Alloy 718 finds application in gas turbine engine components, such as disks, compressor blades and so forth, due to its excellent mechanical corrosion properties at elevated temperatures. Electron beam melting (EBM) is a recent addition the list of additive manufacturing processes has shown capability produce components with unique microstructural features. In this work, specimens were manufactured using EBM process single batch virgin plasma atomized powder. One set as-built was subjected...

The current industry demand is to identify suitable alternatives the risk-of-supply prone and/or toxic, WC-Co and electrolytic hard chrome coatings without comprising desired wear performance. Therefore, compositions based on abundantly available elements (e.g. 'Fe') that possess adequate resistance are desirable from health, sustainability economic standpoints. In this work, crystalline Fe-based (Rockit-401) were processed using two different thermal spray routes, i.e. HVOF HVAF spraying....

Efficiency of a gas turbine can be increased by increasing the operating temperature. Yttria‐stabilized zirconia ( YSZ ) is standard thermal barrier coating TBC material used in applications. However, above 1200°C, undergoes significant sintering and CMAS (calcium magnesium alumino silicate) infiltration. New ceramic materials rare earth zirconate composition such as gadolinium GZ are promising candidates for applications 1200°C. Suspension plasma spray single‐layer , double‐layer /...

Wear resistant coatings that comply with non-toxic environment goals are highly desirable. Cr3C2–NiCr is a promising alternative to the toxic, ‘Co’- containing WC–Co mitigate wear. The purpose of this study was examine suitability for automotive brake disc application by systematically investigating their dry sliding wear behavior at different test conditions. Therefore, High Velocity Air Fuel (HVAF) and Oxy (HVOF) were employed deposit coatings. powder feedstock as-deposited characterized...

This study investigates the corrosion resistance of two-layer Gd2Zr2O7/YSZ, three-layer dense Gd2Zr2O7/ and a reference single-layer YSZ coating with similar overall top coat thickness 300-320 µm. All coatings were manufactured by suspension plasma spraying resulting in columnar structure except for layer. Corrosion tests conducted at 900 °C 8 h using V2O5 Na2SO4 as corrosive salts concentration approximately 4 mg/cm2. SEM investigations after show that Gd2Zr2O7-based exhibited lower...

Thermal spray is a versatile and cost-effective process to deposit wear corrosion resistant coatings. In this work, relatively new 'Fe-based' chemistry comprising boride carbides, explored as 'greener' alternative the expensive carcinogenic Co-based coatings mitigate wear. The emergent thermal of high-velocity air-fuel (HVAF) spraying was chosen Fe-based coatings, with oxy-fuel (HVOF) also being employed solely for purpose preliminary comparison. Detailed characterization HVOF HVAF sprayed...

Thermal barrier coatings (TBCs) prolong the durability of gas turbine engine components and enable them to operate at high temperature. Several degradation mechanisms limit TBCs during their service. Since atmospheric plasma spray (APS) processed 7–8 wt.% yttria stabilized zirconia (YSZ) widely utilized for applications are susceptible erosion damage, this work aims evaluate influence porosity levels on behavior. Eight different APS were produced from 3 powders with ranging 14% 24%. The...

Thermal barrier coatings (TBCs) are bilayer systems comprising a 7–8 wt% yttria partially stabilized zirconia (YSZ) top coat deposited over metallic bond coat. Suspension plasma spraying (SPS) is an advanced and attractive processing technique due to its capability yield variety of microstructures, including the desired columnar microstructure for enhanced strain tolerance durability. This work attempts investigate desirable microstructural features in SPS processed TBCs mitigate hot...

This study explores the possibility of tailoring fusion zone in conduction mode laser welding using a deformable mirror for beam shaping multi-kilowatt continuous wave sources. Three power density distributions were shaped and used bead on plate Ti64 plates at three travel speeds. The effect melt pool free surface geometry, cross section, microstructure hardness profiles was measured studied. It is shown that geometry can be modified mirror. A narrower longer or wider, shorter shallower one...

Higher durability in thermal barrier coatings (TBCs) is constantly sought to enhance the service life of gas turbine engine components such as blades and vanes. In this study, three double layered gadolinium zirconate (GZ)-on-yttria stabilized zirconia (YSZ) TBC variants with varying individual layer thickness but identical total produced by suspension plasma spray (SPS) process were evaluated. The objective was investigate role YSZ on GZ/YSZ double-layered TBCs under different cyclic test...

Graphene nano platelets (GNP) have several attractive properties, including excellent lubricity that can be used to develop wear-resistant coatings. Thermally sprayed chromium carbide–nickel (Cr3C2–NiCr) coatings are widely employed impart wear resistance engineering components. This work attempts improve the of high velocity air fuel (HVAF) Cr3C2–NiCr by incorporating GNP using a hybrid approach in which (powder) and (suspension) co-axially injected. Two different powder-to-suspension...

Deployment of a suspension feedstock has been known to alleviate problems associated with using sub-micron and nanosized powder for thermal spraying monolithic as well powder-suspension 'hybrid' composite coatings. However, hybrid never previously used in high-velocity air-fuel (HVAF) spraying. In this work, the very first time, chromium carbide (Cr3C2) co-sprayed along an Inconel-625 (IN-625) by HVAF process illustrative case study. Two variants IN-625 + Cr3C2 coatings were produced varying...

Thermally sprayed coatings are often used to enhance the surface properties (wear resistance, corrosion etc.) of engineering components in order extend their performance and service lifetime. Typically, industrial be coated possess complex geometries fabricated using different materials, which can influence deposited coating's microstructure performance. High-velocity air fuel (HVAF) process is a relatively new thermal spray processing technique that has shown tremendous potential deposit...