America's Phenix, Inc. (AP), MDS-PRAD Technologies Corporation (MPT) and Penn State Universitys Applied Research Laboratory (PSU-ARL) propose developing high-temperature coating systems for gas turbine engine blades and vanes. The coating composition will consist of an MPT developed base coating in combination with the PSU-ARL developed thermal barrier coating in order to sustain operation in the high temperature environment experienced by turbine blades and vanes. The application of the coating system offers the following advantages: - Adaptable process using one coating system;- Consistent and predictable application with 95 to 100 % success rate;- Low process cost;- Low coating cost with 100% utilization of raw materials;- Application on various manufactured parts;- Application on various types of cobalt and nickel based heat-resistive alloys;- Smooth coating surface;- Part life of 20, 000 to 30, 000 hours in typical industrial engines;- Part life of 8, 000 to 10, 000 hours in typical aircraft turbine engines;- Part service life increases between 200 to 400 % depending on operating conditions;- Increase engine performance (increased thrust and decreased fuel consumption) due to lower cooling airflow required;- Blade and coating can be repaired; and - Ecologically-friendly with minimum waste of materials and no use of harmful materials or chemicals
