Applied materials & OAK ridge national labs propose to develop, advance, and validate alloy-coating systems that use highly conformal, low lifecycle cost, and durable coatings that result in materials…

Applied materials & OAK ridge national labs propose to develop, advance, and validate alloy-coating systems that use highly conformal, low lifecycle cost, and durable coatings that result in materials with a unique and superior combination of high temperature mechanical properties and oxidation resistance for use in corrosive, high temperature, harsh environments. The team has demonstrated initial proof-of-concept results that show up to 2X improvement in oxidation resistance at 950C/10% moisture conditions. The team proposes to advance the TRL of these coatings and processes from TRL 2/3 to TRL 4 with lab-based testing under harsh environments using select coating + alloy system of industrial interest for candidate target applications(s) such as high efficiency heat exchangers. Specifically, the team will coat multiple candidate alloys with a range of coating compositions and thicknesses to evaluate oxidation resistance under application-relevant conditions and environments for selected applications. Coated and uncoated alloy samples subjected to harsh conditions will be evaluated for effects of harsh environments on oxidation resistance, mechanical properties such as creep rupture, fatigue, ductility, etc. For performance improvement in operating life and/or enhanced higher operating temperature capability afforded by superior coatings and processes. They propose to demonstrate a greater than 2X improvement in oxidation lifetime for an alloy that is greater than 25% lower in lifecycle cost under an application-relevant high temperature, harsh environment condition. If successful, this work will advance a new and widely applicable method to improve performance and life cycle costs of coated alloys under harsh operating environments with broad application in a wide range of industries.