Ultra High Temperature Environmentally Robust Nanocomposite Thermal Barrier Coatings for Nickel Super Alloy IGCC Turbine Components

Integrated gasification combined cycle (IGCC) power plants represent the next generation electrical power source for our nation¿s increasing power needs, while also providing an environmentally responsible process for minimizing pollution from greenhouse gases. IGCC systems offer a more efficient process for extracting the thermal energy from coal and are much less expensive than natural gas power plants. However, IGCC systems have yet to reach the 50 % efficiency target, due to current limitations of the high-temperature structural materials integral to their operation. In particular, the inlet temperature of current gas turbines needs to be raised beyond 1500oC for improved efficiency; yet, current gas turbine components lack extended operational durability under these conditions. This project will develop innovative ultra-high-temperature (> 1500oC) nanocomposite thermal barrier coatings for the nickel superalloy components within advanced IGCC turbine systems. Compared to competing line-of-sight vacuum-deposited high-temperature protective coatings, the new coatings will be amenable to spray deposition under ambient conditions. Commercial Applications and other Benefits as described by the awardee: The new thermal barrier coatings should enable IGCC power plant efficiency gains beyond 50% and extended turbine component lifetimes within the harsh thermal environments. Potential public benefits would include a cleaner, more abundant energy supply through the proliferation of more efficient, lower cost IGCC power plants, and a reduction in greenhouse gas pollution