Plasma sprayed coatings are commonly found in hot-sections
of gas turbines. These coatings, due to their low thermal
conductivity, keep the surface temperature of the blade
cooler than the ambient, thereby increasing their lifetimes.
One important feature of these plasma sprayed coatings
is microcracks, which can serve to decrease the thermal
conductivity of the coatings, thereby improving its
performance. However, these microcracks can also lead
to coating spallation, which exposes the blade surface
to higher temperatures and reduces their service lifetimes.
Our research focuses on understanding the mechanism
of microcrack formation during deposition of these coatings,
and in developing a feedback control system that allows
us to engineer the microcrack distribution across the
coating thickness that leads to optimal coating performance
and lifetimes.
Collaborators
M.
Gevelber, Boston University
D.
Wroblewsky, Boston University
Papers
S.N. Basu, G. Ye, M. Gevelber, J. Fincke
J., and D. Swank, "Dependence of Plasma Sprayed
TBC Microstructures on Particle States", in preparation
(2002).
Basu, S.N., Ye G., and Johnson, H.T.,
"Modeling of Residual Stresses during splat Solidification
in Plasma Sprayed Coatings", to be submitted
to J. Materials Science and Engineering A (2002).
G. Ye, S.N. Basu, D. Wroblewski, M.
Gevelber, J. Fincke and D. Swank, "Characterization
of the Plasma Spray Process for Development of Closed
Loop Control", presented at 1999 Materials Solutions
Conference, Cincinnati, OH., November 1-4, 1999.
Molina, C., Basu, S.N., Sahoo, P., and
Shmyreva, T., "Optimization of HVOF Sprayed Inconel
625 Coatings for Corrosion Resistance", presented
at 1999 Materials Solutions Conference, Cincinnati,
OH., November 1-4, 1999.
Funding
NSF - Integrated Plasma Deposition Processing
for Advanced Control of Coating Structure (with M.
Gevelber and D. Wroblewski).
NSF - Advanced Instrumentation Development
for Research for Advanced Instrumentation Development
for Research Education on Plasma Coating Crack Formation
Fundamentals and Control (with M. Gevelber and D.
Wroblewski).
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