Coatings for Advanced Aero Engine Materials

Dr. Wilfried Smarsly Materials Engineering 8 th HIPIMS Conference 1 - 2 July, 2009, University Sheffield, UK

Coatings required for aero engines

Anti-fretting coatings Casing, blades, vanes, discs, shafts Ti-fire protection coating Compressor casing Thermal barrier coating Turbine blades, burner

Corrosion / oxidation protection Coating Turbine blades

Diameter adjustment coatings great numbers of parts

Abradables Casing, tip coating, seals Erosion resistance coating Compressor blades

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Coatings for fretting damage protection (1)

resistance against fretting fatigue and wear

applications on casings, blade roots, discs and shafts dense coatings with high bond strength repairable by recoating

Chromium carbide + nickel chromium coating plasma sprayed Turbine vane nickel alloy cluster
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Coatings for fretting damage protection (2)

APS Coating seal ring

Cobalt-chromium oxide dispersion coating

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Coatings for erosion damage protection

excellent bonding on base material excellent bonding on thin blade leading edge excellent erosion resistance against particle erosion slight influence of coating on the base material (LCF, HCF) repairable by recoating

Titanium blades with erosion mulilayer coating

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Coatings for blade abrasion damage protection

Cubic boron nitride particles attached on blade tip

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Coatings for titanium fire damage protection

applications on titanium compressor casings low thermal conductivity sufficient thickness in order to protect the casing against Ti-fire excellent erosion and bond strength repairable by recoating

Titanium casing with plasma sparyed TBC coating

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Coatings for rotor rub in damage protection

applications on casings,

blade tip coating, seals and rotary parts abrasive in casing harder coating on rotor oxidation resistance at higher temperatures erosion resistance repairable Vane Blade

Abradable Coating Casing

Abradable Coating Rotor

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Coatings for rotor rub in damage protection

HPC clearance control by abradable plasma sprayed coating for rotor rub in

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Coatings for oxidation and corrosion damage protection

applications for turbine blades and vanes coating includes protective elements (Al / Cr) bonding to the base material through diffusion processes dense passivation coating is built (rebuilding after coating loose) smooth and aerodynamically surface applicable at high temperatures repairable by recoating Turbine vane segments

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Oxidation and cracking of component surface

Oxidation changed near surface chemical composition cracks can formed by embritlement
Dechema e.V.
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Hot corrosion typ II 600 800 C

Liquid Alkali Sulfur compounds from hot exhaust gas reacts with component surface
Dechema e.V.
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Hot corrosion typ I > 884 C

Gaseous Sulfur Oxide from hot exhaust gas reacts with component surface

Dechema e.V.
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Stabilty of metal oxides

Alpha aluminium oxide is the most stable oxide for protecting component surfaces

Dechema e.V.
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Aluminium oxid forming coatings

NiAl

Diffusion Zone
Oxidation life h

Ni alloy

Not coated
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+ Al coating

+ PtAl coating
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Coatings for heat damage protection

higher temperatures on the part surfaces compared to the base material are possible applications on blades, burner and casing low thermal conductivity elongation under thermal loading according to metal base material applications at high temperature range (1150C - 1200C on the surface) bonded to the base material through oxidation and corrosions resistant interface layers repairable by recoating

High pressure turbine blade

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Plasma spray process for coatings

Gordon England
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Coating structure for heat damage protection (1)

ZrO2 plasma sprayed thermal barrier coating - porous - micro cracks - poor bond strength

Al diffusion coating NiCrAlY bond coating atmospherically plasma sprayed

nickel-based superalloy

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EB PVD process for coatings

Thermal protective coating on Vane Cluster

Penn State Univ.

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Coating structure for heat damage protection (2)

ZrO2 EB - PVD thermal barrier coating - columnar - strong bond strength - Y stabilized

NiCrAlY bond coating

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Thank You !

FOR YOUR INTEREST AND ATTENTION ! QUESTIONS?

Horst Neubert

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