Sławomir Kotowski

The technology of Plasma Spray Physical Vapour Deposition

Abstract The article presents a new technology of thermal barrier coating deposition called Plasma Spray – Physical Vapour Deposition (PS-PVD). The key feature of the process is the option of evaporating ceramic powder, which enables the deposition of a columnar ceramic coating. The essential properties of the PS-PVD process have been outlined, as well as recent literature references. In addition, the influence of a set of process conditions on the properties of the deposited coatings has been described. The new plasma-spraying PS-PVD method is a promising technology for the deposition of modern thermal barrier coatings on aircraft engine turbine blades.

Influence of Deposition Parameters on Structure of TDCs Deposited by PS-PVD Method

The paper presents an advanced technology of Thermal Barrier Coatings (TBCs) deposition called Plasma Spray – Physical Vapor Deposition (PS-PVD). The PS-PVD is a low pressure plasma spray technology to deposit coatings out of vapor phase, which enables obtaining of columnar ceramic coatings. In this paper, the influence of various gas mixtures on properties of deposited coatings has been investigated. The measurement of coating thickness was conducted by a light microscopy method, followed by a statistical analysis. All processes had been conducted at a very low feed rate, which additionally affected ceramic microstructure.

Microstructural Characterization of Thermal Barrier Coatings Deposited by APS and LPPS Thin Film Methods

In the paper first results of TBCs deposition by LPPS-Thin Film method were presented. The LPPS-Thin Film is a new type of processes for deposition of thermal barrier coatings. In this method deposition of thin ceramic layer in very low pressure is possible as well as coatings with columnar structure (in plasma spraying-physical vapour deposition process). The MeCrAlY bond coats were deposited by APS method. The overaluminising by CVD method of conventional MeCrAlY was also conducted. The analysis of microstructure of both type bond coats as well as outer ceramic layer were presented using light and scanning electron microscopy methods. Results of EDS microanalysis showed the increasing of aluminum content in outer zone of overaluminized MeCrAlY coating. In ceramic layer the columnar structure were observed which was connected with powder evaporation during plasma spraying. The new type of MeCrAlY-NiAl bondcoat could increase the oxidation of TBCs deposited by LPPS Thin Film method.

Numerical Prediction of the Thermodynamic Properties of Ternary Al-Ni-Pd Alloys

Abstract Thermodynamic properties of ternary Al-Ni-Pd system, such as exGAlNPd, µAl(AlNiPd), µNi(AlNiPd) and µPd(AlNiPd) at 1,373 K, were predicted on the basis of thermodynamic properties of binary systems included in the investigated ternary system. The idea of predicting exGAlNiPd values was regarded as calculation of values of the exG function inside a certain area (a Gibbs triangle) unless all boundary conditions, that is values of exG on all legs of the triangle are known (exGAlNi, exGAlPd, exGNiPd). This approach is contrary to finding a function value outside a certain area, if the function value inside this area is known. exG and LAl,Ni,Pd ternary interaction parameters in the Muggianu extension of the Redlich–Kister formalism were calculated numerically using the Excel program and Solver. The accepted values of the third component xx differed from 0.01 to 0.1 mole fraction. Values of LAlNiPd parameters in the Redlich–Kister formula are different for different xx values, but values of thermodynamic functions: exGAlNiPd, µAl(AlNiPd), µNi(AlNiPd) and µPd(AlNiPd) do not differ significantly for different xx values. The choice of xx value does not influence the accuracy of calculations.

Microstructure and Isothermal Oxidation Resistance of Thermal Barrier Coatings Deposited by LPPS, CVD and PS-PVD Methods on Inconel 617 Nickel Superalloy

The paper presents results of research into thermal barrier coatings characterized by higher oxidation resistance. Bondcoats were formed by overaluminizing of the MeCrAlY coating, deposited by low pressure plasma spraying (LPPS). The outer ceramic layer of yttrium oxide stabilized zirconia oxide was deposited by plasma spray physical vapour deposition (PS-PVD). For comparison purposes additionally formed were MeCrAlY bondcoats, which were not subsequently aluminized. The research showed that during CVD overaluminizing there was formed an additional layer built of the β-NiAl phase, which protects the base material from oxidation. Preserved below it increased chromium content ensures resistance to hot corrosion. The outer layer was characterized by columnar structure, similar to that obtained in the EB-PVD process. The isothermal oxidation tests showed that thickness of the TGO layer into overaluminized bondcoat significantly thicker in comparison with conventional LPPS-sprayed MeCrAlY bondcoats.

Microstructure of Thermal Barrier Coatings Deposited by Low Pressure Plasma Spraying and Chemical Vapour Deposition Methods on Rene 80 Nickel Superalloy

The paper presents results of research into thermal barrier coatings characterized by high oxidation resistance and hot corrosion. Bondcoats were formed by overaluminizing of an MeCrAlY–type coating deposited by low pressure plasma spraying. The outer ceramic layer of yttrium oxide stabilized zirconia oxide (Metco 6700) was deposited by plasma spray physical vapour deposition (PS-PVD). For comparison purposes additionally LPPS-sprayed were MeCrAlY bondcoats, which were not subsequently aluminized. Used as base material was Rene 80 nickel superalloy. The research has shown that as a result of aluminizing by the CVD method there was formed in the bondcoat a deposit zone built of the β-NiAl phase which protects from oxidation. Preserved below increased chromium content ensures resistance to hot corrosion. The outer ceramic layer was characterized by columnar structure similar to that obtained in the EB-PVD process.

The Influence of Temperature on Erosion Resistance of Carbide Coatings Deposited by APS Method

The carbide coatings are widely used for wear and erosion protection of different materials. In present paper the WC/Co coatings were deposited by a single-cathode Sulzer Metco F-4 plasma gun. The microstructure and thickness measurements were conducted. The erosion test was conducted using a Koechler Air Jet Errosion tester at the temperature of up to 500oC. The procedure was similar to ASTM G76 standard. Changes in erosion resistance of coating into different temperature were observed.

Numerical prediction of the thermodynamic properties of ternary Al-Ni-Hf alloys

Thermodynamic properties of ternary Al-Hf-Ni system, such as exG, μAl, μNi and μZr at 1373K were predicted on the basis of thermodynamic properties of binary systems included in the investigated ternary system. The idea of predicting exG values was regarded as the calculation of excess Gibbs energy values inside a certain area (a Gibbs triangle) unless all boundary conditions, that is values of exG on all legs of the triangle are known. exG and Lijk ternary interaction parameters in the Muggianu extension of the Redlich-Kister formalism are calculated numerically using Wolfram Mathematica 9 software.Thermodynamic properties of ternary Al-Hf-Ni system, such as exG, μAl, μNi and μZr at 1373K were predicted on the basis of thermodynamic properties of binary systems included in the investigated ternary system. The idea of predicting exG values was regarded as the calculation of excess Gibbs energy values inside a certain area (a Gibbs triangle) unless all boundary conditions, that is values of exG on all legs of the triangle are known. exG and Lijk ternary interaction parameters in the Muggianu extension of the Redlich-Kister formalism are calculated numerically using Wolfram Mathematica 9 software.

Mechanical Aspects of Plastic Deformation of Nickel Based Superalloy

Variations of a true stress vs. true strain illustrate behaviour of materials during plastic deformation. Stress-strain relationship is generally evaluated by a torsion, compression and tensile tests. Results of these tests provide crucial information pertaining to the stress values which are necessary to run deformation process at specified temperature and cooling rate. Uniaxial compression tests at temperatures below the γ solvus were conducted on nickel based superalloy CMSX-4, to study the effect of temperature and strain rate on its flow stress. On the basis of received flow stress values activation energy of a high-temperature deformation process was estimated. Mathematical dependences (σpl -T i σpl - ἐ) and compression data were used to determine material constants. These constants allow to derive a formula that describes the relationship between strain rate, deformation temperature and true stress.

Influence of Low Pressure Plasma Spraying Parameters on MCrAlY Bond Coat and its Microstructure

Low pressure plasma spraying (LPPS) is one of the most advanced processes of an MCrAlY bond coat formation. It ensures the forming of metallic coatings free of oxides which can act as an bond coat for thermal barrier coatings used, among others, for protection of turbine blade surface. The paper presents results of tests into microstructure of coatings made from AMDRY 997 powder on the base of type Inconel 617 heat-resistant nickel alloy. The tests were carried out using light and scanning electron microscopy. Evaluated was the influence of spraying conditions on microstructure, porosity and thickness of the obtained coating. Test results show that the LPPS method allows to form coatings of low porosity and free of oxides which can be used as an bond coat in thermal barrier coatings.