A research team led by the University of Virginia (UVA) has developed new protective coatings that allow turbine engines to run at higher temperatures, increasing their efficiency and performance.
Turbine engines, which are essential for aircraft and power generation, burn fuel to spin turbine blades, converting energy into electricity.
The hotter these engines run, the more efficiently they work.
“Hotter engines are more efficient,” explained Elizabeth Opila, professor and chair of UVA’s Department of Materials Science and Engineering, who led the project.
Higher efficiency means using less fuel, producing fewer emissions, and reducing costs.
However, current turbine engines face temperature limits due to the materials used.
Today’s engines primarily use two types of materials in their high-temperature sections:
- Nickel-based superalloys: These materials can withstand temperatures up to about 2,200°F.
- Ceramic composites: These include multiple protective layers but are limited by the melting point of one layer, silicon, which melts at 2,577°F.
To push beyond these limits, the UVA team focused on refractory metal alloys, which are durable and heat-resistant. However, in the past, these alloys were abandoned due to their poor resistance to oxidation, which occurs when materials react with air and moisture.
To protect the alloys, the researchers developed a single-layer coating using rare earth oxides. This coating combines multiple rare earth elements, such as yttrium, erbium, and ytterbium. According to Kristyn Ardrey, a Ph.D. alumna of Opila’s lab and the study’s lead author, the single-layer approach offers better protection without needing complex multi-layer coatings.
Opila’s team collaborated with other UVA experts, including Associate Professors Bi-Cheng Zhou and Prasanna Balachandran, who used computer simulations and machine learning to predict the best material combinations.
They applied the coatings using two standard methods—one involving a molten spray and the other using a liquid that dries and hardens. Both methods were tested under extreme heat and steam conditions.
The team also worked with UVA Professor Patrick Hopkins’ ExSiTE Lab, which uses lasers to measure how well materials withstand heat.
This collaborative effort allowed them to explore many material options and understand the characteristics of the new coatings.
The researchers believe more testing and refinement are needed, but their work is a significant step forward in turbine engine technology. Improved coatings mean better performance, lower fuel consumption, reduced emissions, and potentially lower costs for consumers.
“Improving engine efficiency benefits industries like energy and aviation,” said Opila. “But it also means a cleaner environment and lower costs for everyone.”
