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Agency: European Commission | Branch: FP7 | Program: CP-IP | Phase: NMP-2007-2.5-1 | Award Amount: 6.89M | Year: 2008

The overall objective of the project is to develop a novel, unconventional and cost efficient type of multipurpose high temperature coating systems on the basis of property tailoring by particle size processing of metallic source materials. It shall possess multi-functionality that will comprise thermal barrier effect, oxidation and corrosion protection, lotus effect, electrical insulation at elevated temperatures and fire protection. The concept of the novel approach to protection of surfaces is a coating consisting in its initial state of nano- and/or micro-scaled metal particles with a defined size, deposited by spraying, brushing, dipping or sol-gel. During the heat treatment, the binder is expelled, bonding to the substrate surface achieved, the metallic particles sinter and oxidise completely resulting in hollow oxide spheres that form a quasi-foam structure. Simultaneously, a diffusion layer is formed below the coating serving as a corrosion protection layer and as a bond coat for the top layer. The structure of the coating system shall be adjusted by parameters like selection of source metal/alloy, particle size, substrate, binder and a defined heat treatment. For fire protection the formation of hollow oxide spheres will be processed in a separate step before deposition. The flexibility of the new coatings integrates a wide field of application areas, such as gas and steam turbines in electric power generation and aero-engines, combustion chambers, boilers, steam generators and super-heaters, waste incineration, fire protection of composite materials in construction as well as reactors in chemical and petrochemical industry. A broad impact will thus be ensured increasing safety and the durability of components by an economic, multifunctional and flexible protection of their surfaces. The novelty will provide a real step change in the understanding of materials degradation mechanisms in extreme environments.

Agency: European Commission | Branch: FP7 | Program: CP-FP | Phase: FoF.NMP.2013-10 | Award Amount: 4.22M | Year: 2013

The main objective of this project is to develop a radically new manufacturing industrial green process based on the electrodeposition of aluminium from ionic liquids and post-processed the aluminium pure coating to obtain high-tech engineered metallic materials for the automotive and aeronautic sectors. This new process will replace conventional harmful techniques and will be more energy and material efficient. For achieving this goal, all barriers that difficult the industrialization of electrodeposition processes based on ionic liquid formulations will be overcome. SCAIL-UP project will seek for overcoming the barriers found in the upscaling of the process for electrodepositing Al with Ionic Liquids by the development of a radically new manufacturing industrial process for the automotive and aeronautic sectors. Thus the SCAIL-UP consortium will work on the design, development and validation of an industrial scale pilot plant that will be able to electroplate Al on current 3D polymeric (ABS) and metal (nickel alloys) industrial parts using Ionic Liquids.

Agency: European Commission | Branch: FP7 | Program: JTI-CP-FCH | Phase: SP1-JTI-FCH.2010.3.1;SP1-JTI-FCH.2010.3.2 | Award Amount: 4.73M | Year: 2012

Lightweight SOFC stacks are currently being developed for stationary applications such as residential CHP units, for automotive applications such as APU and for portable devices. They supply electrical efficiencies of up to 60%, a high fuel flexibility, being able to operate on syn-gas from Diesel reforming as well as LPG, methane or hydrogen, and promising costs due to greatly reduced amounts of steel interconnect material. The project proposal addresses a novel design solution for lightweight SOFC stacks that decouples the thermal stresses within the stack and at the same time allows optimal sealing and contacting. In this way the capability for thermal cycling is enhanced and degradation of contacting reduced. Performance is increased since the force needed for secure contacting is now independent of the force required to secure gas tightness of the sealing joints. The design is highly suitable for industrial manufacturing and automated assembly. The industrial partners will build up the necessary tools and appliances for low cost production of repeating units and the automated quality control, stacking and assembly of stacks. In mobile and portable applications the requirements for thermal cycling are high. It is therefore essential that lightweight stacks have excellent thermal cycling and rapid start-up capabilities. The stack design supplies a compensation of thermo-mechanical stresses between cell and cell frame / repeating unit. Thin steel sheets with protective coating are used for the sake of cost reduction and sufficient stack lifetime, also for stationary applications. The latter will also benefit from improved start-up times, since this allows a more flexible and load-oriented operation.

Agency: European Commission | Branch: FP7 | Program: CP-SICA | Phase: NMP.2012.2.2-3 | Award Amount: 4.62M | Year: 2013

The overall objective is the development of new coatings for supercritical steam power plants for efficient and clean coal utilization. A significant reduction of emissions is expected by increasing efficiencies to > 50%. Currently, an efficiencies of 45% have been achieved in the last 30 years from subcritical 180 bar/540C to ultra-supercritical 300 bar/600-620C corresponding to a specific reduction of 20% of CO2 emissions. Efficiencies of 50% and more can be achieved by further raising the temperature, but conventional ferritic steels are not sufficiently oxidation resistant, since the temperature designed for operation was 550 C. From the mechanical properties perspective, ferritic steels can be used at temperatures up to 650 C and for higher temperatures austenic steels and Ni base alloys are being considered. One of the main objectives of this project is therefore to develop advanced coatings for steam environments which can resist the chemical attack of steam and fireside corrosion at temperatures higher than 620C employing materials with the required high temperature mechanical properties in particular creep strength. Ferriticmartensitic steels will be considered as substrate materials for up to 650 C whereas, austenitic steels will be explored for higher temperatures. In general higher temperatures mean higher oxidation rates, in particular when the oxidant is water vapour instead of oxygen. The introduction of carbon capture and sequestration (CCS) technologies also aiming to reduce emissions in power generation has also increased the interest in developing new material solutions able to reduce the economical and environmental penalty associated to energy production systems when CO2 is generated. For instance oxy-fuel combustion takes place in a N2 free atmosphere so oxygen is burned in near stoichiometric conditions with the fuel (pulverized carbon) producing and exhaust gases mainly composed of CO2 and H2O.

Fossati A.,Consortium for Science and Technology of Materials | DiFerdinando M.,Consortium for Science and Technology of Materials | Bardi U.,Consortium for Science and Technology of Materials | Scrivani A.,Turbocoating | Giolli C.,Turbocoating
Journal of Thermal Spray Technology | Year: 2012

CoNiCrAlY coatings were produced by means of the vacuum plasma spraying (VPS) process onto CMSX-4 single crystal nickel superalloy disk substrates. As-sprayed samples were annealed at high temperatures in low vacuum. Three kinds of finishing processes were carried out, producing three types of samples: as-sprayed, mechanically smoothed by grinding, ground and PVD coated by using aluminum targets in an oxygen atmosphere. Samples were tested under isothermal conditions, in air, at 1000 °C, and up to 5000 h. Morphological, microstructural and compositional analyses were performed on the coated samples in order to assess the high temperature oxidation behavior provided by the three different surface finishing processes. Several differences were observed: grinding operations decrease the oxidation resistance, whereas the PVD process can increase the performances over longer time with respect of the as-sprayed samples. © ASM International.

Agency: European Commission | Branch: FP7 | Program: JTI-CP-FCH | Phase: SP1-JTI-FCH.2012.3.4 | Award Amount: 3.66M | Year: 2013

The economic viability and market place entry of SOFC power systems is directly dependent on their longevity and production costs. Adequate operational life spans can only be achieved, if the performance degradation of the SOFC stacks and Balance of Plant components over time can be considerably reduced. At the same time, manufacturing costs have to be lowered dramatically for the specifically necessary components securing the long component service life. As of now, chromium deactivation of the cathode is considered one of the major contributions to the degradation of SOFC stacks. Since chromium steels, on the other hand, are an essential material in reducing stack costs, methods have to be found to make best use of their advantages whilst avoiding chromium transport to the cathode. Balance of Plant components upstream of the cathode also contribute to the chromium immission, a fact that is often overseen and requires protective coatings also for any components situated in the air flow pathway to the cathode. Finally, the build-up of oxide scales will influence the electrical resistance and contact resistance thus requiring coatings for the stabilisation of the contacts on both cathode and anode side of the SOFC cell. Within the project Real-SOFC first steps have been made towards developing suitable combinations of steels and coatings. It has become apparent that any steel will require a coating in order to sufficiently reduce chromium evaporation and oxide layer build-up, and also sustain a low surface resistivity. More recently, a variety of new coating techniques have been reported that require further evaluation under SOFC relevant operating conditions. The project proposed here aims to further elaborate on the production of coated steel components showing markedly improved properties with regard to chromium release, electrical resistivity and scale growth. The focus of ScoReD 2:0 will be on choosing optimised combinations of protective layer materials with different steel qualities (including low-cost options) and analysing the influence, practicality and cost of different methods of coating. Also in understanding which factors influence the efficacy of such coatings.

A method for removing ceramic coatings using a special equipment without modifying the characteristics of the substrate such as roughness and thickness and able to prepare the substrate to be recoated with a new ceramic layer, is provided. The removing of the ceramic coating without damaging the substrate characteristics is obtained by a combination of coating/substrate pre-heating by irradiation during or immediately before the stripping and improved solid CO_(2 )blasting equipment and parameters.

Turbocoating | Date: 2014-06-10

Machines and installations for processing materials, in particular metalworking machines for special processes and production of protective coatings for components used in industrial gas turbines and engines for aircraft and other industrial sectors. Treatment of metal, treatment of ceramics and polymers, in particular spraying, and surface application treatment of components used in industrial gas turbines and engines for aircraft and other industrial sectors.

Turbocoating | Date: 2012-09-11

Material processing installations, namely, machine for special processes in the nature of spraying and applying surface treatments and coatings on component parts and manufacturing protective coatings for components used in industrial gas turbines and aero engines. Treatment of materials, namely, heat treatment and coating of components used in industrial gas turbines and aero engines; metal treatment; treatment of metal; all the foregoing excluding metal refining services.

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