. This will be a cost-effective process to quickly evaluate a few compositions. One composition will be down-selected from this initial screening for plasma spray deposition in Phase I. In Phase II, plasma spray technologies will be utilized extensively to deposit selected HEA coatings for field applications. COMMERCIAL APPLICATIONS AND OTHER BENEFITS Thermal barrier coatings (TBCs) applied to the surfaces of metallic parts in the hottest part of gas-turbine engines enable modern engines to operate at significantly higher gas temperatures, and therefore, at higher efficiencies than their predecessors. Gas turbine engines are a $42 billion industry worldwide (2010) with 65% of the sales accounting for jet engines and the remainder land-based engines for electricity generation. The latter fueled by natural gas or liquid fuels produce ~25% of all electricity in the U.S. and ~20% worldwide (2010). An increase in the engine efficiency will also decrease air pollution, especially with carbon dioxide, per 1 kW of produced energy, which is critical for regulating global warming.