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| Abstract No.: |
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Scheduled at:
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Wednesday, June 07, 2017, Hall 12 11:10 AM
Aviation & Power Generation Industry I
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| Title: |
Practical aspects of suspension plasma spray for thermal barrier coating on potential turbine components
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| Authors: |
Xinqing Ma* / Curtiss-Wright Corporation, USA
Peter Ruggiero / Curtiss-Wright, USA
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| Abstract: |
Suspension Plasma Spraying (SPS) was first developed in the mid-1990s, and since then SPS process has attracted extensive efforts and interests to produce fine-structured and functional coatings. In particular, thermal barrier coating applied by SPS gains increasing interest due to its potential for superior thermal protection of turbine hot-section components to conventional APS-TBC and even EB-PVD TBC. Unique columnar architecture and nano- and sub-micron sized grains in a SPS-TBC demonstrate some advantages of thermal shock durability, low thermal conductivity and high-temperature sintering resistance. This work will look into some practical aspects of SPS process for TBC application before it becomes a liable industry method. First, the capability of SPS process to apply uniformity thickness and microstructure on a complex curved configuration was evaluated using simulated hardware with different radius. Then, a turbine blade was coated and sectioned to check on coating coverage and uniformity. To test the survival feasibility of SPS-TBC in a high flow and erosive environment, the erosion resistance of SPS-TBC was measured and correlated to incident angles. SPS process was also investigated for its accessibility to the designated coating areas at different standoff distance. The physical property changes and thermal stability of SPS-TBC after heat treatment or thermal aging were estimated to predicate the effect of thermal exposure on its performance. Other practical aspects of SPS process, such as spray efficiency, economy and EHS concerns also were considered in order to meet industrial demands and effective manufacture.
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