Industries / Aviation and land-based turbines
Aviation and land-based turbines
Protection of hot-section components and loaded interfaces.
Thermal spray coatings for aircraft engines and stationary gas turbines. Systems address high temperatures, oxidation, corrosion, erosion and contact wear.
Components and protection zones
Turbine rotor blades
Thermal protection and reduced exposure to hot gases.
- Zones:
- Pressure and suction sides, leading edges, platforms and roots.
- Coatings / bond coat:
- YSZ; MCrAlY (bond coat, if required)
- Substrate:
- Nickel-based superalloys.
Guide vanes
Protection of stationary hot-gas-path components.
- Zones:
- Airfoils, endwalls, platforms and attachment features.
- Coatings / bond coat:
- YSZ; MCrAlY (bond coat, if required)
- Substrate:
- Nickel-based superalloys.
Combustion chamber liners
Thermal insulation and protection of combustor metal.
- Zones:
- Hot-gas-side surfaces, holes and local heat-exposure zones.
- Coatings / bond coat:
- YSZ; MCrAlY (bond coat, if required)
- Substrate:
- Nickel-based superalloys.
Shrouds and seal rings
Reduced wear, oxidation and losses caused by clearance changes.
- Zones:
- Contact and rubbing surfaces.
- Coatings / bond coat:
- WC-CoCr; Diffusion aluminides; Sealing systems
- Substrate:
- Nickel-based superalloys.
Shaft sleeves and journals
Reduced friction and wear at bearings and mating interfaces.
- Zones:
- Bearing surfaces and seal contact zones.
- Coatings / bond coat:
- NiCrAlY, Cr3C2-NiCr, WC-CoCr
- Substrate:
- Nickel alloys and steel.
Compressor blades and dovetail joints
Corrosion and erosion protection with reduced fretting and galling.
- Zones:
- Airfoils, dovetail contact surfaces and seals.
- Coatings / bond coat:
- Engineered system selected for the service environment
- Substrate:
- Engine component alloys.
Materials and applications
| System | Materials | Application |
|---|---|---|
| Thermal barrier ceramic (TBC) | YSZ (ZrO2 / Y2O3) | Blades, guide vanes and combustor liners. |
| Bond coats | MCrAlY, NiCoCrAlY; Pt-NiAl | Bond layers for thermal barrier systems on superalloys. |
| Oxidation and corrosion protection | β-NiAl, CrAlY, Si | Hot-section parts, combustors and shrouds. |
| Wear-resistant metallic | NiCrBSi, NiCrAlY | Shrouds, seal rings and sleeves. |
| Wear-resistant carbide | WC-CoCr, Cr3C2-NiCr | Rubbing surfaces, journals and contact interfaces. |
| Low-friction | Ag, MoS2-Ni, DLC | Bearings, seals and other sliding surfaces. |
Coating structure
- Functional layer
- Bond coat, if required
- Component material
Schematic, not to scale. Layer count and bonding mechanism depend on the selected material and process.
Coating processes
- APS
- VPS
- HVOF
- HVAF
- Cold spray (CS)
Typical applications, not a component specification. Composition, thickness, surface preparation and acceptance criteria must be selected for the operating conditions and validated by testing.