ISSN:
1662-9752
Source:
Scientific.Net: Materials Science & Technology / Trans Tech Publications Archiv 1984-2008
Topics:
Mechanical Engineering, Materials Science, Production Engineering, Mining and Metallurgy, Traffic Engineering, Precision Mechanics
Notes:
Electron beam technology (EB-PVD) and equipment for one-stage deposition of advancedgraded protective coatings using a composite ceramic ingot for evaporation are described. Thistechnology allows replacing the flat interface between coating layers by a graded transition zones andachieve of a high degree of reproducibility of the composition, structure and lifetime of thefunctionally graded coating in compare with traditional multi-stages technologies of protectivecoating deposition.A design of the composite ceramic ingot is considered, as well as the ability toregulate in a broad range the composition, structure and properties of all levels of the gradedprotective coating including transition zones and coating layers. Examples and variants of advancedgraded protective coatings with their structures and properties are given (thermal barrier, harderosion-resistant and damping coatings) for aerospace and gas-turbine industry application depositedby one-stage EB-PVD process. Total cost of one-stage EB-PVD deposition process at least 2 timesless in compare with traditional technological processes of protective coating deposition due to usingonly one EB-PVD unit and elimination of multistage nature of process cycle.Laboratory andproductive electron-beam units designed and manufactured at ICEBT are considered.Development of modern protective coatings, technologies and equipment for their application isfocused, primarily, on improvement of the durability and main service properties of thecoating/protected item system, ensuring a reliable reproducibility of the coating structure andproperties, shortening the cost and time of the entire technological cycle of their deposition. Theexisting traditional technologies of deposition of multilayer protective coatings, for instance, thermalbarrier coatings (TBC), containing a oxidation-resistant metal bond coat and outer lowthermal-conducting ceramic layer, are multi-stage, with combination of such processes as diffusionsaturation, galvanic coating, plasma spraying and electron beam deposition [1-3]. Use of diverseexpensive equipment, availability of intermediate mechanical and thermal treatments, as well as theoperations of surface cleaning, apply considerable limitations both on widening of the sphere of suchcoating application, and their further development in terms of improvement of the structure andproperties.The one-stage electron beam technology developed at ICEBT for deposition of advancedprotective coatings based on evaporation of a composite ingot and allowing deposition of functionallygraded coatings in one process cycle, meets the above goals to a considerable extent [4,5]. Thetechnology is based on the use of the known phenomenon of fractionating at evaporation ofmulticomponent systems, containing elements with different melting temperature and vapourpressure, and their subsequent condensation under vacuum, allowing the flat interface, for instancebetween the metal and ceramic layers, to be replaced by a transition zone of the graded compositionand structure.Fig.1 gives the schematic and appearance of a composite ingot used for one-stage deposition ofadvanced graded protective coatings in vacuum by its electron beam evaporation from one crucible.The ingot base material determines the purpose of the graded coating. For instance, Al2O3, TiC,TiB2, B4C, MgO, etc. can be used as the base of the ingot for deposition of hard wear-resistant,erosion-resistant and damping coatings. For the case of TBC, this is zirconium dioxide with additives
Type of Medium:
Electronic Resource
URL:
http://www.tib-hannover.de/fulltexts/2011/0528/02/16/transtech_doi~10.4028%252Fwww.scientific.net%252FMSF.546-549.1681.pdf
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