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Environmental barrier coatings

 

Uniform 1micron thick protective mullite coating on a 15 micron . diameter SiC fiber.

SEM micrograph of a 10 micron thick CVD environmental barrier coating on SiC.


Silicon-based ceramics such as silicon carbide and silicon nitride are found in microturbines, used in on-site power generation systems. These ceramics can withstand higher operating temperatures than the conventional superalloys, leading to improved efficiency and environmentally cleaner byproducts. However, when exposed to corrosive environments containing high-pressure steam at elevated temperatures, these silicon-based ceramics are susceptible to hot-corrosion and recession. We are currently developing functionally graded chemically vapor deposited mullite environmental barrier coatings with excellent corrosion, recession and thermal shock resistance. These environmental barrier coatings are expected to substantially improve the service lifetimes of these silicon-based ceramic components.

 

Collaborators

V. K. Sarin, Boston University

 

Papers
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S.N. Basu and V.K. Sarin, "Functionally Graded CVD Mullite Coatings", accepted for publication in Materials Research Society Symposium Proceedings, 2002.

P. Hou, S.N. Basu and V.K. Sarin, "Structure and High Temperature Stability of Compositionally Graded CVD Mullite Coatings" International Journal of Refractory Metals and Hard Materials, 19 (4-6), 467 (2001).

S.N. Basu and V.K. Sarin , "Development Of CVD Mullite Coatings", Proceedings of the Fifteenth International Conference on Chemical Vapor Deposition, M. D. Allendorf and M. L. Hitchman eds., The Electrochemical Society Proceedings Series 2000-13, (2000), p 308.

Ping Hou, S. N. Basu and V. K. Sarin, "Nucleation Mechanisms in Chemically Vapor-Deposited Mullite Coatings on SiC", J. Materials Research 14 (7), 2952 (1999).

S. N. Basu, P. Hou and V. K. Sarin, "Formation of Mullite Coatings on Silicon Based Ceramics by Chemical Vapor Deposition", Journal of Refractory Metals and Hard Materials, 16 (4-6), 343 (1998).

D. Doppalapudi and S. N. Basu, "Structure of Mullite Coatings Grown by Chemical Vapor Deposition", Materials Science and Engineering, A231, 48 (1997).

D. Doppalapudi, S. N. Basu and V. K. Sarin, "Structural Evolution of Mullite Coatings on Silicon Based Ceramics", Proceedings of the Thirteenth International Conference on Chemical Vapor Deposition, T. M. Besmann, M. D. Allendorf, McD Robinson and R. K. Ulrich, eds., The Electrochemical Society, pp 664 (1996).

D. Doppalapudi, R. Mulpuri, S. N. Basu and V. K. Sarin, "Phase Transformations in Multilayered CVD Mullite Coatings", Materials Research Society Symposium Proceedings, 363, 95 (1995).

 

Funding

NSF - Growth of Mullite Coatings by Chemical Vapor Deposition (with V.K. Sarin)

DOE - Adherent and Oxidation Resistant Coatings for Ceramic Substrates (with V.K. Sarin).

NSF - Development of Iota-Alumina Coatings (with V.K. Sarin).

NSF - FRG: Functionally Graded High-Al Mullite Environmental Barrier Coatings (with V.K. Sarin and T. Murray)


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