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Aircraft turbines
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Proceedings Papers
ITSC 2022, Thermal Spray 2022: Proceedings from the International Thermal Spray Conference, 447-452, May 4–6, 2022,
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Repair methods are of great interest to the aeronautic industry, especially for turbines. Deposition techniques that can quickly and easily repair small localised areas of damage in Thermal Barrier Coatings (TBCs) on combustion chambers could be financially worthwhile. In a first approach, a Low-Power Plasma Reactor (LPPR) operating at low pressure (< 1000 Pa, 240 W) was tested to locally deposit effective Yttria partially Stabilised Zirconia (YSZ) as TBC; however, a vacuum chamber would be more difficult to implement on an industrial scale. For this reason, a new LPPR (< 1 kW) operating at atmospheric pressure with solution precursors was investigated. The precursors were injected in the plasma afterglow to be sprayed and deposited onto parts of combustion chambers. As the afterglow temperature was cooler than for most thermal spray processes, spray distance was less than 10 mm. As such, YSZ deposition could be performed locally in hard-to-reach areas. YSZ coating characteristics were studied by FTIR and SEM analyses. For example, YSZ coatings exhibited the expected stoichiometry, a precursor conversion of 98 mol%, good adherence, and a porosity evaluated at approximately 30 vol%. In addition, YSZ coating thickness could be greater than 200 μm.
Proceedings Papers
ITSC 2004, Thermal Spray 2004: Proceedings from the International Thermal Spray Conference, 498-503, May 10–12, 2004,
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The use of polymer matrix composites [PMC's] in the gas flow path of advanced turbine engines offers significant benefits for aircraft engine performance, but their useful lifetime is limited by their poor erosion resistance. HVOF and flame sprayed polymer/cermet functionally graded coatings based on a polyimide matrix filled with varying volume fractions of WC-Co are being investigated to improve the erosion and oxidation resistance of polymer matrix composites. A study of the coating's effectiveness as erosion barriers was accomplished through a statistical analysis of the results of solid particle erosion testing of coated and uncoated PMC samples using a design of experiments [DoE] approach. Three coating systems and a control were evaluated in a randomized test matrix. The coatings were tested at room temperature and 250 °C, using an alumina erodent impacting the coatings at a speed of 100 m/s at angles of 20° and 90°. Erosion volume loss at 250 °C was approximately twice than at room temperature, but the maximum erosion volume loss did not exceed 0.30 mm 3 at the elevated temperature. In general, as the angle of incidence of the eroding material increased from 20 degrees to 90 degrees the volume loss increased.
Proceedings Papers
ITSC 2003, Thermal Spray 2003: Proceedings from the International Thermal Spray Conference, 735-740, May 5–8, 2003,
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Abradable seals are used in compressors of aircraft and industrial gas turbines to decrease clearance between the stator casing and rotor blade tips and hence to increase compressor efficiency and decrease fuel consumption. The main interest of abradable materials producers has been concentrated on abradable seals for aircraft engines, and special requirements of industrial gas turbine manufacturers have not been met so far. The most significant requirement in industrial gas turbines is durability. This is driven by the need for several times longer periods between overhauls in industrial gas turbines compared to aircraft engines. Westaim Ambeon has developed a new composite powder, Durabrade2413, that meets these requirements. The new abradable seals fabricated by using this powder have been extensively tested over a prolonged period of time. This paper will present the results of an intensive development, evaluation and abradability testing of seal properties. This paper will also show that Durabrade2413 series coating properties can be altered in a broad range by changing spray parameters to tailor the coating to a particular application. The abradable seals are suitable to rub against steel and Ni alloy blades. The abradability results of Durabrade2413 are compared to Durabrade2222 (the Metco 307-NS equivalent), the well known 75Ni25 Graphite abradable that has been on the market for the last 30 years.
Proceedings Papers
ITSC 2002, Thermal Spray 2002: Proceedings from the International Thermal Spray Conference, 631-634, March 4–6, 2002,
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This paper discusses the ongoing development of a standard for manufacturing and testing thermal spray coatings used in the repair of aircraft engines. Excellent progress has been made in eliminating non-value added tests and in defining a system for preparing metallographic specimens and conducting microstructural evaluations. Paper includes a German-language abstract.
Proceedings Papers
ITSC 2002, Thermal Spray 2002: Proceedings from the International Thermal Spray Conference, 733-738, March 4–6, 2002,
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In a recent effort, AlSi 20wt% BN powder was optimized for clearance control applications in aircraft engines. This paper follows up on the initial results, reviewing the wear mechanism of AlSi, the corrosion behavior of AlSi-BN and AlSi-graphite, and the commercial use of AlSi-BN abradable coatings. Paper includes a German-language abstract.
Proceedings Papers
ITSC1999, Thermal Spray 1999: Proceedings from the United Thermal Spray Conference, 542-545, March 17–19, 1999,
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The application of thermal barrier coatings is increasing in aeroengines. The service life of turbine components could be improved by optimized structures of the zirconia top coating. The thermal barrier coatings on turbine blades were tested in a hot gas thermal shock test. Up to 6500 thermal cycles until first spallation a plasma sprayed ceramic thermal barrier coatings can be very well compared with the service life of EB-PVD thermal barrier coatings with 8000 - 9000 thermal cycles until first spallation. Paper text in German.