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Self-Healing Thermal Barrier Coatings

Self-Healing Thermal Barrier Coatings

This project deals with the creation of a new, unique self-healing thermal barrier coating (TBC) for turbines and other thermally loaded structures in order to realize a significant extension of the lifetime of critical high-temperature components.

As the current TBCs do not exhibit any self-repair, the new self-healing TBC will offer a reduction of the number of TBC replacements during an engine lifetime and enhance the reliability of the critical components. Ceramic thermal barrier coatings are applied on the most critical parts of engines, because it enhances the engine efficiency by allowing higher operation temperatures, which saves fuel and thus reduces CO2 emissions.

Furthermore, it protects the high-tech structural components against severe high-temperature corrosion and consequently extends the lifetime of these components.

The primary goal of this project is to realize and optimize the self-healing capacity of thermal barrier coatings for application in aero engines and industrial gas turbine engines to prolong the lifetime of their components. This will be achieved through a combined theoretical, experimental and modelling approach of a new, innovative self-healing concept. The prospective self-healing concept developed in the frame of this project can be exploited to other high temperature structural ceramics as well. The approach as formulated in this proposal has the potential to initiate a new school to design durable high temperature ceramic systems.

The project is structured around six interrelated work packages, each with clearly defined tasks and deliverables: WP1 deals with co-ordination and project management; WP2 pertains to the concept and design of a self-healing TBC; WP3 is focused on the manufacturing of the TBC systems; WP4 is dedicated to the assessment of the TBC lifetime improvement and associated failure analysis; WP5 concerns the characterization of the microstructure and properties including damage and healing assessment; and finally WP6 addresses the dissemination and exploitation of all results of this project. The project as a whole will span the technology readiness levels (TRLs).

The consortium to carry out this project consists of leading European academic and industrial parties in the field of thermal barrier coating design, manufacturing, characterization and lifetime assessment as well as end-users.