In a significant advancement for the construction and aerospace industries, researchers have unveiled a method for producing thermal barrier coatings that promises to enhance the efficiency and performance of gas turbines. The study, led by Gennady V. Kachalin from the National Research University “Moscow Power Engineering Institute” in Moscow, highlights the potential of magnetron sputtering systems equipped with uncooled extended targets to revolutionize the production of these vital coatings.
Thermal barrier coatings, particularly those based on zirconium oxide doped with rare earth metal oxides, are crucial in protecting turbine components from extreme temperatures and corrosive environments. Kachalin and his team have developed a novel approach that not only increases the deposition rate of these coatings by more than tenfold but also stabilizes the production process, reducing the risks associated with hysteresis phenomena in oxygen partial pressure.
“Our findings show that by utilizing an uncooled target, we can significantly enhance the deposition rate while maintaining quality,” Kachalin stated. “This innovation could lead to more efficient manufacturing processes in the construction of gas turbines, ultimately impacting energy production and operational costs.”
The researchers conducted a series of mass-spectrometric studies to analyze the hysteresis of oxygen partial pressure, revealing that higher temperatures in the sputtering system can effectively narrow the range of operational stability. This is crucial for ensuring consistent coating quality, which has direct implications for the durability and performance of gas turbines in service.
The metallographic analysis presented in the study unveiled a developed porous dendritic structure within the ceramic layer of the thermal barrier coatings. This structure is essential for minimizing thermal conductivity, thereby enhancing the thermal protection offered to turbine components. As industries increasingly seek to improve energy efficiency and reduce emissions, such advancements in thermal barrier coatings could play a pivotal role.
With the potential for these technologies to be implemented in various industrial applications, the implications for the construction sector are profound. Improved thermal barrier coatings mean longer-lasting components, reduced maintenance costs, and enhanced operational efficiencies for gas turbines that power everything from electric grids to aviation.
As Kachalin pointed out, “The ability to produce these coatings more efficiently not only cuts costs but also supports the broader goals of sustainability in energy production.”
This research was published in ‘Frontier Materials & Technologies’, a journal dedicated to the latest developments in materials science. The findings underscore a promising direction for the future of thermal barrier coatings and their critical role in advancing the construction and energy sectors. For more information about Kachalin’s work and the university’s research initiatives, visit National Research University “Moscow Power Engineering Institute”.
