Development of nanostructured Al2O3-Ni(Cr) cermet coatings by high pressure cold spray process for high-strength fatigue performance

MDS涂层技术公司（MCT）正在为工业燃气轮机发动机寻找抗腐蚀表面保护解决方案，这些解决方案既具有成本效益（设备成本，拥有成本，吞吐量），又允许涂层的机械性能控制和应力控制，以最大限度地提高应用性能。MCT目前的真空电弧等离子体膜技术基于物理气相沉积（PVD）方法的原理，可以沉积50微米厚的膜。这一过程极其缓慢，耗费了公司为老客户提供服务的周转时间，并日益削弱了其在地热和可再生能源市场发展的商业愿景。具有挑战性的是，在这些新兴应用中部署的组件需要在热敏基板和真空不兼容的形状上开发表面保护层。这项NSERC参与项目的目标是通过喷涂陶瓷-金属-纳米晶复合材料Al2O3-Ni（Cr）颗粒原料，开发和评估一种新型纳米结构涂层的高温（bbb500℃）流体侵蚀和疲劳性能。该材料由Saha博士在UNB的纳米复合材料和力学（NCM）实验室开发。原料喷雾工作将在boucherville （QC）的国家研究委员会热喷雾实验室使用低热能技术，高压冷喷雾（HPCS）完成。涂层测试和表征工作将在NCM实验室和mct在QC蒙特利尔的内部实验室共同进行。根据预期目标进行评估，获得的结果将使这种工业合作进入三个不同的综合水平：(1)通过将结果应用于现场试验，确定涂层技术就绪等级（TRL），预计在4到6之间；(2)在MCT的PEI制造基地积累HPCS基础设施的资源；(3)开展为期5年的CRD项目，按照严格的研发课程，将技术推向客户服务就绪。这个Engage项目是一个第一手的例子，说明了如何通过将学术、公司和政府的研究和创新力量集中在一起，展开产业合作。

MDS Coating Technologies (MCT) is looking for erosion-corrosion resistant surface protective solutions forindustrial gas turbine engines that are both cost effective (equipment cost, cost of ownership, throughput) andallow mechanical properties' control and stress control of the coatings to maximize application performance.MCT's current vacuum arc plasma film technology works on the principle of physical vapor deposition (PVD)methodology to deposit up to 50-micron thick film. The process is prohibitively slow, costing the companyturnaround time to service established customers, and increasingly depressing its business vision to grow in thegeothermal and renewable energy market. Challenging enough, components deployed in these burgeoningapplications require surface protective layers developed on heat sensitive substrates and vacuum-incompatibleshapes. The goal of this NSERC Engage project is to develop and evaluate the high-temperature (>500-deg C)fluid erosion and fatigue properties of a novel nanostructured coating by spraying ceramic-metallicnanocrystalline composite Al2O3-Ni(Cr) particle feedstock developed in Dr. Saha's Nanocomposites andMechanics (NCM) Lab at UNB. Feedstock spray work will be accomplished using a low thermal energytechnology, high pressure cold spray (HPCS), at the National Research Council's thermal spray lab atBoucherville (QC). The coating test and characterization work will be conducted jointly in NCM Lab andMCT's in-house lab in Montreal, QC. The obtained results, assessed against desired objectives, will take thisindustrial collaboration into three distinct and integrative levels: (1) determine the coating technology readinesslevel (TRL), expected to fall between 4 and 6, by implementing results into field trials, (2) amass resources toown an HPCS infrastructure at MCT's PEI Manufacturing site, and (3) embark on a 5-year CRD project tobring the technology to customer service readiness following rigorous research and development curriculum.This Engage project is a first-hand example of how an industrial collaboration can unfold by bringingacademic, company, and government research and innovation strengths under one umbrella.