Advanced ceramics from liquid feedstock for aerospace propulsion
Lead Research Organisation:
University of Nottingham
Department Name: Faculty of Engineering
Abstract
Ceramics are an important group of materials and their processing into aerospace coatings and components requires specialist techniques. Current methodologies for new materials discovery and development are wasteful, energy inefficient, and not representative of the production scale environment. This Early Career Fellowship in the priority area of Advanced Materials Engineering will demonstrate that new ceramic compositions can be processed from liquids with a high power, high efficiency and high velocity three cathode plasma source with axial injection as the primary technique. My vision is to establish modelling tools and advanced materials processing techniques that will enable the design and manufacture of advanced ceramic coatings and components with tailored microstructure with thermal, electrical and environmental barrier properties fine-tuned to their desired applications. This will enable unique microstructure of ceramic coatings coupled with fine-tuned thermal, environmental and electrical properties for thermal barrier coatings in the aero gas turbines, environmental barrier coatings for ceramic matrix composites in those turbines, electrolytes for fuel cells and solar cells in auxiliary power generation for electric aircraft, dielectric coatings for aero electric motors, wear and high temperature oxidation and corrosion resistant coatings for various critical components in the aero-engine. To facilitate widespread industrial uptake, I will develop a new high throughput process with reduced waste and improved sustainability based on high power, high velocity plasma, enabling the production of tailored ceramic coatings and components of the required nanostructure and microstructure of the required pore architecture in large volumes at a fraction of a cost of current techniques. This will enable the manufacture of coatings with bespoke compositions and provide unprecedented control of pore size, shape, fraction and distribution which are essential for thermal, environmental and electrical properties of these coatings. The integrated approach to materials discovery and manufacture will lead to creation of products for the aerospace industry with improved properties, performances and reduced materials processing times, in line with the aims of the fellowship priority area.
Organisations
- University of Nottingham (Lead Research Organisation)
- American University in Cairo (Collaboration)
- Institute of Minerals and Materials Technology (Collaboration)
- International Advanced Research Centre for Powder Metallurgy and New Materials (Collaboration)
- Rolls-Royce Plc (UK) (Project Partner)
- Concordia University (Project Partner)
- Xi'an Jiatong University (Project Partner)
- Stony Brook University (Project Partner)
- Turbine Surface Technologies Limited (Project Partner)
- University West (Project Partner)
- University of Manchester (Project Partner)
- Treibacher Industrie AG (Project Partner)
- Surface Eng for Advanced Mat. (SEAM) (Project Partner)
Publications
Memon H
(2022)
A new hybrid suspension and solution precursor thermal spray for wear-resistant silicon carbide composite coatings
in Materials & Design
Tejero-Martin D
(2021)
A review on environmental barrier coatings: History, current state of the art and future developments
in Journal of the European Ceramic Society
Lynam A
(2024)
Abradable ytterbium disilicate environmental barrier coatings: A story of CMAS and combined CMAS-erosion performance
in Surface and Coatings Technology
Memon H
(2024)
Active learning-driven uncertainty reduction for in-flight particle characteristics of atmospheric plasma spraying of silicon
in Engineering Applications of Artificial Intelligence
Lynam A
(2024)
An investigation into the erosion and wear mechanisms observed in abradable ytterbium disilicate environmental barrier coatings
in Journal of the European Ceramic Society
Lynam A
(2023)
Atmospheric plasma spraying of ytterbium disilicate for abradable and environmental barrier coatings: A story of processing-microstructure relationships
in Ceramics International
Sudigdo P
(2025)
Cold Spray of Ni-Based Superalloys: A Review on Processing and Residual Stress
in Journal of Thermal Spray Technology
Lynam A.
(2022)
Correction to: Thermal Spraying of Ultra-High Temperature Ceramics: A Review on Processing Routes and Performance (Journal of Thermal Spray Technology, (2022), 31, 4, (745-779), 10.1007/s11666-022-01381-5)
in Journal of Thermal Spray Technology
Bano S
(2021)
Development and Characterization of Phosphate-Based Glass Coatings via Suspension High-Velocity Oxy-Fuel (SHVOF) Thermal Spray Process
in Journal of Thermal Spray Technology
Liu C
(2022)
Enhancing wear performance by depositing alumina/GNPs coating on textured WC-TiC-Co substrates
in Surface and Coatings Technology
Tejero-Martin D
(2021)
Evolution of porosity in suspension thermal sprayed YSZ thermal barrier coatings through neutron scattering and image analysis techniques
in Journal of the European Ceramic Society
Liu C
(2021)
Fracture behaviour, microstructure, and performance of various layered-structured Al2O3-TiC-WC-Co composites
in Ceramics International
Derelizade K
(2022)
High temperature (900 °C) sliding wear of CrNiAlCY coatings deposited by high velocity oxy fuel thermal spray
in Surface and Coatings Technology
Akisin C
(2024)
Influence of Annealing Treatment on the Microstructure and Mechanical Properties of Cold-Sprayed CoCrFeNiMn High Entropy Alloy
in Journal of Thermal Spray Technology
Memon H
(2024)
Influence of Yttria content in YSZ: An evaluation of water-based SPS coatings and spark plasma sintered pellets
in Surface and Coatings Technology
Tejero-Martin D
(2022)
Interaction of CMAS on thermal sprayed ytterbium disilicate environmental barrier coatings: A story of porosity
in Ceramics International
Venturi F
(2021)
Internal diameter HVOAF thermal spray of carbon nanotubes reinforced WC-Co composite coatings
in Materials & Design
Faisal N
(2021)
Large-scale manufacturing route to metamaterial coatings using thermal spray techniques and their response to solar radiation
in Emergent Materials
Hussain T.
(2021)
Machine learning ai
in Advanced Materials and Processes
Wang J
(2021)
Metallic skeleton promoted two-phase durable icephobic layers.
in Journal of colloid and interface science
Akisin C
(2023)
Microstructural Study of Cold-Sprayed CoCrFeNiMn High Entropy Alloy
in Journal of Thermal Spray Technology
Liu C
(2021)
Microstructure and wear performance of alumina/graphene coating on textured Al2O3/TiC substrate composites
in Journal of the European Ceramic Society
Akisin C
(2021)
Microstructure, mechanical and wear resistance properties of low-pressure cold-sprayed Al-7 Mg/Al2O3 and Al-10 Mg/Al2O3 composite coatings
in Emergent Materials
Leng K
(2024)
Multilayer GZ/YSZ thermal barrier coating from suspension and solution precursor plasma spray
in Ceramics International
Leng K
(2023)
Multilayer GZ/YSZ thermal barrier coating from suspension and solution precursor thermal spray
in Journal of the European Ceramic Society
Rojas-Ulloa C
(2021)
Nanomechanical Characterization of the Deformation Response of Orthotropic Ti-6Al-4V
in Advanced Engineering Materials
Zhou H
(2021)
Numerical Analysis of Deformation Behavior and Interface Bonding of Ti6Al4V Particle After Subsequent Impact During Cold Spraying
in Journal of Thermal Spray Technology
Akisin C
(2022)
Numerical and Experimental Analysis of the Deformation Behavior of CoCrFeNiMn High Entropy Alloy Particles onto Various Substrates During Cold Spraying
in Journal of Thermal Spray Technology
Lokachari S
(2024)
Processing-Microstructure-Properties of Columns in Thermal Barrier Coatings: A Study of Thermo-Chemico-Mechanical Durability.
in ACS applied materials & interfaces
Venturi F
(2023)
SiC/YAG composite coatings by a novel liquid fuelled high velocity oxy-fuel suspension thermal spray
in Surface and Coatings Technology
Leng K
(2022)
Solution precursor thermal spraying of gadolinium zirconate for thermal barrier coating
in Journal of the European Ceramic Society
Tejero-Martin D
(2022)
Steam Degradation of Ytterbium Disilicate Environmental Barrier Coatings: Effect of Composition, Microstructure and Temperature
in Journal of Thermal Spray Technology
Owusu E
(2024)
Suspension plasma sprayed ytterbium disilicate coatings: Phase stability and microstructural evolution in extreme environments
in Journal of the European Ceramic Society
Zhang B
(2024)
Thermal properties and calcium-magnesium-alumino-silicate (CMAS) interaction of novel ?-phase ytterbium-doped yttrium disilicate (?-Y1.5Yb0.5Si2O7) environmental barrier coating material
in Advanced Composites and Hybrid Materials
Faisal N
(2022)
Thermal Spray Coatings for Electromagnetic Wave Absorption and Interference Shielding: A Review and Future Challenges
in Advanced Engineering Materials
Lynam A
(2022)
Thermal Spraying of Ultra-High Temperature Ceramics: A Review on Processing Routes and Performance
in Journal of Thermal Spray Technology
Sun J
(2024)
TiN/TiO2 composite coatings: preparation, microstructures and tribological properties
in Ceramics International
Owoseni T
(2021)
YAG thermal barrier coatings deposited by suspension and solution precursor thermal spray
in Ceramics International
| Description | - We have developed a machine learning protocol to develop new thermal barrier coatings and environmental barrier coatings with low thermal conductivity and range of environmental barrier coatings which are suitable for CMAS resistance - The work has led to a significant no of high entropy compositions, which are suitable for the next generation of coating materials. - Active learning is being developed as a tool for parameter development of plasma spray process. - Our high throughput materials discovery lab is now equipped with a cobot that is resulting in delivering new compositions for the coatings community. |
| Exploitation Route | Directly developing new coatings at a fraction of time (compared to several decades) for the aerospace and power generation industry. It cuts the development cycle from several decades to a couple of years. |
| Sectors | Aerospace Defence and Marine |
| URL | https://www.nottingham.ac.uk/coatings/ |
| Description | Our research is well aligned with the industry, and most of our work directly impacts industrial products. The knowledge of new composition, artificial intelligence, new processes and coatings developed from this EPSRC fellowship have resulted in engine testing of components at Rolls-Royce engine test bed under several different programmes. The coatings developed with the tools and techniques from this fellowship are leading the way to be incorporated into commercial products worth hundreds of millions in value. The work on machine learning leading to a software that is ready to be licensed by the thermal spray operators (a USD 16 billion industry) as well as the composition development framework is influencing how to use more abundant materials to keep the earth habitable. The work has contributed to working with NASA on the development of the next generation of space coatings. We are being invited to the table for manufacturing national strategy level meetings to help shape the manufacturing agenda and the output is contributing at an international level. In addition, a spin-out company is going through the pipeline of the university and another spin-out on the battery sector is working with us to commercialise the output. |
| First Year Of Impact | 2023 |
| Sector | Aerospace, Defence and Marine,Energy,Environment,Manufacturing, including Industrial Biotechology,Transport |
| Impact Types | Economic Policy & public services |
| Description | Interaction with Indian State's governor, chief minister and minister of trade |
| Geographic Reach | Asia |
| Policy Influence Type | Influenced training of practitioners or researchers |
| Impact | This leads to sustainable materials for the country and awareness of harmful emissions in the processing. We were also keen to explore utilising non rare earth materials and repair technologies to improve the performance of the materials. |
| URL | https://www.indtsa.org/ntsc-2025 |
| Description | EPSRC Centre for Doctoral Training in Digital Transformation of Metals Industry |
| Amount | £7,420,613 (GBP) |
| Funding ID | EP/Y035461/1 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 05/2024 |
| End | 09/2032 |
| Description | Hot Section Lifing and Materials ( HOTLINE ) |
| Amount | £11,871,092 (GBP) |
| Funding ID | 10101878 |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 02/2024 |
| End | 01/2028 |
| Description | IGNITE Network+: Innovation and Growth Needs Inclusion and engagement of all Talent in Energy research |
| Amount | £1,020,388 (GBP) |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 08/2022 |
| End | 08/2026 |
| Description | REFURBISHMENT AND ADDITIVE MANUFACTURING ACCOMPLISHED BY KINETIC DEPOSITION (RE-MAKE) |
| Amount | £260,676 (GBP) |
| Funding ID | EP/Y036093/1 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 09/2023 |
| End | 09/2027 |
| Description | REINSTATE: Repair, Enhanced Inspection, and Novel Sensing Techniques for increased Availability and reduced Through life Expense |
| Amount | £10,442,163 (GBP) |
| Funding ID | 51689 |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 08/2020 |
| End | 12/2024 |
| Description | REPLENISH: Repair and Evaluation of aerospace Products LinE side, Near wing, and In SHop |
| Amount | £19,870,397 (GBP) |
| Funding ID | 10112182 |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 05/2024 |
| End | 12/2027 |
| Description | ARCI, Hyderabad |
| Organisation | International Advanced Research Centre for Powder Metallurgy and New Materials |
| Country | India |
| Sector | Public |
| PI Contribution | Access to their state of the art - SAXS measurements - HVAF spray - Their proprietary cold spray - Nanoindentation mapping |
| Collaborator Contribution | Provide access and technical input to unique spray and characterisation facility only available in India. Knowhow and technical expertise from Indian industrial experience. |
| Impact | Samples and papers in progress |
| Start Year | 2023 |
| Description | American University in Cairo |
| Organisation | American University in Cairo |
| Country | Egypt |
| Sector | Academic/University |
| PI Contribution | We have provided processing route for carbon nanotube incorporated aluminium alloy powders using high pressure cold spray, developed coatings from them, examined using EIS and other complimentary techniques. |
| Collaborator Contribution | They made carbon nanotube with aluminium alloy and perfected the method of incorporation. On top of that they have developed how to characterise all these in advanced electron microscopy. |
| Impact | Three journal papers, relationship with working with Egypt on cutting edge technologies. |
| Start Year | 2024 |
| Description | CSIR-IMMT |
| Organisation | Institute of Minerals and Materials Technology |
| Country | India |
| Sector | Public |
| PI Contribution | Dr Sisir Mantry, a senior researcher, was hosted at the University of Nottingham for 6 months on a prestigious Raman Research Fellowship. We have helped develop new suspension and solution precursor thermal spray for thermal barrier coatings for their applications and |
| Collaborator Contribution | The collaboration started on developing new thermal barrier coatings for the aviation industry. He brought over a range of suspensions, including 2D materials like Maxene and various other materials like a dental implant. They have examined and studied all the coatings and explored their processing-microstructure-properties relationships. |
| Impact | Two journal papers on suspension thermal spray have been submitted for publications to two journals. |
| Start Year | 2023 |
| Title | THERMAL SPRAY SYSTEM AND COATING |
| Description | A method do spray SiC from a precursor salt |
| IP Reference | EP4448186 |
| Protection | Patent / Patent application |
| Year Protection Granted | 2024 |
| Licensed | No |
| Title | THERMAL SPRAY SYSTEM AND COATING |
| Description | A novel way to deposit SiC from suspension thermal spray |
| IP Reference | DJC125924P.GBA |
| Protection | Patent / Patent application |
| Year Protection Granted | 2023 |
| Licensed | No |
| Impact | A novel way to deposit SiC from suspension thermal spray |
| Title | Machine learning tool to predict spray parameters |
| Description | The software can predict processing conditions based on the spray parameters |
| Type Of Technology | Software |
| Year Produced | 2025 |
| Impact | The software was developed by two researchers and it will eventually lead to a licensing route for the university. |
| Description | 11th RIPT (Les Recontres Internationales de la Projection Thermique), |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Professional Practitioners |
| Results and Impact | Suspension Plasma Spray parameter development of EBC (Y1.5Yb0.5Si2O7) & SPS TBC (YSZ) to capture the latest output from the EPSRC funded work to help shape the narrative in the sector. |
| Year(s) Of Engagement Activity | 2024 |
| URL | https://www.fz-juelich.de/en/imd/imd-2/news/news/11-ript-2024-conference |
| Description | 2nd National Thermal Spray Conference |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Professional Practitioners |
| Results and Impact | Indian National Thermal Spray event received a welcome address from the President of India, Governor and Chief Minister of the state of Odisha and the industry minister for trade and industry opened the expo. The talk was a keynote talk to update the whole community on the direction of travel. |
| Year(s) Of Engagement Activity | 2025 |
| URL | https://www.indtsa.org/ntsc-2025 |
| Description | 50th International Conference on Metallurgical Coatings and Thin Films (ICMCTF 2024), |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Professional Practitioners |
| Results and Impact | Invited talk on the Next generation of Compositions & Microstructure for Netzero & Sustainable aviation, |
| Year(s) Of Engagement Activity | 2024 |
| URL | https://icmctf2024.avs.org/ |
| Description | Navigating a Greener Sky: Symposium on Advances in Thermal Spray and PVD Coatings for the Aerospace Industries |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Professional Practitioners |
| Results and Impact | Navigating a Greener Sky: Symposium on Advances in Thermal Spray and PVD Coatings for the Aerospace Industries by ASM is an initiative to bring EU, UK, USA and Canadian researchers together. We delivered a keynote on Clearance coatings in lower emission aviation gas turbines :Ytterbium disilicate abradable coatings spraying and steam-CMAS performance. |
| Year(s) Of Engagement Activity | 2023,2024 |
| URL | https://www.asminternational.org/tss-topical-event-france/ |
| Description | Outreach for school children |
| Form Of Engagement Activity | Participation in an open day or visit at my research institution |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Schools |
| Results and Impact | A school group with 71 students came over to see the facilities. It was very well received by everyone involved. |
| Year(s) Of Engagement Activity | 2023 |
| Description | TSSEA conference |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Postgraduate students |
| Results and Impact | Thermal Spray and Surface Engineering Conference |
| Year(s) Of Engagement Activity | 2024 |
| URL | https://sustainability2024.tssea.org/ |