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Design and development of smart coatings for Aerospace applications

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Advanced gas turbine engines necessitate the innovation of newer materials with enhanced properties for obtaining ever-greater efficiency. The newer materials facilitate to use the turbine engines at higher operating temperatures, as the efficiency is proportional to it. Increased temperatures lead to high temperature corrosion (HTC) problems like oxidation, type I and II hot corrosion. HTC is highly detrimental and catastrophic failures are imminent if appropriate coatings are not chosen.

This demand can be satisfied only by using smart coatings, which can provide total protection to the construction materials by forming appropriate protective oxide scales depending on the temperatures experienced during service conditions. The project aims at designing and developing such smart coatings by using multiple surface engineering techniques in conjunction with optimised coatings compositions in an appropriate / well ordered manner to effectively combat oxidation, type I and II hot corrosion by creating a more stable oxide scale at a wide temperature range for gas turbine engines.

These coatings are planned to prepare by using several surface engineering techniques like electrochemical, PVD, EB-PVD, sputtering, HVOF, chromizing, pack cementation etc, with varying coating compositions, thicknesses at different coating conditions followed by suitable treatments thereby micro structures and optimise them. Characterization of coated specimens (both singular and multiple coatings) by various characterisation technique s like XRD, OP, SEM, EDX, AFM, STM, SIMS and XPS before and after high temperature corrosion studies. This development helps not only in achieving ever-greater efficiency of advanced gas turbine engines but also avoids failures during service.

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FP6-2004-MOBILITY-7
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