Automated Plasma Spray (APS) process feasibility study

An automated plasma spray (APS) process was developed to apply two layer (NiCrAlY and ZrO2-12Y2O3) thermal barrier coatings to aircraft and stationary gas turbine engine blade airfoils. The APS process hardware consists of four subsystems: a mechanical positioning subsystem incorporating two interlaced six degree of freedom assemblies (one for coating deposition and one for coating thickness monitoring); a noncoherent optical metrology subsystem (for in process gaging of the coating thickness buildup at specified points on the specimen); a microprocessor based adaptive system controller (to achieve the desired overall thickness profile on the specimen); and commerical plasma spray equipment. Over fifty JT9D first stage aircraft turbine blade specimens, ten W501B utility turbine blade specimens and dozens of cylindrical specimens were coated with the APS process in preliminary checkout and evaluation studies. The best of the preliminary turbine blade specimens achieved an overall coating thickness uniformity of 53 micrometers (2.1 mils), much better than is achievable manually. Comparative evaluations of coating thickness uniformity for manually sprayed and APS coated specimens were performed. One of the preliminary turbine blade evaluation specimens was subjected to a torch test and metallographic evaluation. Some cylindrical specimens coated with the APS process survived up to 2000 cycles in subsequent burner rig testing

A Comparison of Coated Paper Surfaces by Photomicrography

Five different types of coated papers were photomicrographed, namely cast coated, roll coated, trailing blade coated, air brush coated, and brush coated grades. All cast coated papers were found to be extremely smooth and essentially free of pattern. Roll coated papers displayed a microscopic pattern which resembled the magnified surface of an orange peel. Trailing blade coated papers displayed sharp-edged pits and, in some cases, scuffed surfaces. Air brush coated papers had a microscopic pattern which resembled the non-magnified surface of a pie crust. Brush coated papers closely resembled air brush coated papers microscopically, however, they also carried a macroscopic pattern of brush marks which distinguished them from the air brush coated grades. It was concluded that various types of coating processes leave typical patterns which may be used in conjunction with other characteristics of the paper to identify the particular coating process used

A study on wear failure analysis of tungsten carbide hardfacing on carbon steel blade in a digester tank

This paper addresses wear failure analysis of tungsten carbide (WC) hardfacing on a carbon steel blade known as the continuous digester blade (CD blade). The CD blade was placed in a digester tank to mix ilmenite ore with sulphuric acid as part of a production process. Tungsten carbide hardfacing was applied on the CD blade to improve its wear resistance while the CD blade was exposed to an abrasive and acidic environment. Failure analysis was car-ried out on the hardfaced CD blade in order to improve its wear resistance and lifetime. A thickness and hardness comparison study was conducted on worn and unworn specimens from the CD blades. The carbide distribution along with elemental composition analysis of the hardfaced CD blade specimens was examined using scanning electron microscopy and energy-dispersive spectroscopy. The investigation revealed that an inconsistent hardfacing thickness was welded around the CD blade. Minimum coating thickness was found at the edges of the blade surfaces causing failure to the blades as the bare carbon steel blades were exposed to the mixed environment. The wear resistance of the CD blade can be improved by distributing the carbide uniformly on the hardfaced coating. Applying extra coating coverage at the critical edge will prevent the exposure of bare carbon steel blade, thus increasing the CD blade lifetime

Overlay metallic-cermet alloy coating systems

A substrate, such as a turbine blade, vane, or the like, which is subjected to high temperature use is coated with a base coating of an oxide dispersed, metallic alloy (cermet). A top coating of an oxidation, hot corrosion, erosion resistant alloy of nickel, cobalt, or iron is then deposited on the base coating. A heat treatment is used to improve the bonding. The base coating serves as an inhibitor to interdiffusion between the protective top coating and the substrate. Otherwise, the protective top coating would rapidly interact detrimentally with the substrate and degrade by spalling of the protective oxides formed on the outer surface at elevated temperatures

Automated Plasma Spray (APS) process feasibility study: Plasma spray process development and evaluation

An automated plasma spray (APS) process was developed to apply two layer (NiCrAlY and ZrO2-12Y2O3) thermal-barrier coatings to aircraft gas turbine engine blade airfoils. The APS process hardware consists of four subsystems: a mechanical blade positioner incorporating two interlaced six-degree-of-freedom assemblies; a noncoherent optical metrology subsystem; a microprocessor-based adaptive system controller; and commercial plasma spray equipment. Over fifty JT9D first stage turbine blades specimens were coated with the APS process in preliminary checkout and evaluation studies. The best of the preliminary specimens achieved an overall coating thickness uniformity of + or - 53 micrometers, much better than is achievable manually. Factors limiting this performance were identified and process modifications were initiated accordingly. Comparative evaluations of coating thickness uniformity for manually sprayed and APS coated specimens were initiated. One of the preliminary evaluation specimens was subjected to a torch test and metallographic evaluation

Can Polymer Solar Cells Open the Path to Sustainable and Efficient Photovoltaic Windows Fabrication?

Sunlight is among the most abundant energy sources available on our planet. Finding adequate solutions to properly and efficiently harvest it is of major importance to potentially solve the global energy crisis. Polymer solar cells have been introduced in the late 20th century as low‐cost and easily processed alternative to the state‐of‐the‐art silicon photovoltaics. Their power conversion efficiencies, which were initially rather low, are constantly improving and now reach values close to 15 %. As their optical properties can be easily tuned, designing active layer which absorb homogeneously throughout the visible spectrum is relatively simple. These peculiar characteristics enable the possibility to fabricate visibly transparent solar cells with high color rendering indices which can be employed as photovoltaic windows. After reviewing some of the most successful examples of polymer solar cell‐based transparent photovoltaic window fabrication, I will discuss the possibility to produce these devices in a sustainable and/or eco‐friendly manner while maintaining their performances

An Investigation into the Parameters Affecting Vehicle Migration During the Redistribution of Aqueous Coatings

The purpose of this study was to determine what effect shear has upon the vehicle migration in aqueous coatings. The roll inclined-plane apparatus was utilized to generate various ranges of shear rate. An immobilization factor was then calculated for these different rates of shear indicating the degree of vehicle penetration. The particle size of the binder and the particle size of the pigment were varied to determine their effect on the penetration into the base substrate. It was concluded that high shear rates pack the particles, either binder or pigment, into the pores of the base substrate. This phenomenon prevents the migration of the liquid phase

Suppression of intrinsic neutron background in the Multi-Grid detector

One of the key requirements for neutron scattering instruments is the Signal-to-Background ratio (SBR). This is as well a design driving requirement for many instruments at the European Spallation Source (ESS), which aspires to be the brightest neutron source of the world. The SBR can be effectively improved with background reduction. The Multi-Grid, a large-area thermal neutron detector with a solid boron carbide converter, is a novel solution for chopper spectrometers. This detector will be installed for the three prospective chopper spectrometers at the ESS. As the Multi-Grid detector is a large area detector with a complex structure, its intrinsic background and its suppression via advanced shielding design should be investigated in its complexity, as it cannot be naively calculated. The intrinsic scattered neutron background and its effect on the SBR is determined via a detailed Monte Carlo simulation for the Multi-Grid detector module, designed for the CSPEC instrument at the ESS. The impact of the detector vessel and the neutron entrance window on scattering is determined, revealing the importance of an optimised internal detector shielding. The background-reducing capacity of common shielding geometries, like side-shielding and end-shielding is determined by using perfect absorber as shielding material, and common shielding materials, like B$_{4}$C and Cd are also tested. On the basis of the comparison of the effectiveness of the different shielding topologies and materials, recommendations are given for a combined shielding of the Multi-Grid detector module, optimised for increased SBR.Comment: 26 pages, 18 figures, revise

Modelling rain drop impact on offshore wind turbine blades

The effects of rain and hail erosion and impact damage on the leading edge of offshore wind turbine blades have been investigated. A literature review was conducted to establish the effects of exposure to these conditions and also to investigate the liquid impact phenomena and their implications for leading edge materials. The role of Explicit Dynamics software modelling in simulating impact events was then also established. Initial rain impact modelling is then discussed with the results showing good agreement with theoretical predictions both numerically and with respect to the temporal and spatial development of the impact event. Future development of the rain model and a proposed hail model are then detailed. Planned rain impact and erosion testing work is addressed which will be used to validate, inform and compliment the ongoing modelling efforts