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Home Aerospace & Aeronautics Advanced One-Stage EB-PVD Coatings For Aerospace and Gasmturbine Applications

Advanced One-Stage EB-PVD Coatings For Aerospace and Gasmturbine Applications

Description

Electron beam technology and equipment are developed for one-stage deposition of functional graded coatings with the use of a composite ceramic ingot for evaporation. This technology allows replacing the flat interface between metal and ceramic layers with a graded transition zone and achieving good adhesion of the coating to the substrate.

The composite ingot incorporates the program of evaporation and deposition of a graded coating, embodied in composition, shapes and sizes, of the respective inserts, number of them, and also in arrangement of them inside of the basic ingot. Inserts determine composition, structure, and properties of a graded coating at all levels including transition zones and coating layers.

Innovative Aspect and Main Advantages

As compared to traditional multi-stages technologies of protective coating deposition, this technology allows to achieve higher reproducibility level of composition, structure, and lifetime of the functional graded coatings. Due to using only one EB-PVD unit and reducing number of stages, total cost of one-stage EB-PVD deposition process is at least 2 times smaller than that of traditional multistage technological processes of protective coating deposition.

Graded thermal$barrier coatings (NiAl/YSZ, NiCo-CrAlY/AlCr/YSZ) with about 250 μm thickness allow to increase gas turbine engine gas temperature up to 100°C maintaining the same temperature of the cooling blade surface. Outer ceramic YSZ layer has low level of thermal conductivity of about 1.2 W/m·K and reliable adhesion strength with bond coat (more than 100 MPa). Thermal-cyclic lifetime of graded TBC is about 1.8–2 times higher in comparison with traditional TBC.

Graded hard erosion$resistant coatings (TiN-based, TiC-based) of 15–25 μm thickness that deposited with high deposition rate (up to 1 μm/min) can increase the erosion resistance up to 15–30 times as compared to steel substrate.

Graded hard damping coatings (Sn-Cr-MgO) with thickness of about 25–50 μm allow to increase by several times the damping capability and erosion resistance of Ti-based articles with 25 % improvement of fatigue resistance.


Fig. 1. Composite ceramic ingot                             Fig. 2. Graded thermal barrier coating NiAl/YSZ microstructure

Areas of Application

  • Gas turbine blades and vanes;
  • Hot parts of aerospace technique;
  • Compressor steel and titanium blades.

Stage of Development

Patented and tested, available for demonstration.

Contacts

Organization: International Center for Electron Beam Technologies of E. O. Paton Electric Welding Institute of NASU
Contact person: Kostyantyn Yakovchuk
Address: 68, Gorky str., Kiev-150, 03150, Ukraine
Tel.: 044 289$2176
Fax: 044 287$3166
E-mail: yakovchuk@paton$icebt.kiev.ua
http://www.paton-icebt.kiev.ua

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