Grant: Alliance Grants

Ceramic matrix composites (CMCs) offer a promising alternative to superalloys for the hot-section components of gas turbines due to their lighter weight and superior heat tolerance. To protect these components from the challenging operational conditions of gas turbines such as water vapor exposure, CMAS attack and corrosive atmospheres, environmental barrier coatings (EBCs) are applied using thermal spray processes. Enhancing the performance of EBCs requires achieving high levels of crystallinity, dense, crack-free microstructures, near-stoichiometric phase compositions, and controlled secondary phase formation. Optimizing the Atmospheric Plasma Spray (APS) process is essential for producing superior EBCs with the desired structural integrity and performance. Understanding the mechanisms behind the microstructural evolutions, crystallization, phase formation, and silicon evaporation, and their impact on the final coating properties, is crucial. In this project, a comprehensive process map coupled with CFD models and machine learning tools will be used to establish the relationship between process parameters and the microstructure and properties of EBCs. The primary aim of this project is to advance the development of enhanced EBCs capable of operating at elevated temperatures, thereby improving gas turbine efficiency, reducing fuel consumption, and mitigating greenhouse gas emissions. This endeavour contributes to broader efforts aimed at reducing Canada's carbon footprint and environmental impact.