A Novel Erosion Resistant Coating for High-Temperature Composites

High-temperature polymer matrix composite (HTPMC) components for gas turbine engines have significant advantages over the currently used metal components, including weight savings, strength improvements, lower part counts, and reduced manufacturing costs. However, HTPMCs have a critical need for developing an improved metallic bond coat with a highly erosion resistant top coat before they can be widely used. Lynntech, Inc. proposes a novel process to deposit a functionally gradient metal matrix ceramic composite coating on a metallic bond coat followed by a surface modification process to produce a highly erosion resistant crack-free coating. Both coating and surface modification steps are suited for implementation on HTPMC surfaces. In Phase I, appropriate coating compositions will be determined by erosion resistance measurements conducted in an independent laboratory. The erosion test results will be submitted to the engine manufacturer supplying the HTPMCs; optimization work will be done with their consultation. The successful completion of this Phase I study will enable the coating process to be implemented on engine components to be tested by an already identified turbine engine manufacturer during a possible follow-on-Phase II project.