SBIR-STTR Award

In this Phase I effort, new advanced multifunctional thin-layered erosion-resistant (ERC) systems and process technologies will be developed. The goal of the research is to develop innovative and advanced multifunctional damping coating systems in thin layer configurations not only to enhance high damping for prevention of HCF but also to significantly improve resistance to erosion. An additional goal is to further enhance fatigue strength of gas turbine compressor IBRs or blisks in harsh sand ingestion and/or combustion gas environments. The advanced multifunctional erosion-resistant damping coating system consists of a duplex coating system which consists of a top coat, a state-of-the-art multi-layered erosion resistant coating and a bond coat, our damping coating system. The damping bond coating can be seen as a soft core supporting a hard outer surface (ERC). The combination of a hard surface and a soft interior has been greatly valued in modern engineering because it can withstand very high stress and fatigue which thus acts as a damage barrier to prevent crack penetration into the substrate from ERC and to arrest cracks initiated from the substrate.

Benefit:
This Phase I project is expected to enhance the readiness of the Navy and other Armed Forces air fleets as well as significantly reduce the multi-billion dollar annual costs of fatigue preventative maintenance. Potential commercial applications of this project are fan & compressor blades/IBRs in advanced gas turbine engines, bearings, power generation equipments, automotive & offshore structures. Commercialization opportunities will be studied thoroughly throughout the project.

Keywords:
gas turbine engine, gas turbine engine, Erosion, blisk, Blades, IBR, coating

The objective of the proposed work is to further develop the erosion-resistant damping coating technology to Technology Readiness Level (TRL) 5 & 6 and to demonstrate TRL 5 & 6 by testing a coated IBR via a bench test and by testing in a relevant environment engine test, respectively. The efforts will be carried out by a team of investigators at Herman Advanced Engineering and several other institutions. The successful completion of the effort will advance this erosion-resistant damping coating and coating process technologies to a position of readiness in entering the service with an effective solution, providing not only significant damping but also significant improvement in resistance to erosion, fatigue, and corrosion for large size blisks/IBRs. The primary goal of the proposed project is to develop new advanced multifunctional thin-layered erosion-resistant damping (ERD) coating systems and process technologies for large size blisks/IBRs. For this, in this project, we are proposing innovative and advanced multifunctional damping coating systems (ERDs) in thin layer configurations (0.001-0.005 in) that include erosion-resistant damping coating to significantly suppress blade vibration and improve interface adhesion as well as to resist surface related degradations of fan and compressor components in harsh sand ingestion and/or combustion gas environments. Emphasis is placed on the development of affordable industrial scale thermal spray and physical vapor deposition methods for IBRs/Blisks.

Benefit:
Other commercial applications of our erosion-resistant damping coating technology are commercial aircraft engines, land-based gas turbines, wind turbines, bearings, implants, power generation equipment, automotive & offshore structures.

Keywords:
erosion-resistant damping coating IBR blisk