Looking to study recent material development trends in the turbine blades' industry. Any suggested readings or links to recent development/ongoing research (be it institutional or industrial) in the fabrication/processing of such materials/coatings would be appreciated.
There are four primary areas of interest:
1) Single crystal superalloys and their compositional modification.
2) Thermal barrier coatings (TBC) systems which are used to protect the metallic alloys from the oxidation and high temperatures of combustion.
a) Bond coatings: A good summary is provided by D.K. Das, Microstructure and High Temperature Oxidation Behavior of Pt-Modified Aluminide Bond Coats on Ni-Base Superalloys, Prog. Mater. Sci., Elsevier Ltd, 2013, 58(2), p 151–182, doi:10.1016/j.pmatsci.2012.08.002.
b) Top coatings: Read everything from the following authors and/or their groups to get a feel for advanced TBC materials, processing, structures, compositional modification, testing, and analysis: Carlos Levi (UC Santa Barbara), Douglas Wolfe (Penn State), Robert Vaßen (Julich), Uwe Shulz (DLR), Haydn Wadley (Univ. of Virginia), Bryan Harder, Dongming Zhu, Robert Miller (all NASA).
3) Replacement of metallic superalloys with ceramic matrix composites (CMCs)
a) NASA Glenn is heavily involved in this area among others, Naraottam Bansal, Dongming Zhu, etc.
4) Incorporation of environmental barrier coatings (EBCs) to protect the CMCs from SiO2 receesion due to water vapor.
a) For fundamentals, read Carlos Levi and David Poerschke (UCSB). Considerable CMAS, processing, and high temperature steam testing has been performed by NASA (Valeria Wiesner, Bryan Harder). This is a burgeoning field and there are many other others, but these present a good view of the fundamentals and current testing/performance and processing
In general the developments which are the most relevant for high temperature materials in gas turbines are in the domain of ceramics, with the biggest focus now on ceramic matrix composites and the coatings for such materials. A good starting book for this is :
Ceramic Matrix Composites: Materials, Modeling and Technology
https://www.wiley.com/en-us/Ceramic+Matrix+Composites%3A+Materials%2C+Modeling+and+Technology-p-9781118231166
coating materials selection depends with environment. Cr2O3 and Al2O3 coating in nano range is suitable for high temperature application
There are four primary areas of interest:
1) Single crystal superalloys and their compositional modification.
2) Thermal barrier coatings (TBC) systems which are used to protect the metallic alloys from the oxidation and high temperatures of combustion.
a) Bond coatings: A good summary is provided by D.K. Das, Microstructure and High Temperature Oxidation Behavior of Pt-Modified Aluminide Bond Coats on Ni-Base Superalloys, Prog. Mater. Sci., Elsevier Ltd, 2013, 58(2), p 151–182, doi:10.1016/j.pmatsci.2012.08.002.
b) Top coatings: Read everything from the following authors and/or their groups to get a feel for advanced TBC materials, processing, structures, compositional modification, testing, and analysis: Carlos Levi (UC Santa Barbara), Douglas Wolfe (Penn State), Robert Vaßen (Julich), Uwe Shulz (DLR), Haydn Wadley (Univ. of Virginia), Bryan Harder, Dongming Zhu, Robert Miller (all NASA).
3) Replacement of metallic superalloys with ceramic matrix composites (CMCs)
a) NASA Glenn is heavily involved in this area among others, Naraottam Bansal, Dongming Zhu, etc.
4) Incorporation of environmental barrier coatings (EBCs) to protect the CMCs from SiO2 receesion due to water vapor.
a) For fundamentals, read Carlos Levi and David Poerschke (UCSB). Considerable CMAS, processing, and high temperature steam testing has been performed by NASA (Valeria Wiesner, Bryan Harder). This is a burgeoning field and there are many other others, but these present a good view of the fundamentals and current testing/performance and processing
I am interested in high pressure application or coating under extreme Hertzian pressure. Application will always come under high contact specially in the point and line contact domain. whether from wear debris or from the point contact under high load. Therefore temperature play an important role in this process and no specific coating will be super. For example M50 steel under roller contact and extreme loading will favour TiN coating, where under moderate contact it will favour WC. Thus several variable play a role: Materials, Temp, Contact Mechanics and coating.... In the lubricant environment and probably you can find several publication. coating and healing process are proportional to temperature. Even though chemist want to tell us that this coat is better for certain materials, but we find that high contact will favour another. So it is not a one way street. We should use optimization techniques to be able to understand all stated variables and interactions related to coating. Several high profile articles in surface coating and technology journal wrote about DLC, but we found out that it is not good under high pressure applications specially for AISI 52100 steel bearing. Again I am not trying to discourage you here, but we should optimize techniques using several variables, unstead of counting on what people tell us from the chemistry prospective.
for high temperature coating you can go nano alumina and chromia with a
Atmospheric [DC] plasma spraying (APS)
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