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Dayton, OH, United States

Agency: Department of Defense | Branch: Air Force | Program: SBIR | Phase: Phase II | Award Amount: 412.74K | Year: 2016

ABSTRACT: This Phase II SBIR program involves a novel process to produce new hybrid ultra-high temperature (UHTC) ceramic composites that can survive hypersonic flight conditions. The new process will produce a very unique grain and graded microstructure that can offer high strength (> 100 kpsi), high fracture toughness (> 10 MPam), high thermal shock resistance, and high oxidation resistance over 2000oC. Thus, the new hybrid composites can serve as leading edges for hypersonic applications. Spark plasma sintering or hot-pressing will be used as a means for densification. In addition, near-net shape fabrication will be explored to produce sharp leading edges during the Phase II program.; BENEFIT: The successful completion of the Phase II program will provide the foundation needed to produce oxidation and thermal shock resistant UHTCs. Examples of primary applications are leading edges for hypersonic vehicles, as well as solid rocket motors (SRM) for various DoD applications including all rocket nozzles, and other ground-based missile interceptors.

Agency: Department of Energy | Branch: | Program: STTR | Phase: Phase II | Award Amount: 846.11K | Year: 2014

Gas turbine engines utilized in electric power production and aircraft propulsion need to operate at higher temperatures for enhanced efficiency and lower emissions. Development of the proposed thermal barrier coating technology with unique architectural design will enable the operation of turbine engines at higher operating temperature.

Agency: Department of Defense | Branch: Navy | Program: SBIR | Phase: Phase II | Award Amount: 750.00K | Year: 2014

Particle impacts cause erosion of leading edges of the compressor airfoils as well as the side or surface of the airfoil beyond the leading edge. Although erosion resistant coatings have been developed and applied on the airfoils during the past decade or two and that have protected the side or surface of the airfoil quite satisfactorily, the erosion of the leading edge (LE) is still a serious issue. The objective of this project is to develop an advanced, robust solution that improves the durability of the LEs of a compressor's airfoils while incurring minimal to no impact on the original performance of the airfoils. In Phase I, UES has demonstrated the feasibility of building up an impact resistant leading edge with higher yield strength and harder material than the substrate airfoil. In Phase II, UES and the team will optimize the process and assess the performance of the LE-modified airfoils using a series of standard verification tests in a field-representative environment.

Agency: Department of Energy | Branch: | Program: STTR | Phase: Phase I | Award Amount: 225.00K | Year: 2015

Corrosion induced degradation of material components in the harsh environment of light water reactor can impact reactor reliability, availability, safe operation and eventually life. A possible remedy could be to replace the replaceable components at appropriate moments which may not be economically favorable. Thus there is a need to develop technologies to repair degraded materials. STATEMENT OF HOW THIS PROBLEM IS BEING ADDRESSED Corrosion resistant weld overlays are currently being used to improve the service life of material components made with corrosion prone material. However, the welding technology has serious issues such as dilution and susceptibility to cracking. In this program a novel technology will be developed that will not have the issues associated with the currently utilized welding process. WHAT IS TO BE DONE IN PHASE I In this Phase I STTR work samples appropriate for testing in light water reactor environment will be fabricated and treated with the proposed technology. The relevant performance of the as- treated samples will be evaluated in light water reactor environment. Based on the performance data the feasibility of the proposed technology will be demonstrated. COMMERCIAL APPLICATIONS AND OTHER BENEFITS Given limits on new nuclear reactor builds imposed by economics and industrial capacity, the extended service of the existing fleet will be essential. The proposed technical approach to increase the life of the existing nuclear reactors consists of the repair of the degraded materials. This approach is expected to minimize the new builds with concomitant economic benefit. The proposed technology can be easily utilized in many other non-nuclear commercial applications involving restoration of metallic components having corrosion related damage. KEY WORDS Light water reactor, Stainless steel, Ni base alloys, Stress corrosion cracking, Repair, Welding SUMMARY FOR MEMBERS OF CONGRESS The life of nuclear reactor can be seriously impacted by the degradation of material components in the harsh environment of reactor. The proposed technology is expected to extend the service life of the existing nuclear reactor fleet through damage repair/mitigation of reactors metallic components.

Agency: Department of Energy | Branch: | Program: STTR | Phase: Phase II | Award Amount: 849.93K | Year: 2015

For advanced gas turbines where turbine inlet temperature reaches 2650F and beyond, the current state-of-the-art thermal barrier coating (TBC) systems are not adequate to provide the needed protection for the metallic components of the turbine engine. Thus there is a need to develop new chemistries for TBC systems, consisting of bond coat and top coat, with enhanced durability. We propose to modify the coating chemistry of high temperature top coat material to impart higher toughness needed for high temperature durability. We also propose to develop highly durable bond coat chemistry. The Phase I approach consists of the feasibility demonstration of the developed coating chemistries whereas the phase II approach involves optimization of the bond coat and top coat chemistries in relation to their relevant properties. In the Phase I work, appropriate top and bond coat materials were selected and appropriately processed to render their chemistry suitable for high temperature applications. The processed top and bond coats were characterized to show that they have the desired characteristics that were lacking for application at higher temperature with enhanced durability. In the Phase II work, the top and bond coat chemistries will be further optimized to impart optimal desired characteristics. Also in Phase II, approaches will be developed to manufacture optimal top coat material on a commercial scale. Complete TBC systems with optimal top and bond coat will be manufactured and characterized to demonstrate their relevant characteristics needed for high temperature applications. Commercial Applications and Other Benefits: The TBC systems developed in this program will have application in turbine engines utilized in electric power production, propelling aircraft, pumping fluids etc. Successful completion of the project will enable gas turbine engines to operate at elevated temperatures with higher efficiency (lower cost), lower emission (less environmental pollution) and increased reliability and performance.

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