The methodologies and strategies for the development of novel material systems and coatings for applications in extreme environments − a critical review

Abstract

Abstract. The aim of this paper is to present a critical analysis of existing methodologies, approaches and strategies used to develop materials systems and coatings for uses in extreme environments. The extreme or harsh conditions encompass a large variety of in-service forms such as: extreme temperatures, abrasion, corrosion, impact and radiation that can exist in various applications such as those associated with aerospace and aeronautical engineering, land and marine transport, manufacturing machinery, and even microelectronics products. This article describes how working environment and required service performance of a particular part or structure could affect the choice of materials and surfaces to which it is composed. In addition, the paper explains the relevance that abusive working environments have for industry, especially relating to their costs, being followed by an overview of surface deposition approaches that are currently popularly used to improve performance of mechanical devices that need to combat adverse conditions. Finally, a material system and three kinds of protective coatings that could be used in applications in extreme conditions are described. The critical review is an outcome of the strategic review from the EU H2020 SUPERMAT project which deals with materials and manufacture for the products/structural parts used in extreme conditions. Keywords: extreme environment / material system / surface treatment / coating / economic impacts / case study Extreme environment and material-related issuesA harsh environment could be any environment that impedes the operation of a device/system. Many types of the conditions could be considered to be harsh, such as: extreme pressure/temperature, shock, vibration, chemical reactivity, radiation, corrosion and humidity, ranging from the applications in, such as alloy production, component manufacture, transport and biomedical implants [1] while the energy sector faces additional harsh environment such as that in various power plants [2], some of such examples being listed below: -Transport: Automobiles and airplanes that are operated in extreme conditions, being exampled by engines components and high-friction paired parts; -Energy: The devices/pipelines/components used for energy conversions, transports and storages, which faces high-temperature, various kinds of mediums and nuclear/chemical reactions, and suffer from corrosion and fatigue failures; -Manufacturing: Tools (e.g. cutting tools, dies and moulds, welding tools, high-temperature nozzles, etc.) used in manufacturing processes;

Accident-Tolerant Barriers for Fuel Road Cladding of CANDU Nuclear Reactor

“…Among the various deposition methods [27][28][29][30][31], PVD methods were identified to be the most suitable for developing coatings on materials used in the nuclear field [32][33][34][35][36]. In the present study, a 2 µm chrome coating was applied by the Electron Beam Physical Vapor Deposition (EBPVD) method [37,38]. The main deposition parameters used for applying the chromium coating are starting vacuum (4 × 10 −5 Torr), working vacuum (2 × 10 −5 Torr), deposition rate (2 A/s), total deposition time (4.5 h), E-beam power (1-2 kW), the distance between the crucible, and Zy-4 substrate (1.2 m).…”

Critical Raw Materials Saving by Protective Coatings under Extreme Conditions: A Review of Last Trends in Alloys and Coatings for Aerospace Engine Applications

“…The increasing demand for new functional coatings has been a strong incentive for research, not only towards understanding the fundamentals and technical aspects of film nucleation and growth, but also towards developing new deposition techniques allowing for a better control of the deposition process [ 132 ]. EB-PVD, powder flame spraying, plasma thermal spray, cold gas dynamic spray coating, sputtering and CVD (Chemical Vapor Deposition) are techniques suited for creating different types of TBCs [ 133 , 134 , 135 , 136 , 137 , 138 , 139 , 140 ].…”

“…for the components to be used in extreme conditions. A specific aspect of EB-PVD coatings is related to their columnar microstructure determining the behavior of the coating during its service life [ 132 , 144 , 145 ].…”

Development of TiAl–Si Alloys—A Review

“…The replacement of CRM should lead to innovative materials with comparable or better properties; materials should be easily and quickly integrated into production processes, with lower risks to the human health, environment, and lower prices [ 80 ]. Substitution of critical raw materials for use in extreme conditions is an important request, as extreme temperatures, wear, and corrosion often occur in many applications [ 80 , 84 ]. On the other hand, when some material is used as a substitute of a particular CRM, it increases its economic importance and it might become critical, which is probably the case of titanium.…”