SBIR-STTR Award

AlphaSTAR Corporation proposes to enhance the ICME (Integrated Computational Material Engineering) and lifing model in support of the Design Framework for Optimized Multifunctional Coatings for high temperature thermal/environmental Barrier Coatings (TBC/EBC)) with extended durability/reliability and life.A multiphysics-based multi-objective topology optimization methodology, and virtual design of experiment (DOE), random sampling methodology will be developed to design multifunctional materials including high temperature special technology coatings for use in engine/aircraft high temperature exhaust regions.The innovation centers around:1) Material Modeling of Coating and Substrate, predicting material performance (strength, stiffness, conductivity) Vs. temperature considering the effect of defects; 2) Structural Analysis and Durability and Damage Tolerance, predicting coating and substrate failure type such as spallation, oxidation/corrosion during thermo-mechanical in-service loading; 3) Thermal Modeling (Zero Order Model), predicting material thermal history profile, voids and densities for each layer of the TBC during coating process for Plasma Spraying and Electron Beam-Physical Vapor Deposition (EB-PVD) ;and 4) Single or Multiple Objective Topology Optimizations to maximize durability, minimize residual stress, and enhance coating life.Verification, validation and accreditation will be performed using existing test data and planned rig testing of TBC/EBC coating systems on metallic and ceramic materials.Coating Design Frame work,Thermal/Environmental Barrier Coating (TBC/EBC),ICME computational models,Effect of defects,Multi-Physics Progressive Damage Analysis durability/reliability,Thermal history profile,topology optimization,Extended life/Retir

In Phase I, AlphaSTAR developed and partially validated an Integrated Computational Material Engineering (ICME): (i) APS Manufacturing Process, (ii) a DOE optimization capability that minimizes thermal conductivity(TC) and residual stress (RS) of metal/TBC thermal protection systems; and (iii) an ICME D&DT tool predicting damage and fracture evolutions that addressed TMF and RUL considering recession, oxidation, thermal growth oxidation (TGO), and debonding. In Phase II, AlphaSTAR will extend the ICME technology to ceramic/EBC including: (1) APS process development with (i) rumpling, (ii) thermodynamic CMAS reactions and (iii) and optimization of TC and RS and (2) D&DT optimization for extended RUL. Objective is to (1) optimize and extend exhaust nozzle remaining useful life (RUL) by maximizing manufacturing Air Plasma Spraying (APS) of environmental/thermal barrier coating (EBC/TBC) material systems; (2) optimize material performance within the substrate, bond/intermediate/top coat; and (3) perform Durability and Damage Tolerance (D&DT) analysis and optimization under thermal mechanical fatigue (TMF) in-service loading. Software will be extensively test validated for Ceramic/EBC and Metal/TBC systems: (a) RS using in-situ-coating properties sensor measurement; (b) Rig testing; TGO measurement, CMAS reactions, and TMF testing. Software will be made available to industry with training, tutorials, baseline/optimized models supported by validated results and material database.