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Proceedings Papers
ITSC 2009, Thermal Spray 2009: Proceedings from the International Thermal Spray Conference, 397-402, May 4–7, 2009,
Abstract
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A noncryogenic milling process was recently developed to produce equiaxed nanostructured NiCrAlY powders. In this study, the powders are used to deposit metal bond coats, with and without thermal barrier topcoats, via HVOF and low-pressure plasma spraying. TBCs with bond coats derived from non-cryogenically milled nanopowder show a reduction in porosity and TGO growth rate, delayed formation of mixed oxides, and a 50% increase in cycles to failure during thermal cycle testing. The presence of very fine alumina in the powder and bond coats plays a significant role in these improvements.
Proceedings Papers
ITSC 2007, Thermal Spray 2007: Proceedings from the International Thermal Spray Conference, 604-609, May 14–16, 2007,
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Thermal barrier coatings (TBCs) with nanostructured bond coats have shown significant thermal cycling enhancements over their conventional microstructured counterparts; however, the high cost inherent to the cryomilling processing of the MCrAlY powder limits commercial application. Hence, this study characterizes and evaluates nanostructured bond coats derived from non-cryogenically milled MCrAlY powder with emphasis placed on reduced processing cost and scale-up capability. After extensive development of both a high-energy planetary mill and its operating parameters, fine-grained equiaxed NiCrAlY powder has been produced. XRD and SEM characterization of the milled powder will be presented. Microstructural analyses of the coatings sprayed via the HVOF and cold spray processes will also be carried out, in addition to some preliminary static oxidation test results of the conventional and milled NiCrAlY.