Molten-Volcanic-Ash-Phobic Thermal Barrier Coating based on Biomimetic Structure

Area of Science:

• Materials Science
• Surface Engineering
• Tribology

Background:

• Volcanic ash poses a significant risk to aviation safety due to its low melting point, which can damage thermal barrier coatings (TBCs) in aero-engines.
• Molten volcanic ash can compromise the integrity and performance of TBCs, leading to premature engine failure.

Purpose of the Study:

• To develop a novel molten-volcanic-ash-phobic TBC inspired by natural superhydrophobic surfaces.
• To investigate the feasibility of biomimetic microstructures for repelling molten volcanic ash.
• To enhance the durability and safety of aero-engines against volcanic ash contamination.

Main Methods:

• Fabrication of hierarchically structured surfaces on (Gd0.9 Yb0.1)2Zr2O7 (GYbZ) pellets using ultrafast laser direct writing.
• Development of biomimetic-structured GYbZ TBCs via plasma spray physical vapor deposition.
• High-temperature evaluation of ash-phobic properties and microstructure analysis.

Main Results:

• The designed TBC surfaces exhibited a lotus-leaf-like dual-scale microstructure.
• The biomimetic TBCs demonstrated significant molten volcanic ash (silicate) phobicity at elevated temperatures.
• The hierarchical structure, including nanoparticle emulation, was crucial for repelling molten ash.

Conclusions:

• A molten-volcanic-ash-phobic TBC inspired by natural superhydrophobic surfaces has been successfully developed.
• The biomimetic microstructure effectively repels molten volcanic ash, offering a potential solution to TBC failure in aviation.
• This advancement represents a significant step towards next-generation aviation engines with reduced vulnerability to volcanic debris.