航空发动机叶片热障涂层技术AircraftEnginerTBCbenchmark精品文档21页

Novel TBC material, microstructure Spallation model, lifetime prediction Failure analysis, bondcoat modification Morphology, porosity Process para, material EBDVD, systematical exp&simulation
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EB-PVD
Advantages •Strong adherence, wear resistance •Dense, atom/ion evaporation •Columnar grain
Drawbacks •High temp •Vacuum •High cost
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Outline
• Project Charter (N Blocker) • TBC System • Current Tech
– Technologies – Applications • Key Players • Our Approaches • Appendix
Drawbacks •Partially melted particle •Cracks •Porosities
Applications •Topcoat APS •Bond coat LPPS •Corrosion/Wear resistance
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•Evaluation Criteria:
Thermal cycling test
Microstructure
* Adhesive strength, Oxidation resistance, Phase stability, Thickness
homogeneity, Cost estimation
High quality & cost effective coating
•Operating condition:
Stage 1 Turbine Blades (HPT)
•Substrate:
Ni-base Superalloy/SX (N5)
•Coating: (Al2O3)
Bond Coat (NiAl, MCrAlY, PtAl) & TGO TBC (8YSZ)
•High Pressure: ~40atm
•High Rotating Speed: ~11,000rpm
•Centrifugal force, airflow impact and vibration
•Oxidation and erosion
•Thermal Mechanical Cycling
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TBC System
Temperature vs. Lifetime
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TBC Structure & Failure
• Rupture: CTE mismatch, sharp thermal gradient, thermomechanical cycling • Delamination: TGO, degradation of bond coating, • Incipient crack nucleate&grow: thermomechanical fatigue • Inclusion: Processing method derived • FOD(foreign object damage), CMAS(Calcia, Magnesia, Alumina and Silica)
Industrial
USA UK USA USA USA Germany
GE Aircraft Engine Rolls-Royce (England) Prat&Whitney (US&Cannada) PRAXAIR S.T. Tech, INC. Chromalloy No.1~5, 6(UK) Sulzer Metco Inc.
Operating Condition of Turbine Blades
Fan LPC HPC HPT LPT
Journey through a jet engine
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Data for Turbine Blades
•High Temperature: ~1400oC
Байду номын сангаас
HPT blade lifetime: •Currently: 16,000 hours (2~3years) •Expected: 30,000+ hours
Rough estimate of cost: •A set of blades for HPT: 1.5M gbp •Refurbishment: 0.3M to 1M gbp
Applications •Topcoat/MCrAlY •Tool coating •Functional film
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Plasma Spraying
Advantages •Lamellar strip •Low k •Composition control •Thickness capability
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16.04.2020
Project Background
Develop cost-effective aluminide and TBC coating on Ni based alloys
•Customer
MQTD, Avaiation
•Project Objective: process
Front Runners
Academic
USA USA USA Germany Ukraine USA
UCSB* Univ of Connecticut* Univ of Pittsburgh DLR-German Aerospace Center PEW, Paton Electric Weld. Inst Univ of Virginia*