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1、TechBenchmarkTurbineBladesCoatingHighTempProtectiveCoatingtechforSXTurbineBladesOperatingConditionofTurbineBladesJourneythroughajetengineFanLPCHPCHPTLPTDataforTurbineBladesHighTemperature:~1400oCHighPressure:~40atmHighRotatingSpeed:~11,000rpmCentrifugalforc
2、e,airflowimpactandvibrationOxidationanderosionThermalMechanicalCyclingHPTbladelifetime:Currently:16,000hours(2~3years)Expected:30,000+hoursRoughestimateofcost:AsetofbladesforHPT:1.5MgbpRefurbishment:0.3Mto1MgbpOutlineProjectCharter(NBlocker)TBCSystemCurrent
3、TechTechnologiesApplicationsKeyPlayersOurApproachesAppendixProjectBackgroundDevelopcost-effectivealuminideandTBCcoatingonNibasedalloysCustomerMQTD,AvaiationProjectObjective:Highquality&costeffectivecoatingprocessOperatingcondition:Stage1TurbineBlades(HPT)Su
4、bstrate:Ni-baseSuperalloy/SX(N5)Coating:BondCoat(NiAl,MCrAlY,PtAl)&TGO(Al2O3)TBC(8YSZ)EvaluationCriteria:ThermalcyclingtestMicrostructure*Adhesivestrength,Oxidationresistance,Phasestability,Thicknesshomogeneity,CostestimationTBCSystemTemperaturevs.LifetimeT
5、BCStructure&FailureLayerFunctionRequirementt/µmMaterialTechniqueTBCtopcoatThermallyinsulatingLowk,highCTE,porousmorphology100~400YSZAPS,EBPVDTGOOxidationresistanceDensealumina<1-10Al2O3-BondCoatAluminide,Solidadhesion,transitionGradientlayer,Phasestability<
6、50-100NiAlPtAlMCrAlYCVD,PackCemPlating,CVDVPS,HVOF,EBRupture:CTEmismatch,sharpthermalgradient,thermomechanicalcyclingDelamination:TGO,degradationofbondcoating,Incipientcracknucleate&grow:thermomechanicalfatigueInclusion:ProcessingmethodderivedFOD(foreignobj
7、ectdamage),CMAS(Calcia,Magnesia,AluminaandSilica)EB-PVDAdvantagesStrongadherence,wearresistanceDense,atom/ionevaporationColumnargrainDrawbacksHightempVacuumHighcostApplicationsTopcoat/MCrAlYToolcoatingFunctionalfilmPlasmaSprayingAdvantagesLamellarstripLowkC
8、ompositioncontrolThicknesscapabilityDrawbacksPartiallymeltedparticleCracksPorositiesApplicationsTopcoatAPSBondcoatLPPSCorrosion/WearresistanceFrontRunnersFocusofEffortsApproaches:Improvecoatingmaterial
