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Beams for Surface Treatment

#0975.2


Development of Methods of Large Area, Repetition Rate Electron and Ion Beam Formation for Improvement of Properties of Material Surface

Tech Area / Field

  • MAT-ALL/High Performance Metals and Alloys/Materials
  • PHY-PFA/Particles, Fields and Accelerator Physics/Physics

Status
8 Project completed

Registration date
08.05.2001

Completion date
10.11.2005

Senior Project Manager
Weaver L M

Leading Institute
NIIEFA Efremov, Russia, St Petersburg

Collaborators

  • Forschungszentrum Karlsruhe Technik und Umwelt / Institut für Hochleistungsimpuls und Mikrowellentechnik, Germany, Karlsruhe\nSiemens AG / Power Generation (KWU), Germany, Mülheim/Ruhr

Project summary

During the execution of the Working Plan of the Project 975-98, which was completely and successfully finished, the very interesting results were obtained concerning increase of high-temperature oxidation stability of protective coatings of turbine blades for electric generators and fatigue durability of turbine blades for aviation engines.

After deposition of the MeCrAlY protective coating on a blade, the working surface of the blade is melted by the pulsed high-current electron beam. It leads to polishing of the surface, changing of microstructure and phase composition of a surface layer on depth of 20-30 mm. It results in decrease of oxygen diffusion rates inward the protective coating by factor 2-2.5 and, hence, increase of the service life of the blades by factor 2-2.5. These changes of the microstructure and phase composition of the surface layer of the coating lead also to sufficient improving of adhesive properties of its surface that is very important in the case when on the MeCrAlY coating the additional thermal-barrier coating (TBC) is deposited (for example – ZrO2). The preliminary tests showed that durability of the TBC can be increased by this way by the factor more then 10.

Results of the fatigue tests of the turbine blades samples for aviation engines treated by the pulsed high-current electron beam showed sufficient increase of theirs fatigue durability. These results are of great interest for Russian and foreign companies dealing with production of electric turbines and aviation engines. However for promotion of these results (obtained at the first phase of the project) in industry it is necessary to perform additional investigations aimed optimization of the electron beam parameters and treatment regimes of real parts as well as to perform theirs testing under the conditions maximally closed to the operation ones.

The objective of the second phase of the project is optimization of the pulsed electron-beam parameters and treatment regimes of the turbine blades and theirs protective coatings, which provide sufficiently increase of thermal and fatigue durability of the blades.

Expected results are: development of technology of turbine blades for electrical generators and aviation engines treatment by the pulsed electron beam, which provide sufficiently increase stability of the protective thermal-barrier coatings of blades and improve theirs fatigue durability; development of the methods of formation of the pulsed electron beams with a high spatial homogeneity needed for ensure of high quality of the turbine blades processing.


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