Integrated Gasification Combined Cycle (IGCC) approaches to coal gasification require high temperature filters for removal of particulates directly after the primary reaction step. These filters must have high flexure strength during reverse flow cleaning. Ceramic coatings for the fibers promise to improve the strength and corrosion resistance of filter fibers. The planned work is to develop high performance ceramic coatings based on flake particles. The flakes adhere to the surface of fibers and sheets to provide mechanical and chemical protection. These ceramic flakes are made in a vacuum-plasma process, using a wide range of materials. Release coatings allow very thin films of ceramics to be collected and separated into bulk particles with a flat aspect ratio. Preliminary studies using microflakes on fiberglass weaves have shown promising results. It is projected that the current coating will extend the temperature and corrosion resistance of ceramic fiber filters by providing a chemical and antifriction layer that is strong and adherent. Anticipated Results/Potential Commercial Applications as described by the awarder: Potential applications include high temperature corrosion barriers for furnaces, flues, filters, and engines. Because the flakes can have hardness approaching diamond, antiabrasion coatings can be developed. Finally, the tailorability of electrical and optical properties will allow specialty coatings such as conductive inks and transparent conductive coatings that can be applied like a paint.
