| 1. |
- Chen, Y., et al.
(författare)
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Characterization and understanding of residual stresses in a NiCoCrAlY bond coat for thermal barrier coating application
- 2015
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Ingår i: Acta Materialia. - : Elsevier BV. - 1359-6454 .- 1873-2453. ; 94, s. 1-14
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Tidskriftsartikel (refereegranskat)abstract
- The residual stresses in a NiCoCrAlY bond coat deposited on a Ni-base superalloy substrate after oxidation at 1150 °C were studied by X-ray diffraction using the sin2Ψ technique. The stresses were found to be tensile; they first increased and then decreased with oxidation time. High temperature stress measurement indicated that the stress developed and built up upon cooling, predominantly within the temperature range from 1150 °C to 600 °C. Microstructural examination suggested that, due to the limited penetration depth into the bond coat, the X-ray only probed the stress in a thin surface layer consisting of the single γ-phase formed through Al depletion during oxidation. Quantitative high temperature X-ray diffraction analysis revealed that, above 600 °C, the volume fraction of the β-phase in the bond coat increased with decreasing temperature. The mechanisms of stress generation in the bond coat were examined and are discussed based on the experiments designed to isolate the contribution of possible stress generation factors. It was found that the measured bond coat stresses were mainly induced by the volume change of the bond coat associated with the precipitation of the β-phase upon cooling.
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| 2. |
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| 3. |
- Medricky, Jan, et al.
(författare)
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Optimization of High Porosity Thermal Barrier Coatings Generated with a Porosity Former
- 2015
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Ingår i: Journal of thermal spray technology (Print). - : Springer Science and Business Media LLC. - 1059-9630 .- 1544-1016. ; 24:4, s. 622-628
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Tidskriftsartikel (refereegranskat)abstract
- Yttria-stabilized zirconia thermal barrier coatings are extensively used in turbine industry; however, increasing performance requirements have begun to make conventional air plasma sprayed coatings insufficient for future needs. Since the thermal conductivity of bulk material cannot be lowered easily; the design of highly porous coatings may be the most efficient way to achieve coatings with low thermal conductivity. Thus the approach of fabrication of coatings with a high porosity level based on plasma spraying of ceramic particles of dysprosia-stabilized zirconia mixed with polymer particles, has been tested. Both polymer and ceramic particles melt in plasma and after impact onto a substrate they form a coating. When the coating is subjected to heat treatment, polymer burns out and a complex structure of pores and cracks is formed. In order to obtain desired porosity level and microstructural features in coatings; a design of experiments, based on changes in spray distance, powder feeding rate, and plasma-forming atmosphere, was performed. Acquired coatings were evaluated for thermal conductivity and thermo-cyclic fatigue, and their morphology was assessed using scanning electron microscopy. It was shown that porosity level can be controlled by appropriate changes in spraying parameters.
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| 4. |
- Bolelli, G., et al.
(författare)
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Tribology of HVOF- and HVAF-sprayed WC-10Co4Cr hardmetal coatings : A comparative assessment
- 2015
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Ingår i: Surface and Coatings Technology. - : Elsevier. - 0257-8972. ; 265, s. 125-144
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Tidskriftsartikel (refereegranskat)abstract
- his paper provides a comprehensive assessment of the sliding and abrasive wear behaviour of WC–10Co4Cr hardmetal coatings, representative of the existing state-of-the-art. A commercial feedstock powder with two different particle size distributions was sprayed onto carbon steel substrates using two HVOF and two HVAF spray processes.Mild wear rates of < 10-7 mm3/(Nm) and friction coefficients of ≈ 0.5 were obtained for all samples in ball-on-disk sliding wear tests at room temperature against Al2O3 counterparts. WC–10Co4Cr coatings definitely outperform a reference electrolytic hard chromium coating under these test conditions. Their wear mechanisms include extrusion and removal of the binder matrix, with the formation of a wavy surface morphology, and brittle cracking. The balance of such phenomena is closely related to intra-lamellar features, and rather independent of those properties (e.g. indentation fracture toughness, elastic modulus) which mainly reflect large-scale inter-lamellar cohesion, as quantitatively confirmed by a principal component analysis. Intra-lamellar dissolution of WC into the matrix indeed increases the incidence of brittle cracking, resulting in slightly higher wear rates. At 400 °C, some of the hardmetal coatings fail because of the superposition between tensile residual stresses and thermal expansion mismatch stresses (due to the difference between the thermal expansion coefficients of the steel substrate and of the hardmetal coating). Those which do not fail, on account of lower residual stresses, exhibit higher wear rates than at room temperature, due to oxidation of the WC grains.The resistance of the coatings against abrasive wear, assessed by dry sand–rubber wheel testing, is related to inter-lamellar cohesion, as proven by a principal component analysis of the collected dataset. Therefore, coatings deposited from coarse feedstock powders suffer higher wear loss than those obtained from fine powders, as brittle inter-lamellar detachment is caused by their weaker interparticle cohesion, witnessed by their systematically lower fracture toughness as well.
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| 5. |
- Curry, Nicholas, 1984-
(författare)
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Design of Thermal Barrier Coating Systems
- 2012
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Thermal barrier coatings (TBC’s) are used to provide both thermal insulation and oxidation protection to high temperature components within gas turbines. The development of turbines for power generation and aviation has led to designs where the operation conditions exceed the upper limits of most conventional engineering materials. As a result there has been a drive to improve thermal barrier coatings to allow the turbine to operate hotter for longer.The focus of this study has been the development of a new generation of TBC system for industrial implementation. The goal for these new coatings was to achieve lower conductivity and longer lifetime than those coatings used today. The route taken to achieve these goals has been twofold. Firstly an alternative stabiliser has been chosen for the zirconium oxide system in the form of dysprosia. Secondly, Control of the powder morphology and spray parameters has been used to generate coating microstructures with favourable levels of porosity.Samples have been heavily characterised using the laser flash technique for evaluation of thermal properties. Measurements were performed at room temperature and at intervals up to 1200°C. Samples have also been tested in their as produced state and after heat treatments of up to 200 hours.Lifetime evaluation has been performed using the thermo-cyclic fatigue test to expose coating systems to successive cycles of heating and cooling combined with oxidation of the underlying metallic coating.Microstructures have been prepared and analysed using SEM. An image analysis routine has been used to attempt to quantify changes in microstructure features between coating types or coating exposure times and to relate those changes to changes in thermal propertiesResults show that dysprosia as an alternative dopant gives a reduction in thermal conductivity. While small at room temperature and in the as produced state; the influence becomes more pronounced at high temperatures and with thermal exposure time. Overall, the greatest sustained influence on thermal conductivity has been from creating coatings with high levels of porosity.In relation to lifetime, the target of double the thermo-cyclic fatigue life was achieved using a coating with engineered porosity. Introducing a polymer to the spray powder helps to generate large globular pores within the coating together with a large number of delaminations. Such a structure has shown to be highly resistant to TCF testing.
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| 6. |
- Li, Peigang, 1978, et al.
(författare)
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Characterization of cold lap defects in tandem arc welding
- 2012
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Ingår i: Welding in the World, Le Soudage Dans Le Monde. - 1878-6669 .- 0043-2288. ; 56:9-10, s. 20-25
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Tidskriftsartikel (refereegranskat)abstract
- The objective of this investigation was to classify and characterize the small lack of fusion defects, called coldlap, located at the weld toe. Since the defects are very small (0.01–1.5 mm) and diffi cult to detect by NDTmethods, a better understanding of the formation mechanism is required to be able to avoid their formation.The investigation consisted of two parts. Firstly, a study was made on the type and frequency of cold laps.Three types were identified, namely “spatter cold lap”, and “overlap cold lap” and “spatter-overlap cold lap”. Norelation between type or frequency of cold laps and the welding parameters could be established. Secondly,the interface between spatter and the base material was investigated using optical and scanning electronmicroscopy, to better understand the cold lap formation mechanism. Manganese-silicate particles were foundin the interface located in such a way that they may assist cold lap formation.
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| 7. |
- Uczak de Goes, Wellington, 1990-, et al.
(författare)
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Thermal barrier coatings with novel architectures for diesel engine applications
- 2020
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Ingår i: Surface & Coatings Technology. - : Elsevier. - 0257-8972 .- 1879-3347. ; 396
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Tidskriftsartikel (refereegranskat)abstract
- The increased demands for higher efficiency and environmentally friendly diesel engines have led to a continuous search for new coating processing routes and new ceramic materials that can provide the required properties when applied on engine components such as pistons and exhaust manifolds. Although successful in gas turbine applications, thermal barrier coatings (TBCs) produced by suspension plasma spraying (SPS) processes have not been employed so far in the automotive industry. This work aims to achieve a better understanding of the role of thermal conductivity and thermal effusivity on the durability of SPS TBCs applied to pistons of diesel engines. Three different coating architectures were considered for this study. The first architecture was yttria-stabilized zirconia (YSZ) lamellar top coat deposited by APS (Atmospheric Plasma Spray) and used as a reference sample in this study. The second architecture was a columnar SPS top coat of either YSZ or gadolinium zirconate (GZO) while the third architecture was an SPS columnar top coat, “sealed” with a dense sealing layer deposited on the top coat. Two types of sealing layers were used, a metallic (M) or a ceramic thermal spray layer (C). Laser Flash Analysis (LFA) was used to determine the thermal conductivity and thermal effusivity of the coatings. Two different thermal cyclic tests were used to test the TBCs behavior under cyclic thermal loads. Microstructure analysis before and after the thermal cyclic tests were performed using SEM in different microstructures and materials. The thermal cyclic test results were correlated with coatings microstructure and thermophysical properties. It was observed that the columnar coatings produced by SPS had an enhanced service life in the thermal cyclic tests as compared to the APS coatings.
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| 8. |
- Zhang, Pimin, 1990-, et al.
(författare)
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Effects of surface finish on the initial oxidation of HVAF-sprayed NiCoCrAlY coatings
- 2019
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Ingår i: Surface & Coatings Technology. - Elsevier : Elsevier BV. - 0257-8972 .- 1879-3347. ; 364, s. 43-56
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Tidskriftsartikel (refereegranskat)abstract
- Oxide scale formed on HVAF-sprayed NiCoCrAlY coatings and the effect of surface treatment were investigated by a multi-approach study combining photo-stimulated luminescence, microstructural observation and mass gain. The initial oxidationbehaviour of as-sprayed, polished and shot-peened coatings at 1000 °C is studied. Both polished and shot-peened coatings exhibited superior performance due to rapid formation of α-Al2O3 fully covering the coating and suppressing the growth of transient alumina, assisted by a high density of α-Al2O3 nuclei on surface treatment induced defects. Moreover, the fast development of a two-layer alumina scale consisting of an inward-grown inner α-Al2O3 layer and an outer layer transformed from outward-grown transient alumina resulted in a higher oxide growth rate of the as-sprayed coating.
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| 9. |
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| 10. |
- Jafari, Reza, et al.
(författare)
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KCl-Induced High Temperature Corrosion Behavior of HVAF-Sprayed Ni-Based Coatings in Ambient Air
- 2018
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Ingår i: Journal of thermal spray technology (Print). - : Springer Science and Business Media LLC. - 1059-9630 .- 1544-1016. ; 27:3, s. 500-511
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Tidskriftsartikel (refereegranskat)abstract
- KCl-induced high temperature corrosion behavior of four HVAF-sprayed Ni-based coatings (Ni21Cr, Ni5Al, Ni21Cr7Al1Y, and Ni21Cr9Mo) under KCl deposit has been investigated in ambient air at 600°C up to 168h. The coatings were deposited onto 16Mo3 steel - a widely used boiler tube material.Uncoated substrate, 304L and Sanicro25 were used as reference materials in the test environment.SEM/EDS and XRD techniques were utilized to characterize the as-sprayed and exposed samples.The results showed that the small addition of KCl significantly accelerated degradation to the coatings. All coatings provided better corrosion resistance compared to the reference materials. The alumina-forming Ni5Al coating under KCl deposit was capable of forming a more protective oxide scale compared to the chromia-forming coatings as penetration of Cl through diffusion paths was hindered. Both active corrosion and chromate formation mechanisms were found to be responsible for Page 1 of 23ASM the corrosion damages. The corrosion resistance of the coatings based on the microstructure analysis and kinetics had the following ranking (from the best to worst): Ni5Al >Ni21Cr> Ni21Cr7Al1Y>Ni21Cr9Mo.
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