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Superalloy
Coating of superalloys
Superalloy products that are subjected to high working temperatures
and corrosive atmosphere (such as high pressure turbine region of jet
engines) are coated with various kinds of coating. Several kinds of
coating process are applied: pack cementation process, gas phase
coating (both are a type of chemical vapor deposition (CVD)), thermal
spraying, and physical vapor deposition. In most cases, after the
coating process near-surface regions of parts are enriched with
aluminum, the matrix of the coating being nickel aluminide.
Pack cementation process
The pack cementation process is carried out at lower temperatures,
about 750 C. The parts are loaded into boxes that contain a mixture of
powders: active coating material, containing aluminum, activator
(chloride or fluoride), and thermal ballast, like aluminum oxide. At high
temperatures the gaseous aluminum chloride is transferred to the
surface of the part and diffuses inside (mostly inward diffusion). After
the end of the process the so-called "green coating" is produced, which
is too thin and brittle for direct use. A subsequent diffusion heat
treatment (several hours at temperatures about 1080 C) leads to
further inward diffusion and formation of the desired coating.
Thermal spraying
Thermal spraying is a process of applying coatings by heating a
feedstock of precursor material and spraying it on a surface. Different
specific techniques are used depending on desired particle size, coat
thickness, spray speed, desired area, etc. [39] The coatings applied by
thermal spraying of any kind, however, rely on adhesion to the surface.
As a result, the surface of the superalloy must be cleaned and
prepared, usually polished, before application of the thermal coating.[40]
Plasma spraying
Of the various thermal spray methods, one of the more ideal and
commonly used techniques for coating superalloys is plasma spraying.
This is due to the versatility of usable coatings, and the high-
The bond coat adheres the thermal barrier coating to the superalloy
substrate. Additionally, the bond coat provides oxidation protection
and functions as a diffusion barrier against the motion of substrate
atoms towards the environment.
There are five major types of bond coats, the aluminides, the platinumaluminides, MCrAlY, cobalt-cermets, and nickel-chromium.
For the aluminide bond coatings, the final composition and structure of
the coating depends on the composition of the substrate. Aluminides
also lack ductility below 750 C, and exhibit a limited by
thermomechanical fatigue strength.
The Pt-aluminides are very similar to the aluminide bond coats except
for a layer of Pt (5-10 m) deposited on the blade. The Pt is believed to
aid in oxide adhesion and contributes to hot corrosion. The cost of Pt
plating is justified by the increased blade life span.
The MCrAlY is the latest generation of bond coat and does not strongly
interact with the substrate. Normally applied by plasma spraying,
MCrAlY coatings are secondary aluminum oxide formers. This means
that the coatings form an outer layer of chromium oxide (chromia), and
a secondary aluminum oxide (alumina) layer underneath. These oxide
formations occur at high temperatures in the range of those that
superalloys usually encounter.[44] The chromia provides oxidation and
hot-corrosion resistance. The alumina controls oxidation mechanisms
by limiting oxide growth by self-passivating. The yttrium enhances the
oxide adherence to the substrate, and limits the growth of grain
boundaries (which can lead to flaking of the coating). [45] Investigation
indicates that addition of rhenium and tantalum increases oxidation
resistance.
Cobalt-cermet based coatings consisting of materials such as tungsten
carbide/cobalt can be used due to excellent resistance to abrasion,
corrosion, erosion, and heat.[46] These cermet coatings perform well in
situations where temperature and oxidation damage are significant
concerns, such as boilers. One of the unique advantages of cobalt
cermet coatings is a minimal loss of coating mass over time, due to the
strength of carbides within the mixture. Overall, cermet coatings are
useful in situations where mechanical demands are equal to chemical
demands for superalloys.
Nickel-chromium coatings are used most frequently in boilers fed by
fossil fuels, electric furnaces, and waste incineration furnaces, where
the danger of oxidizing agents and corrosive compounds in the vapor
must be dealt with.[47] The specific method of spray-coating depends on