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Commercial Applications for Recycled Thermal Barrier Coatings



OBJECTIVE: The Defense Logistics Agency (DLA) seeks to provide responsive, best value supplies consistently to our customers.DLA continually investigates diverse technologies for manufacturing which would lead to the highest level of innovation in the discrete-parts support of fielded weapon systems (many of which were designed in the 1960’s, 1970’s and 1980’s) with a future impact on both commercial technology and government applications.As such, advanced technology demonstrations for affordability and advanced industrial practices to demonstrate the combination of improved discrete-parts manufacturing and improved business methods are of interest.All these areas of manufacturing technologies provide potential avenues toward achieving breakthrough advances.Proposed efforts funded under this topic may encompass any specific discrete-parts or materials manufacturing or processing technology at any level resulting in a unit cost reduction.Research and Development efforts selected under this topic shall demonstrate and involve a degree of risk where the technical feasibility of the proposed work has not been fully established.Further, proposed efforts must be judged to be at a Technology Readiness Level (TRL) 6 or less, but greater than TRL 3 to receive funding consideration.TRL 3.(Analytical and Experimental Critical Function and/or Characteristic Proof of Concept) TRL 6.(System/Subsystem Model or Prototype Demonstration in a Relevant Environment)

DESCRIPTION:The Department of Defense (DoD) is looking for a domestic capability that demonstrates the ability to recycle waste from thermal barrier coatings and find commercial applications of the recycled material. Thermal barrier coating (TBC) and environmental barrier coating (EBC) materials are among the most critical advanced materials utilized in aviation applications.Modern commercial and military aircraft rely on these materials to provide thermal protection for aircraft engine components, allowing the engines to operate at higher temperatures and increased efficiencies while also protecting against the damaging effects of various environmental factors present during operation.Many of the most prevalent TBCs and EBCs presently employed in military aircraft engine coatings contain rare earth zirconate and silicate materials.However, many of the rare earth and zirconium raw materials necessary for the production of these TBC and EBC materials are not readily available from domestic sources.The need to maintain secure supply chains for these raw materials creates an imperative for alternate raw materials sources to be developed.Developing an economically viable process for enhancing the production of existing recycling processes could facilitate the establishment of a viable, competitive domestic supply chain of TBC and EBC coatings for the aerospace industry. Economical reclamation and reuse of thermal barrier coating waste could result in improved supply security and lower costs of these crucial raw material.

PHASE I: Phase I – 6 Months $100KDetermine, insofar as possible, the scientific, technical, and commercial feasibility of the concept.Include a plan to demonstrate the innovative discrete-parts manufacturing process and address implementation approaches for near term insertion into the manufacture of Department of Defense (DoD) systems, subsystems, components, or parts.

PHASE II: Phase II – 24 Months $1.6MDevelop applicable and feasible process demonstration for the approach described, and demonstrate a degree of commercial viability.Validate the feasibility of the innovative process by demonstrating its use in the production, testing, and integration of items for DLA.Validation would include, but not be limited to, prototype quantities, data analysis, laboratory tests, system simulations, operation in test-beds, or operation in a demonstration system.A partnership with a current or potential supplier to DLA, OEM, or other suitable partner is highly desirable.Identify commercial benefit or application opportunities of the innovation.Innovative processes should be developed with the intent to readily transition to production in support of DLA and its supply chains.

PHASE III: Technology transition via successful demonstration of a new process technology.This demonstration should show near-term application to one or more Department of Defense systems, subsystems, or components.This demonstration should also verify the potential for enhancement of quality, reliability, performance and/or reduction of unit cost or total ownership cost of the proposed subject.Private Sector Commercial Potential: Material manufacturing improvements, including development of domestic manufacturing capabilities, have a direct applicability to all defense system technologies.Material manufacturing technologies, processes, and systems have wide applicability to the defense industry including air, ground, sea, and weapons technologies.Competitive material manufacturing improvements should have leverage into private sector industries as well as civilian sector relevance.Many of the technologies under this topic would be directly applicable to other DoD agencies, NASA, and any commercial manufacturing venue.Advanced technologies for material manufacturing would directly improve production in the commercial sector resulting in reduced cost and improved productivity.



1. 2. 2015 Strategic and Critical Materials Report on Stockpile Requirements3. National Defense Authorization Act For Fiscal Year 2014

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