Multidisciplinary optimization techniques provide a novel method for rapid product development that also meets sustainability goals.

Use of radiography to inspect insulated generator components without the need to strip insulation offers advantages over other inspection methods to assess serviceability and need for repair. This article outlines some of the considerations involved in using nondestructive radiography techniques to assess component integrity.

Thermal spray coatings are widely used to keep power plants running at full capacity. An example is the application of HVOF-sprayed CrC-NiCr to protect generating and superheater banks from sulfuric and vanadium gases. Other examples include the use of arc spraying to deposit high Cr content Ni alloy to extend the life of coal-fired boiler tubes and to apply amorphous work hardening coatings to surfaces in the flu gas path that are susceptible to high-temperature corrosion and wear.

This article presents a brief overview of thermally sprayed thermal barrier coatings (TBCs) used in gas turbines that generate electrical power.

This article discusses some of the newer thermal barrier coating materials being considered for use in gasified coal-based turbines and how they compare with conventional materials in terms of bond coat oxidation and topcoat damage due to particle erosion and molten ash deposits.

The growth and exfoliation of thermally grown oxides, or scales, in steam power plants is a complex phenomenon that depends on alloy composition, microstructure (including surface condition), temperature, pressure, and plant operation. This article discusses the factors that contribute to oxide scale buildup in ultrasupercritical boiler tubes and ongoing efforts to mitigate problems due to steam-side oxidation and exfoliation in high-efficiency power plants.

Compared to traditional power plant materials, creep strength enhanced ferritic steels require new approaches to nondestructive examination and weld repair. The metallurgical complexity of these steels prompted EPRI to conduct research to define and/or improve the detection limits of ultrasonic testing techniques, explore novel electromagnetic techniques, evaluate the sensitivity and applicability of acoustic emission testing, and conduct studies on improved weld repair procedures.

A powder metallurgy and hot isostatic pressing technology offers a new way to manufacture high pressure-retaining components for use in the power-generation industry.