1、1/Confidential/1/14/2023Tech BenchmarkTurbine Blades Coating High Temp Protective Coating tech for SX Turbine Blades2/Confidential/1/14/2023Operating Condition of Turbine BladesJourney through a jet engine Fan LPC HPC HPT LPT3/Confidential/1/14/2023Data for Turbine BladesHigh Temperature:1400oCHigh
2、Pressure:40atmHigh Rotating Speed:11,000rpmCentrifugal force,airflow impact and vibrationOxidation and erosionThermal Mechanical CyclingHPT blade lifetime:Currently:16,000 hours(23years)Expected:30,000+hoursRough estimate of cost:A set of blades for HPT:1.5M gbp Refurbishment:0.3M to 1M gbp 4/Confid
3、ential/1/14/2023Outline Project Charter(N Blocker)TBC System Current Tech TechnologiesApplications Key Players Our Approaches Appendix5/Confidential/1/14/2023Project BackgroundDevelop cost-effective aluminide and TBC coating on Ni based alloys CustomerMQTD,AvaiationProject Objective:High quality&cos
4、t effective coating processOperating condition:Stage 1 Turbine Blades(HPT)Substrate:Ni-base Superalloy/SX(N5)Coating:Bond Coat(NiAl,MCrAlY,PtAl)&TGO(Al2O3)TBC(8YSZ)Evaluation Criteria:Thermal cycling testMicrostructure*Adhesive strength,Oxidation resistance,Phase stability,Thickness homogeneity,Cost
5、 estimation6/Confidential/1/14/2023TBC SystemTemperature vs.Lifetime7/Confidential/1/14/2023TBC Structure&FailureLayerFunctionRequirementt/mMaterialTechniqueTBC top coatThermally insulatingLow k,high CTE,porous morphology100 400YSZAPS,EBPVDTGOOxidation resistanceDense alumina1-10Al2O3-Bond CoatAlumi
6、nide,Solid adhesion,transitionGradient layer,Phase stability50-100NiAlPtAlMCrAlYCVD,PackCem Plating,CVD VPS,HVOF,EB Rupture:CTE mismatch,sharp thermal gradient,thermomechanical cycling Delamination:TGO,degradation of bond coating,Incipient crack nucleate&grow:thermomechanical fatigue Inclusion:Proce
7、ssing method derived FOD(foreign object damage),CMAS(Calcia,Magnesia,Alumina and Silica)8/Confidential/1/14/2023EB-PVDAdvantagesStrong adherence,wear resistanceDense,atom/ion evaporationColumnar grainDrawbacksHigh tempVacuumHigh costApplicationsTopcoat/MCrAlYTool coatingFunctional film 9/Confidentia
8、l/1/14/2023Plasma SprayingAdvantagesLamellar stripLow kComposition controlThickness capability DrawbacksPartially melted particleCracksPorositiesApplicationsTopcoat APSBond coat LPPSCorrosion/Wear resistance 10/Confidential/1/14/2023Front RunnersUSAUCSB*Novel TBC material,microstructureUSAUniv of Co
9、nnecticut*Spallation model,lifetime predictionUSAUniv of Pittsburgh Failure analysis,bondcoat modificationGermanyDLR-German Aerospace CenterMorphology,porosityUkrainePEW,Paton Electric Weld.InstProcess para,materialUSAUniv of Virginia*EBDVD,systematical exp&simulationAcademicUSAGE Aircraft EngineEBP
10、VD,Plasma sprayUKRolls-Royce(England)EBPVD,Plasma sprayUSAPrat&Whitney(US&Cannada)EBPVD,Plasma sprayUSAPRAXAIR S.T.Tech,INC.EBPVDUSAChromalloy No.15,6(UK)EBPVDGermanySulzer Metco Inc.Plasma sprayIndustrialBeijingBIAM BJ Inst of Aero MatEBPVD processBeijingBUAA BJ Univ of Aviation&AstronauticsLow k m
11、aterial,EBPVDShenyang Institue of Metal Research.CASHVOF/detonation sprayAcademic locallyShenyang Shenyang Liming Aero EngineEBPVD,PlasmaXianXIAN AERO ENGINEEBPVD,plasmaChengduSichuan Chengfa Aero Co.LtdPlasma,EBPVDGuizhouLiyang Aero EngineEBPVDIndustrial locally11/Confidential/1/14/2023Focus of Eff
12、ortsApproaches:Improve coating materialCoating Structure Design*Coating microstructure*Processing Para.Optim.Brand-new process/tech*Rare earth additiveMultilayer and continual gradient layerVertical micro cracklePorous or 3D Mesh structure Hollow ceramic particleMicrocrystal coatingAmorphous phasePa
13、ck CementationEB-Directed Vapor Deposition Thermalchemical reaction12/Confidential/1/14/2023Potential Coating TechnologiesProcessesAdvantageDrawbackApplicationSHS/Combustion SynthesisNo heat sourceHigh efficiencyLow costInclusionThickness controlPowder prep.SinteringWeldingMicro Spark DepositionMeta
14、llurgical bondingVarious coating materials Electrode makingMicro crackWear resistance coatingCold weldingSol-gelLow Temp.DopantLow costLong cyclePercursorCrack/InclusionNano powderTool coatingSensor filmSputtering DepositionDenseLow Temp.Low rateHigh Equip.costIon implantationFilmPLDHigh rateHigh po
15、wer densityFlexible controlComplicationMore Para.PlumeBiomedicalSolar cellsSuper-conductor13/Confidential/1/14/2023SHS/Combustion synthesisAdvantagesEnergy EfficientLow costSolid adhesionDrawbacksInclusionProcess controlApplicationsPowder prep.Ceramics SinteringTarget MaterialsNi+Al=NiAl-118.4kJ/mol
16、(RT)Cr2O3+2Al=Al2O3+2Cr-549.7kJ/mol(RT)3NiO+2Al=Al2O3+3Ni-954.9kJ/mol(RT)Zr+O2=ZrO2-1097.5kJ/mol(RT)2Y+O2=Y2O3-1913.3kJ/mol(RT)14/Confidential/1/14/2023Micro Spark DepositionAdvantagesMetallurgical bondingVarious coating materialsDrawbacksElectrode makingMicro crackApplicationsWear resistance coatin
17、gCold weldingTo deposit consumable electrodes of alloys/intermetallic compounds on the work piece by means of micro electric sparks at frequencies of 10-1000 per second for 10-6-10-5 seconds per spark.Direct current heated the electrode up to 8,000-25,000oC only at contact areas,transfers a small qu
18、antity of the electrode to the work piece to form a strong metallurgical bonding.15/Confidential/1/14/2023Tech Roadmap16/Confidential/1/14/2023Appendix17/Confidential/1/14/2023Operating Condition of Turbine BladesJourney through a jet engine Fan LPC HPC HPT LPT18/Confidential/1/14/2023Data for Turbi
19、ne BladesHigh Temperature:1400oCHigh Pressure:40atmHigh Rotating Speed:11,000rpmCentrifugal force,airflow impact and vibrationOxidation and erosionThermal Mechanical CyclingHPT blade lifetime:Currently:16,000 hours(23years)Expected:30,000+hoursRough estimate of cost:A set of blades for HPT:1.5M gbp Refurbishment:0.3M to 1M gbp 19/Confidential/1/14/2023Mat para&phase diagram Plot of k vs.CTE Yttria-Zirconia Phase Diagram20/Confidential/1/14/2023Comparison of morphology
