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耐冲刷腐蚀的表面保护解决方案，这种解决方案既具有成本效益(设备成本、拥有成本、生产能力)，又允许控制涂层的机械性能和应力控制，以最大限度地提高应用性能。MCT目前的真空电弧等离子薄膜技术基于物理气相沉积(PVD)方法的原理，可以沉积多达50微米的厚膜。这一过程慢得令人望而却步，耗费了该公司为现有客户提供服务的周转时间，并日益压低了其在地热和可再生能源市场增长的业务愿景。具有足够挑战性的是，在这些蓬勃发展的应用中部署的组件需要在热敏基板和真空不兼容形状上开发的表面保护层。NSERC Engage项目的目标是通过喷涂萨哈博士在UNB的纳米复合材料和机械(NCM)实验室开发的陶瓷-金属纳米晶复合Al_2O_3-Ni(Cr)颗粒原料，开发和评估一种新型纳米结构涂层的高温(&gt；500℃)流体侵蚀和疲劳性能。原料喷涂工作将在国家研究委员会位于布切维尔(昆士兰)的热喷涂实验室使用一种低热能的高压冷喷涂技术(HPCS)来完成。涂层测试和表征工作将在NCM实验室和MCT位于昆士兰蒙特利尔市的内部实验室联合进行。根据预期目标评估获得的结果，将把这一行业合作提升到三个不同的综合水平：(1)通过将结果实施到现场试验，确定涂层技术准备级别(TRL)，预计在4到6之间；(2)积累资源，在MCT的PEI制造基地拥有HPCS基础设施；以及(3)启动一个为期5年的CRD项目，在严格的研究和开发课程之后，将技术带到客户服务准备状态。该Engage项目是一个第一手例子，说明如何通过将学术、公司和政府的研究和创新优势集中在一个保护伞下来开展行业合作。

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.