Development of Nanoscale Coatings by Cold Gas Dynamic Spraying Techniques

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Gas turbine engines are amongst the most hostile operating environments for material systems. Increasing demands for higher engine performance, efficiency and durability have led to the development of thermal barrier coating (TBC) systems. However, the full potential of TBC systems is yet to be reached due to premature failure, usually occurring at the bond coat / top coat interface. Based on the recent progress in research activities, the long-term objective of this research program is to successfully produce TBC systems that will exhibit enhanced performances with respect to delamination/cracking and that can be produced commercially, on a large scale. A three-step objectives will be used to reach the overall goal: 1) In the short term (years 1-3), dense conventional and nanocrystalline CoNiCrAlY bond coats, free of oxides, are to be produced using the CGDS, PCGDS and modified HVOF (Warm Spray) processes, and their oxidation behaviour will be characterised, without the presence of a substrate. 2) In the intermediate term (years 2-4), similar bond coats will be produced, and their oxidation will be characterized in the presence of a substrate. 3) In the longer term (years 3-5), the complete TBC system (including the top coat) using similar bond coats will be produced, and their performance will be characterized. Process cost analysis shall be performed in conjunction with performance evaluation to determine which process and which powders are the most suitable for technology transfer.