Grant: Discovery Grants Program - Individual

The aerospace industry's ambitious goal of achieving net-zero emissions by 2050 necessitates revolutionary advancements in gas turbine engines. A critical challenge in this endeavor is the demand for materials that can endure extreme conditions, particularly temperatures exceeding 1600°C. However, existing high-temperature materials face substantial limitations in critical tribological interfaces such as dynamic and static seals, bearings, gears, and blade root interfaces. Thermal softening and mechanical properties loss are significant concerns under these demanding operational conditions. As gas turbine engines push for enhanced efficiency and reduced fuel consumption, the need for materials capable of withstanding larger temperature ranges and increased contact pressures has intensified. Metallic materials develop third-bodies (materials generated from the two first bodies) when subjected to tribological loading. While third-bodies are crucial for reducing friction and wear, their effectiveness is determined by factors such as microstructure, mechanical properties, and adhesion to the subsurface. Recognizing these challenges, the proposed research program focuses on harnessing the potential of refractory multi-principal element alloys (R-MPEAs) to design advanced materials with superior strength-ductility balance and wear resistance. Through a combination of state-of-the-art machine learning models, interdisciplinary high-throughput manufacturing and screening techniques, and tribological analyses, the proposed research will lead to transformative solutions in aerospace tribological materials. The program's overarching objective includes innovative methodologies for designing, developing, and characterizing R-MPEA coatings. These coatings, fabricated using advanced techniques, are expected to withstand elevated temperature and high contact pressure tribological loading. Furthermore, the program explores the synthesis of oxygen-doped R-MPEA thin films, simulating tribo-oxidation and the formation of wear-resistant tribofilms. Tribology analysis forms a crucial aspect, where wear tests and mapping wear mechanisms will provide valuable insights into the microstructural and mechanical behavior of these advanced materials. The outcomes of this program have the potential to increase gas engine efficiency, lower operational costs, and reduce carbon emissions in industries reliant on gas turbine engines, such as aviation, power generation, and marine operations. The impact of the proposed research program extends beyond the domain of gas turbine engines. It can potentially revolutionize materials research, offering innovative solutions for various applications. By combining cutting-edge technologies with an interdisciplinary approach, the program aims to contribute to developing a highly skilled workforce capable of addressing future challenges in advanced materials and industrial applications.