Search Results for turbine engine components

This article describes the development and evaluation of a novel atmospheric plasma spray torch designed to overcome limitations in coating internal diameter surfaces. A case study demonstrates the torch's effectiveness in producing high-quality thermal barrier coatings (TBCs) for turbine components, applying NiCoCrAlY+HfSi bond coats and 8 wt% YSZ topcoats with appropriate porosity levels. Analysis results confirm that this torch delivers comparable performance to conventional torches while enabling the critical capability of operating in confined geometries, addressing a significant gap in thermal spray applications for gas turbine engine components subjected to extreme operating conditions.

Vacuum plasma and low pressure plasma spray technologies each provide unique solutions for achieving superior properties in metallic coatings that require low oxide content and high density. Applications include various turbine engine components, as well as biomedical and electronics components.

A microscale fatigue testing technique for characterizing mechanical response and relating it to microstructure promises to improve fatigue life prediction for turbine engine components.

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

Single crystal and directionally solidified casting processes are among the most complex techniques available, requiring stringent process control and a thorough understanding of engineered materials and specialty alloys. This article examines how an aerospace material company utilizes advanced investment casting techniques to create components that meet the increasingly demanding requirements of modern aerospace and gas turbine engines. The article highlights how solidification modeling and integrated computational materials engineering (ICME) have accelerated development processes by predicting material behaviors and optimizing casting parameters without extensive experimental testing.

During the past 30 years, enormous research has been devoted to developing titanium-base intermetallics for use in gas turbine engines as lightweight alternative to nickel-base superalloys. This article presents a brief history of Ti 2 AlNb and efforts to mature this material for commercial component production. The article includes processing experience insights gained from a current R&D program in China.

Neutron-based imaging and measurement techniques are an ideal complement to x-ray methods for characterizing additively manufactured materials and components. This article presents examples showing how neutron radiography and residual strain measurements reveal the internal structure and stress distributions in highly engineered turbine blades produced by additive processes. It also discusses the development of neutron characterization tools at ORNL and a recent effort in which they were used to evaluate stress-relief treatments for large-scale metal AM structures.

Clearance-control coatings play a major role in gas turbine engines by minimizing the air gap between rotating blade tips and engine casings. An improvement of just 125 µm can reduce fuel consumption by 0.5%. This article discusses the potential impact of new materials being considered for blade tip coating systems, including NiCoCrAlY bond coats and matrix layers with Hf, Re, or Si additions for better oxidation and creep resistance, embedded angular CBN particles for enhanced incursion of abradable shroud coatings, and double or Pt aluminide topcoats for extended oxidation protection.

Thermal barrier coatings (TBCs) with segmented or cracked microstructures exhibit enhanced thermal cyclic behavior and erosion resistance, along with improved application economics, over conventional TBCs.

Advanced materials engineering is being used to solve component life cycle improvement challenges in extremely harsh working conditions. This article discusses examples from various industries where new materials and surface modifications are used to extend the useful life of engineering components and equipment.

Field assisted sintering technology (FAST) enables hybrid components for aerospace to be designed with reduced weight and without sacrificing performance. FAST can be used to produce metal, ceramic, and composite components with tailored properties via a powder metallurgy approach. In many cases, it is a one-step, cost-effective manufacturing process for production of net-shape components.

An industry pioneer shares a historical overview of the early days of single crystal superalloy development.

High-speed rotating components in gas turbines, flywheels, and turbo machinery can be a lethal threat in the event of a failure due to the energy they possess. To assess the risks associated with such failures, rotor assemblies can be evaluated by spin testing although there are inherent risks in the tests themselves. This article discusses these risks and explains what can be done to minimize the potential dangers of high-speed performance testing.

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.

News about ASM members, chapters, events, awards, conferences, affiliates, and other society activities. Topics include: ASM's 2014 Class of Fellows; ASM Indian Institute of Metals announces 2014 recipients of two Visiting Lecturer Programs; Brian Wright named 2014 Kishor M. Kulkarni Distinguished High School Teacher.

In North America, renewable power sources and gas turbines are often in the news, but globally, steam turbines generate the largest portion of electricity, and they will remain a predominant power-generation technology for many decades. Because steam turbines represent a preponderance of our power-generation base, it is essential to continue to drive turbine technology development. Until now, the main technical barrier limiting large efficiency improvements was the temperature constraint imposed by available materials. Today, the game is changing. Due to advancements in materials, we now have a chance to make unprecedented improvements in steam turbine power plant efficiency by raising the inlet temperature hundreds of degrees through the use of new tailored superalloys.

Oxide dispersion strengthened (ODS) alloys have potential to improve turbine blade temperature capability beyond that of superalloy single crystals. In this article, the case is made for the potential to replace single crystals as high-pressure turbine blades with ODS nickel-base alloys. ODS alloys combine proven technology, substantial gains in capability over today’s single crystal alloys, and a clear development path to overcome identified risks.

Case studies from a range of industries illustrate how advanced additive manufacturing capabilities optimize both material performance and value. The materials discussed are Inconel 718, Ti-6Al-4V, aluminum F357, and Hastelloy X.

For those who are active within the thermal spray industry, 2017 offered a dramatic mix of jubilation and concern over conditions within the global thermal spray market. This article briefly reviews some of the market factors influencing the industry in 2017 and future outlook.

Nanobrazing is an innovative brazing technique that uses nanomaterials as the filler materials. Incorporating nanobrazing into conventional technologies such as vacuum and laser brazing creates a new frontier for repairing turbine blades and vanes. Due to the unique “nanopowdering” of filler materials, the metallurgical mechanisms and thermodynamics of nanobrazing show promise for innovative applications.