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R.K. Schmid
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Proceedings Papers
ITSC 2005, Thermal Spray 2005: Proceedings from the International Thermal Spray Conference, 438-443, May 2–4, 2005,
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Low pressure plasma spraying (LPPS) is well established as coating process for the deposition of TBC systems for industrial gas turbines as well as aero applications under industrial standards. With the extension to LPPS Thin Film process, the operating conditions can vary in a wide range from only a few mbar up to typically 200 mbar which imposes different characteristics of the corresponding spray conditions and resulting coating properties. The flexibility of this process allows for subsequent coating of different layers for bond and top coat of a complex TBC system by using only a single TS technology. This simplifies the operational needs for industrial production and offers the potential of increased technological and economical benefits. Depending on the process conditions a broad variety of different TBC layers, multi-layer systems including bond coats & diffusion barriers, dense, porous or graded YSZ layers as well as EB-PVD like layers with columnar microstructure, can be realized using the LPPS-TF technology. Proper adjustment of spraying conditions and suited material selection allows controlling the grade of “columnarity” of the layer. Thermal cycling as well as GE erosion tests have been used to characterize and benchmark the coating quality. Transfer of such coatings onto real turbine blade has demonstrated that all substrate areas could be coated with a columnar TBC structure up to a thickness of about 250 microns. This offers the possibility either to develop coatings with optimized performance or of comparable quality at reduced production costs when compared to established vapour deposition techniques like EB-PVD. This paper presents an overview on the development of various TBC systems such as multi-layers or columnar structures by using the LPPS Thin Film technology.
Proceedings Papers
ITSC 2004, Thermal Spray 2004: Proceedings from the International Thermal Spray Conference, 61-65, May 10–12, 2004,
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Plasma spraying at low pressure conditions (LPPS) is a well established thermal spray process with a broad variety of important applications in different industrial segments. The operating conditions for LPPS processes can vary in a wide range from only a few mbar up to typically 200 mbar which imposes different characteristics of the corresponding spray conditions and resulting coating properties. Thermal spray processes have been approved being suitable for integrated fabrication of various layers for SOFC components. Depending on the process conditions, different layers used as functional coatings of SOFC components such as dense electrolyte layers as well as porous electrodes can be realized using the LPPS technology. Due to the flexibility of these processes, an optimized performance of the application on different target materials and geometries is possible with an increased technological and economical benefit compared to conventional thermal spray techniques. This paper presents an overview on the general potential and spray conditions of the LPPS process and its application for the deposition of various functional layers such as electrolyte and electrodes for SOFC components.
Proceedings Papers
ITSC2000, Thermal Spray 2000: Proceedings from the International Thermal Spray Conference, 1087-1093, May 8–11, 2000,
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Very many gap-sealing products are now available for use in the compressor section of gas turbines. This paper attempts to give an overview of these and where they are best used. Data is presented for abradability, erosion resistance and application technique. By explaining how abradables function tribologically it is hoped that selection will be simpler for designers. New products are introduced as well as the way forward described. It is shown how with time the diversity of application techniques has decreased with thermal spraying becoming the preferred technique, and that abradables are now available to run against titanium blading up to 600°C.
Proceedings Papers
ITSC1998, Thermal Spray 1998: Proceedings from the International Thermal Spray Conference, 139-144, May 25–29, 1998,
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Aluminium silicon alloys have shown favourable properties when used as the matrix for abradable coatings in low pressure compressors of gas turbines [1 and 2]. This paper aims to describe the wear mechanisms found in aluminium silicon based abradables. To this end three thermally sprayed coatings are investigated. Aluminium silicon polyester, aluminium silicon-graphite and the most recently developed, aluminium silicon-hexagonal boron nitride (hBN) examined here are amongst a few of these materials. To be able to design materials to function in as wide a parameter range as possible, a test ng simulating engine mechanisms is required. Tests were conducted using titanium blades at velocities ranging from 250 - 450 m/s, temperatures of ambient to 450°C and controlled incursion rate of 5, 50 and 500 µm/s. The data obtained from these tests is best interpreted in the form of wear maps which characterise the seal performance and therefore are of use to engine and material designers.