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Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,20,/,Confidential/,9/13/2024,Tech BenchmarkTurbine Blades Coating,High Temp Protective Coating tech for SX Turbine Blades,Operating Condition of Turbine Blades,Journey through a jet engine,Fan LPC HPC HPT LPT,Data for Turbine Blades,High Temperature: 1400,o,C,High Pressure: 40atm,High Rotating Speed: 11,000rpm,Centrifugal force, airflow impact and vibration,Oxidation and erosion,Thermal Mechanical Cycling,HPT blade lifetime:,Currently: 16,000 hours (23years),Expected: 30,000+ hours,Rough estimate of cost:,A set of blades for HPT: 1.5M gbp,Refurbishment: 0.3M to 1M gbp,Outline,Project Charter (N Blocker),TBC System,Current Tech,Technologies,Applications,Key Players,Our Approaches,Appendix,Project Background,Develop cost-effective aluminide and TBC coating on Ni based alloys,CustomerMQTD, Avaiation,Project Objective: High quality & cost effective coating process,Operating condition: Stage 1 Turbine Blades (HPT),Substrate: Ni-base Superalloy/SX (N5),Coating: Bond Coat (NiAl, MCrAlY, PtAl) & TGO (Al,2,O,3,),TBC (8YSZ),Evaluation Criteria: Thermal cycling test,Microstructure,* Adhesive strength, Oxidation resistance, Phase stability, Thickness homogeneity, Cost estimation,TBC System,Temperature vs. Lifetime,TBC,Structure & Failure,Layer,Function,Requirement,t/m,Material,Technique,TBC top coat,Thermally insulating,Low,k, high CTE, porous morphology,100 400,YSZ,APS, EBPVD,TGO,Oxidation resistance,Dense alumina,1-10,Al,2,O,3,-,Bond Coat,Aluminide, Solid adhesion, transition,Gradient layer, Phase stability,50-100,NiAl,PtAl,MCrAlY,CVD,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: Processing method derived,FOD(foreign object damage), CMAS(Calcia, Magnesia, Alumina and Silica),EB-PVD,Advantages,Strong adherence, wear resistance,Dense, atom/ion evaporation,Columnar grain,Drawbacks,High temp,Vacuum,High cost,Applications,Topcoat/MCrAlY,Tool coating,Functional film,Plasma Spraying,Advantages,Lamellar strip,Low,k,Composition control,Thickness capability,Drawbacks,Partially melted particle,Cracks,Porosities,Applications,Topcoat APS,Bond coat LPPS,Corrosion/Wear resistance,Front Runners,Focus of Efforts,Approaches:,Improve coating material,Coating Structure Design*,Coating microstructure*,Processing Para. Optim.,Brand-new process/tech*,Rare earth additive,Multilayer and continual gradient layer,Vertical micro crackle,Porous or 3D Mesh structure,Hollow ceramic particle,Microcrystal coating,Amorphous phase,Pack Cementation,EB-Directed Vapor Deposition,Thermalchemical reaction,Potential Coating Technologies,Processes,Advantage,Drawback,Application,SHS/ Combustion Synthesis,No heat source,High efficiency,Low cost,Inclusion,Thickness control,Powder prep.,Sintering,Welding,Micro Spark Deposition,Metallurgical bonding,Various coating materials,Electrode making,Micro crack,Wear resistance coating,Cold welding,Sol-gel,Low Temp.,Dopant,Low cost,Long cycle,Percursor,Crack/Inclusion,Nano powder,Tool coating,Sensor film,Sputtering Deposition,Dense,Low Temp.,Low rate,High Equip. cost,Ion implantation,Film,PLD,High rate,High power density,Flexible control,Complication,More Para.,Plume,Biomedical,Solar cells,Super-conductor,SHS/Combustion synthesis,Advantages,Energy Efficient,Low cost,Solid adhesion,Drawbacks,Inclusion,Process control,Applications,Powder prep.,Ceramics Sintering,Target Materials,Ni+Al=NiAl-118.4kJ/mol(RT),Cr,2,O,3,+2Al=Al,2,O,3,+2Cr-549.7kJ/mol(RT),3NiO+2Al=Al,2,O,3,+3Ni-954.9kJ/mol(RT),Zr+O,2,=ZrO,2,-1097.5kJ/mol(RT),2Y+O,2,=Y,2,O,3,-1913.3kJ/mol(RT),Micro Spark Deposition,Advantages,Metallurgical bonding,Various coating materials,Drawbacks,Electrode making,Micro crack,Applications,Wear resistance coating,Cold welding,To 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 8,000-25,000,o,C only at contact areas, transfers a small quantity of the electrode to the work piece to form a strong metallurgical bonding.,Tech Roadmap,Appendix,Operating Condition of Turbine Blades,Journey through a jet engine,Fan LPC HPC HPT LPT,Data for Turbine Blades,High Temperature: 1400,o,C,High Pressure: 40atm,High Rotating Speed: 11,000rpm,Centrifugal force, airflow impact and vibration,Oxidation and erosion,Thermal Mechanical Cycling,HPT blade lifetime:,Currently: 16,000 hours (23years),Expected: 30,000+ hours,Rough estimate of cost:,A set of blades for HPT: 1.5M gbp,Refurbishment: 0.3M to 1M gbp,Mat para&,p,hase diagram, Plot of,k,vs. CTE, Yttria-Zirconia Phase Diagram,Comparison of morphology,
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