SPORIAN MICROSYSTEMS, INC — Department of Energy SBIR Phase I: 18

Description

Problem that is being addressed. Technologies are needed that can improve the operating costs and efficiency of gas turbines. Multifunctional components need to be economically manufactured that can withstand the harsh environments of gas turbines while enhancing structural integrity. Ideal manufacturing techniques will decrease weight, be readily available, increase operational temperatures, and reduce operation and maintenance costs. Such systems should also have capabilities extending to material properties, including functional gradients, thermal barrier coatings, and ceramic-matrix composites. How this problem is being addressed. Sporian proposes to develop additive manufacturing (AM) techniques to produce high-temperature turbine components from polymer-derived ceramics (PDC). The anticipated developments will provide a system for manufacturing on-demand intricate turbine parts that can withstand ultra-high temperature, are corrosion resistant, and have high mechanical strength. What is to be done in Phase I. Sporian will leverage its extensive prior experience in PDC to refine material processing techniques to create lab-scale prototypes for technology feasibility demonstrations. Parts fabricated utilizing additive manufacturing Commercial Applications and Other Benefits. Because of the large market demand, Sporian’s targeted approach focuses on gas turbine components for both aircraft engines and energy-generating systems due to the lightweight and complex competencies of additively-manufactured PDC. Cost-effective additive manufacturing of ceramics has applications in numerous markets including medical/dental, power plants, automotive, and rockets and propulsion. Key Words: Additive Manufacturing, Gas Turbines, Polymer-Derived Ceramics, Nozzle, Inlet Vane components for gas turbine applications.