Manufacturing Efficiency

QuesTek Innovations will apply computational materials design, additive manufacturing (AM), coating technology, and turbine design/manufacturing to develop a comprehensive solution for a next-generation turbine blade alloy and coating system capable of sustained operation at 1300°C.

The demand for lithium, a critical component of lithium-ion batteries, is expected to soar over the coming decades. As favorable sources are depleted, a new source must be tapped: recycling end-of-life lithium-ion batteries. SiTration is developing a new type of filtration membrane that is well suited to selectively extract lithium in the existing battery recycling process flow. Today’s commercial membranes are either incompatible with the harsh chemical environments of battery recycling or not selective enough to extract lithium from a complex solution.

InventWood proposes to develop and manufacture lightweight 3D wood corrugated honeycomb structures to replace metal counterparts. Compared with widely used aluminum, 3D wood has similar mechanical strength, possesses one-third the density and one-fourteenth the cost, and reduces CO2 emissions by 90% in its manufacture.

GE Research has proposed transformational material solutions to potentially enable a gas turbine blade alloy-coating system capable of operating at a turbine inlet temperature of 1800 °C for more than 30,000 hours.

Pennsylvania State University (PSU) will develop an integrated computational and experimental framework for the design and manufacturing of ULtrahigh TEmperature Refractory Alloys (ULTERAs). PSU will generate alloy property data through high-throughput computational and machine learning models; design ULTERAs through a neural network inverse design approach; manufacture the designed alloys utilizing field assisted sintering technology and/or additive manufacturing; and demonstrate the performance through systematic characterization in collaboration with industry.

A turbine engine's combustion environment can rapidly degrade high temperature alloys, which means they must be coated. This coating must be able to expand with the alloy so it adheres during temperature cycling, prevent combustion gases from permeating to the underlying alloy, and possess ultra-low thermal conductivity to protect the alloy from high surface temperatures. The University of Virginia will develop a novel coating for high temperature alloys that enables both a dramatic increase in upper use temperature for turbine engine blades and increased engine efficiency.

Current Ni-based alloys used in turbine blade applications are operating at 1100°C, which is approximately 90% of their melting temperatures. Refractory alloys, such as niobium (Nb) alloys, can withstand higher temperatures.

Thermal barrier coatings (TBCs) on turbine blades are designed to protect the blade from reaching temperatures higher than the operational capability of the base metal. Pacific Northwest National Laboratory aims to develop a new type of TBC that performs dual functions. The coating will act as a barrier to conventional heat transfer and have ability to alter the wavelength of light radiated from the hot turbine blade surface. This normally wasted energy will be absorbed in the turbine exhaust where it can then produce additional electrical power or thrust.

The National Energy Technology Laboratory (NETL) will develop lightweight, cost-effective, precipitation-strengthened refractory high entropy alloys (RHEAs) for additive manufacturing. The advantage is an alloy with all phases in thermodynamic equilibrium, promoting high microstructural stability. The alloys will be comprised of a ductile high entropy solid solution matrix strengthened by fine precipitates of the high entropy carbides. NETL will use high throughput, multi-scale computer modeling, and machine learning to identify novel alloys within the large compositional space.

Current alloys used in gas turbines operate at about 90% of their melting temperature, which sets a limit on achieving higher temperatures. Refractory metal alloys (RMA) have the capability to enable continuous operation at 1300°C and with compatible coatings along with cooling systems to allow for gas inlet temperatures to reach 1800°C. The high RMA melting temperatures present challenges for traditional manufacturing methods, however.