Thermal Spray Technology Growth in Gas Turbine Applications

Abstract

This article provides an overview of key thermal spray coatings used in compressors, combustors, and turbine sections of a power-generation gas turbine. It describes the critical components, including combustors, transition ducts, inlet nozzle guide vanes, and first-stage rotating airfoils. Design requirements are reviewed and compared between aerospace and power generation coatings. Application process improvement areas are also discussed as a method of reducing component cost.

Design of the Thermal Restructured Carbon–Inorganic Composite Aerogel for Efficient Thermal Protection of Aero-Engines

“…With the increase in the thermal efficiency and thrust-to-weight ratio, advanced aero-engines are currently operated at higher and higher pressure ratios and turbine inlet temperatures . Therefore, more efficient thermal protection schemes are urgently needed to prevent the hot end components of aero-engines from invalidation and damage .…”

“…With the increase in the thermal efficiency and thrust-to-weight ratio, advanced aero-engines are currently operated at higher and higher pressure ratios and turbine inlet temperatures. 1 Therefore, more efficient thermal protection schemes are urgently needed to prevent the hot end components of aeroengines from invalidation and damage. 2 Laminated cooling with the thermal protection layer, which combines the high efficiency of the active cooling method and the heat insulating effect of advanced material, has been widely deemed as one of the most promising approaches to address the protection issue of hot end components at extremely high heat flux 3 (Scheme 1a).…”

Performance of wear resistant MCrAlY coatings with oxide dispersion strengthening

“…>1000 °C) [2]. In order to enable the use of superalloys even beyond the service temperature limits, parts are coated by thermally sprayed thermal barriers to protect them against high temperatures and oxidation [3,4]. To merge the ceramic top coat of a thermal barrier system with the substrate, an interconnecting bond coat layer is necessary: it enhances the adhesion of the ceramic top coat and provides oxidation protection to the substrate material.…”

“…To merge the ceramic top coat of a thermal barrier system with the substrate, an interconnecting bond coat layer is necessary: it enhances the adhesion of the ceramic top coat and provides oxidation protection to the substrate material. MCrAlYs, where M stands for Co or Ni, are the state of the art thermally-sprayed bond-coat materials used in turbine engine applications [3,4].…”

Electroless nickel–phosphorus plating on WC–Co powders using HVOF feedstock

“…Wear-resistant coatings are applied in many parts of gas turbines such as bearings and labyrinth seals to increase the lifetime of the components. Among the typical wear-resistant coatings are WC–Co and Cr 3 C 2 –NiCr produced at different temperatures [9]. For damping applications, it is possible to use WC–Co-based materials or oxides dispersed in an oxidation-resistant matrix such as MCrAlY by HVOF [10].…”