Tech Benchmark Turbine 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: 1400oC 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+ hoursRough estimate of cost: A set of blades for HPT: 1.5M gbp Refurbishment: 0.3M to 1M gbp,Outline,Project Charter (N Blocker)TBC SystemCurrent Tech Technologies Applications Key Players Our ApproachesAppendix,Project Background,Develop cost-effective aluminide and TBC coating on Ni based alloysCustomer MQTD, 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 (Al2O3)TBC (8YSZ) Evaluation Criteria: Thermal cycling testMicrostructure * Adhesive strength, Oxidation resistance, Phase stability, Thickness homogeneity, Cost estimation,TBC System,Temperature vs. Lifetime,TBC Structure & Failure,Rupture: CTE mismatch, sharp thermal gradient, thermomechanical cyclingDelamination: TGO, degradation of bond coating, Incipient crack nucleate&grow: thermomechanical fatigueInclusion: Processing method derivedFOD(foreign object damage), CMAS(Calcia, Magnesia, Alumina and Silica),EB-PVD,Advantages Strong adherence, wear resistance Dense, atom/ion evaporation Columnar grainDrawbacks High temp Vacuum High costApplications Topcoat/MCrAlY Tool coating Functional film,Plasma Spraying,Advantages Lamellar strip Low k Composition control Thickness capability Drawbacks Partially melted particle Cracks PorositiesApplications 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 DepositionThermalchemical reaction,Potential Coating Technologies,SHS/Combustion synthesis,Advantages Energy Efficient Low cost Solid adhesionDrawbacks Inclusion Process controlApplications Powder prep. Ceramics SinteringTarget Materials Ni+Al=NiAl-118.4kJ/mol(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),Micro Spark Deposition,Advantages Metallurgical bonding Various coating materialsDrawbacks Electrode making Micro crackApplications 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 8,000-25,000oC 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: 1400oC 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+ hoursRough estimate of cost: A set of blades for HPT: 1.5M gbp Refurbishment: 0.3M to 1M gbp,Mat para&phase diagram, Plot of k vs. CTE Yttria-Zirconia Phase Diagram,Comparison of morphology,