A test flight was cut short after a fire warning came on indicating a problem with one of the four engines on an aircraft. A visual examination following the precautionary landing revealed several burned hoses, a melted bolt, and fuel leaking from the base of the main burner. The fuel nozzle was also damaged, and based on its microstructure, came very close to melting. Investigators determined that the burner was mounted backwards, facing the compressor rather than the turbine. They also recommended a redesign to prevent the fuel nozzle from being reversed.

This article provides a brief description of commercially important thermal spray processes and gives examples of applications and application requirements. The processes covered are flame, wire arc, plasma, high-velocity oxyfuel processes, detonation gun, and cold spray methods. Examples are provided of the applications in aerospace, automotive, and medical device industries as well as the use of thermal spray as an additive manufacturing technique.

The Nuclear Waste Management Organization (NWMO) investigates approaches for managing Canada's used nuclear fuel. As part of a larger program investigating concepts of copper coatings, NWMO has begun exploring copper cold spray in collaboration with the National Research Council. Within the coating program, a large variety of copper coating sizes have been investigated, from small corrosion coupons to full-scale used-fuel containers/canisters (UFCs). This chapter demonstrates the successful application of copper coating technology to full-scale geometric representative Mark II UFC mock-up configurations through activities involving powder selection, general coating development, UFC coating optimization, and prototyping.

This chapter explains how the authors assessed the potential risks of creep-fatigue in several aerospace applications using the tools and techniques presented in earlier chapters. It begins by identifying the fatigue regimes encountered in the main engines of the Space Shuttle. It then describes the types of damage observed in engine components and the methods used to mitigate problems. It also discusses the results of analyses that led to changes in design or approach and examines fatigue-related issues in turbine engines used in commercial aircraft.

This chapter provides a brief overview of iron and steel manufacturing and the major equipment involved in the process as well as identifying where casting fits into the overall process. In addition, it provides an overview of cast iron manufacturing, including the processes involved in converting pig iron into cast iron and steel.

This chapter examines the hot corrosion resistance of various nickel- and cobalt-base alloys in gas turbines susceptible to high-temperature (Type I) and low-temperature (Type II) hot corrosion. Type I hot corrosion is typically characterized by a thick, porous layer of oxides with the underlying alloy matrix depleted in chromium, followed (below) by internal chromium-rich sulfides. Type II hot corrosion is characterized by pitting with little or no internal attack underneath. As the chapter explains, chromium additions make alloys more resistant to all types of hot corrosion attacks.

This chapter covers the basics of weldability of cast steels such as carbon and low alloy steels, corrosion-resistant high alloy steels, nickel-base alloys, heat-resistant high alloy steels, and wear-resistant high austenitic manganese steels. It provides an overview of weld overlay and hard facing; cast-weld construction; and plasma arc cutting and plasma arc welding. The chapter discusses different types of welding processes. These include shielded metal-arc welding, air carbon arc cutting process, gas tungsten-arc welding, gas metal-arc welding process, flux-cored arc welding, submerged arc welding, and electroslag and electro-gas welding.

The modeling and simulation activities in the field of high-pressure cold spray can be divided into two main parts: solid mechanics and fluid dynamics. This chapter focuses on these parts of modeling work in cold spray research. The discussion covers the objective, principal concepts, methods, and outcome of modeling and simulation of particle impact and of in-flight history of particles in cold spraying. The concept of integration of particle impact and fluid flow modeling to optimize cold spray deposition for a given material is also explained.

This chapter describes various units and process streams that are often susceptible corrosion inhibitors in crude oil refineries, discusses the types and applications of corrosion inhibitors, and provides some information on corrosion monitoring techniques used at refineries.

Combustion turbines consist of a compressor, a combustor, and a turbine. As commonly configured, the compressor and turbine mount on a single shaft that connects directly to a generator. This chapter reviews the materials of construction, damage mechanisms, and life-assessment techniques for nozzles and buckets. It also presents key information from a detailed review of the literature and the results of a survey on combustion-turbine material problems.

This chapter reviews the current understanding of high-pressure cold spraying for different materials, covering widely accepted general mechanisms for particle deposition and the processes and parameters involved. It begins by reviewing the mechanisms of bonding. An overview of the optimization of the critical process parameters for improving coating qualities is then provided. This is followed by a separate section dealing with bonding between different materials and addressing influences on adhesion to the substrate as well as the cohesion between dissimilar coating constituents. The knowledge of the basic science and mechanisms finally allows for discussion on the requirements for suitable cold spray equipment and of the parameter sets needed for successful coating deposition.

This chapter focuses on resistance characteristics and methods of protecting different forms of high-temperature gaseous corrosion, namely high-temperature oxidation, sulfidation, carburization, hydrogen effects, and hot corrosion.

This chapter gives a brief review of the development of additive manufacturing (AM) and the appeal of different of different AM methods.

This chapter describes the processes involved in alloy production, including melting, casting, solidification, and fabrication. It discusses the effects of alloying on solidification, the formation of solidification structures, supercooling, nucleation, and grain growth. It describes the design and operation of melting furnaces as well as melting practices and the role of fluxing. It also discusses casting methods, nonferrous casting alloys, and atomization processes used to make metal powders.

Ferritic stainless steels are essentially iron-chromium alloys with body-centered cubic crystal structures. Chromium content is usually in the range of 11 to 30%. The primary advantage of the ferritic stainless steels, and in particular the high-chromium, high-molybdenum grades, is their excellent stress-corrosion cracking resistance and good resistance to pitting and crevice corrosion in chloride environments. This chapter provides information on the classifications, properties, and general welding considerations of ferritic stainless steels. The emphasis is placed on intergranular corrosion, which is the most common cause of failure in ferritic stainless steel weldments. Two case histories involving intergranular corrosion failures of ferritic stainless steel weldments are included. A brief discussion on hydrogen embrittlement is also provided.

This chapter discusses the application of high-pressure cold spray to the automotive industry field, with special attention to three applications: additive manufacturing, fabrication methods, and protective coatings. Various studies on the automotive application of cold spray are reviewed. The background and purpose of each application are presented and practical cases are discussed.