B. Witala

Characteristics of Phenomena in Powders Type RE2Zr2O7-Al2O3 in High Temperature Annealing Conditions

The paper presents test results and characterizes the structural stability of powders, which form a mixture of aluminium oxide (Al2O3) and gadolinium, based on rare earth zirconates. This mixture is provided to create thermal barrier coatings (TBCs) by spraying. The purpose of the tests was to determine the influence of temperature on reactions, occurring between those powders within a temperature range from 25°C to 1500°C, while such conditions were to simulate the conditions, which occur during creation of TBCs and they give an answer to the question concerning mutual reactivity of the powders. The requirements for new materials, provided to spray the TBCs, indicate the necessity to prepare the materials, which do not show tendency towards reactions with the Al2O3, formed during oxidation of Ni (Co) CrAlY, while this reaction is of type bond coat. The tests included differential scanning calorimetric (DSC) analysis and differential thermal analysis (DTA) of powder mixtures. Diffraction analysis was also performed before and after the tests have been finished. The DSC analysis results, obtained at a range of high temperature, did not show any thermal effects, which indicate a low level of mutual reactivity of the powders. However, the DTA analysis suggests presence of such effects at temperature close to 1300°C, and it indicates the necessity to verify exactly the obtained results. Results of the XRD measurement showed that after annealing process already at 1100°C the perovskite oxide of GdAlO3 was present.

Oxidation Resistance of Diffusion Silicide Coatings on Mo and TZM Alloy

Characterization of microstructure of pack cemented silicide coatings based on MoSi2 phase was described in this article as well as a short term oxidation resistance of these types of coatings at temperature 1200oC. Silicide coatings were deposited on top surface of Mo and Mo alloys of TZM type by diffusional process of siliconizing in activated powders. Morphology of coatings was characterized by evaluation of chemical and phase’s composition of deposited coatings by EDS and XRD methods respectively. In the case of Mo sheet after diffusion process of siliconizing single layer of MoSi2 type was obtained, but in the case of TZM alloy, in the same conditions of process, double layered coating was generated. Thick outer layer was build form MoSi2 phase, but very thin internal layer consist Mo5Si3 phase. The thicknesses of coatings were ca. 45μm, and were uniform. Morphology of coatings was free from inclusion and contaminations in their cores. The isolated cracks were observed, but their volume was very small. The oxidation test was performed at temperature 1200oC. The specimens were tested at 25, 500 and 100 hours of test. After each period of test characterization of coatings top surface was made. Total destruction of specimens was observed in range between 50 and 100 h of test.

Non-destructive measurement of top coat thickness in TBC systems by 3D optical topometry

This paper proposes a 3D optical topometry as a thickness evaluation method of ceramic layers in a sprayed state and after exposition. The measurements were taken using the advanced topometric sensor system, which allows for fast measurements of the elements geometry with high resolution. The results of evaluations are presented in the form of spot numerical values, coloured cross sections and 3D maps of thickness distributions. These data provide simple and quick localisations of non-uniform thickness areas or places of failure initiations with relatively high accuracy. This information is important for production engineers in failure analysis processes.

Characterization of Microstructure and Properties of Plasma Sprayed Ceramic Coatings on AZ91 Magnesium Alloy

The paper presents the microstructure test results of carbide layers with bond coat obtained on the magnesium alloy with WC/Co – NiCr – AZ91D type thermal spraying method. Layers were sprayed with the APS method on the sandblasted surfaces of approx. 5 mm thick elements manufactured with high pressure die casting (HPDC). The standard process parameters were used for the powders sprayed. The scope of the tests included characteristics of the AZ91D alloy top surface after HPDC process and after sandblasting. The stereometric analysis of surface was performed by using the laser profilometer. The top surface geometric parameters were determined and presented in the form of numbers and topographic maps. Both surfaces were subject to SEM analysis by using the Hitachi S3400N microscope and chemical composition analysis in micro areas (EDX analysis by using the Noran System Six software) to determine presence of impurities and other type of artefacts on the alloy surface before plasma spraying. The alloy surfaces were also subject to detailed tests after spraying process (on lateral micro-sections) to determine the influence of the spraying process on the substrate quality and consequently layer adhesion. Phase composition assessment of the NiCr 80/20 type bond coat and carbide layers WC/10Co and WC/8Co was also performed. Further tests referred to top surface morphology of both carbide layers and chemical composition assessment in micro areas.

Influence of Measurement Results of Thermal Conductivity and Heat Transfer Coefficients on the Simulation Results of Casting Process of Aircraft Engine Elements

The paper presents results of tests concerning influence of accuracy in measurements of selected thermal properties of materials of a ceramic mould, insulating mat and an alloy itself on effects of simulation of a casting process provided for elements of an aero-engine. A simulation process was realized by means of the PROCAST program. In initial simulations, thermal parameters were applied and they are accessible in literature and concern materials of a mould and nickel superalloys. Results of simulation revealed presence of numerous defects in a form of gaps, pores and cracks. These results were proved in trial casting. In consequence, it was impossible to select correctly right casting parameters. In order to solve this problem, a value of thermal conductivity was defined experimentally and basing on it, coefficients of heat exchange in metal – mould, mould – insulation mat systems were defined as well. A value of partial coefficients of heat exchange was used to determine values of substitute coefficient of heat exchange for the whole metal – mould, mould – insulation mat systems. By introducing the got data, one managed to define parameters of a casting process, providing improvement in a level of quality of cast elements.