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Coatings for Advanced Aero Engine Materials
Dr. Wilfried Smarsly
Materials Engineering
8 th HIPIMS Conference
1 - 2 July, 2009, University Sheffield, UK
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 2
Anti-fretting coatingsCasing, blades, vanes, discs, shafts
Ti-fire protection coatingCompressor casing
Thermal barrier coatingTurbine blades, burner
Corrosion / oxidationprotection Coating
Turbine blades
AbradablesCasing, tip coating, seals
Erosion resistance coatingCompressor blades
Diameter adjustment coatingsgreat numbers of parts
Coatings required for aero engines
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 3
resistance against fretting fatigue and wear
applications on casings, blade roots, discs and shafts
dense coatings with high bond strength
repairable by recoating
Chromium carbide
+ nickel – chromium coating
plasma sprayed
Coatings for fretting damage protection (1)
Turbine vane
nickel alloy cluster
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 4
Coatings for fretting damage protection (2)
Cobalt-chromium oxide dispersion coating
seal ring
APS
Coating
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 5
Titanium blades witherosion mulilayer coating
excellent bonding on base material
excellent bonding on thinblade leading edge
excellent erosion resistance againstparticle erosion
slight influence of coating on thebase material (LCF, HCF)
repairable by recoating
Coatings for erosion damage protection
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 6
Coatings for blade abrasion damage protection
Cubic boronnitride
particlesattached
on blade tip
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 7
applications on titanium compressor casings
low thermal conductivity
sufficient thicknessin order to protect the casingagainst Ti-fire
excellent erosion and bond strength
repairable by recoating
Coatings for titanium fire damage protection
Titanium casing withplasma sparyed TBC coating
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 8
applications on casings,blade tip coating, sealsand rotary parts
abrasive in casing
harder coating on rotor
oxidation resistance athigher temperatures
erosion resistance
repairable
Coatings for rotor rub in damage protection
Casing
Rotor
Abradable Coating
Abradable Coating
Vane
Blade
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 9
Coatings for rotor rub in damage protection
HPC clearance
control
by
abradable
plasma sprayed
coating
for rotor
rub in
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 10
applications for turbine blades and vanes
coating includes protectiveelements (Al / Cr)
bonding to the base material throughdiffusion processes
dense passivation coating is built(rebuilding after coating loose)
smooth and aerodynamically surface
applicable at high temperatures
repairable by recoating
Coatings for oxidation and corrosion damage protection
Turbine vane
segments
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 11
Oxidation and cracking of component surface
Oxidation
changed
near surface
chemical
composition
cracks
can formed
by
embritlement
Dechema e.V.
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 12
Hot corrosion typ II 600 – 800 °C
Liquid
Alkali Sulfur
compounds
from
hot exhaust gas
reacts
with
component
surface
Dechema e.V.
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 13
Hot corrosion typ I > 884 ° C
Gaseous
Sulfur Oxide
from
hot exhaust gas
reacts
with
component
surface
Dechema e.V.
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 14
Stabilty of metal oxides
Dechema e.V.
Alpha aluminium
oxide
is the most stable
oxide
for protecting
component
surfaces
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 15
Aluminium oxid forming coatings
Not + Al + PtAl
coated coating coating
Ox
ida
tio
nli
feh
NiAl
Diffusion
Zone
Ni alloy
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 16
higher temperatures on the part surfaces comparedto the base material are possible
applications on blades, burner and casing
low thermal conductivity
elongation under thermal loading according tometal base material
applications at high temperature range(1150°C - 1200°C on the surface)
bonded to the base material through oxidation andcorrosions resistant interface layers
repairable by recoating
Coatings for heat damage protection
Highpressure
turbine
blade
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 17
Plasma spray process for coatings
Gordon England
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 18
Coating structure for heat damage protection (1)
ZrO2 plasma sprayed thermalbarrier coating- porous- micro cracks- poor bond strength
Al diffusion coating
NiCrAlY bond coatingatmospherically plasma sprayed
nickel-based superalloy
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 19
EB PVD process for coatings
Thermal
protective
coating on
Vane Cluster
Penn State Univ.
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 20
Coating structure for heat damage protection (2)
ZrO2 EB - PVD thermalbarrier coating
- columnar
- strong bond strength
- Y stabilized
NiCrAlY bond coating
copyrigth by MTU Aero Engines GmbH, TEW Dr. W. Smarsly 21
Thank You !
Horst Neubert
FOR YOUR INTEREST
AND ATTENTION !
Q U E S T I O N S ?