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research-article

FABRICATION AND CHARACTERIZATION OF ADDITIVE MANUFACTURED NICKEL-BASED OXIDE DISPERSION STRENGTHENED COATING LAYER FOR HIGH TEMPERATURE APPLICATION

[+] Author and Article Information
Zheng Min

Department of Mechanical Engineering and Material Science, University of Pittsburgh, Pittsburgh, Pennsylvania, PA 15261, US
zhm10@pitt.edu

Sarwesh Narayan Parbat

Department of Mechanical Engineering and Material Science, University of Pittsburgh, Pittsburgh, Pennsylvania, PA 15261, US
snp34@pitt.edu

Li Yang

Department of Mechanical Engineering and Material Science, University of Pittsburgh, Pittsburgh, Pennsylvania, PA 15261, US
thudteyl@gmail.com

Bruce Kang

Mechanical and Aerospace Engineering Department, West Virginia University, Morgantown, West Virginia, WV 26506, US
Bruce.Kang@mail.wvu.edu

Minking K. Chyu

Department of Mechanical Engineering and Material Science, University of Pittsburgh, Pittsburgh, Pennsylvania, PA 15261, US
mkchyu@pitt.edu

1Corresponding author.

ASME doi:10.1115/1.4038351 History: Received July 07, 2017; Revised August 30, 2017

Abstract

Increasingly high thermal load causes severe oxidation and corrosion for base alloy in turbine airfoils. To survive in this extreme high temperature and harsh oxidation environment, development of structural bond coating layers consequently becomes one of the key technologies for extremely efficient cooling. Present study proposed a method to fabricate structural coating layers on top of turbine blades with the aid of additive manufacturing and oxide dispersion strengthened (ODS) nickel based alloy. ODS powder comprised of evenly distributed host composite particles (Ni, Al, Cr) with oxide coating layer (Y2O3) was subjected to a direct metal laser sintering process to fabricate a desirable structural coating layer above Nickel based superalloy substrates. Systematic experimental tests were carried out focusing on the effect of laser power on interface adhesion, microstructure and surface finish of the ODS coating layer. Based on characterization results from indentation tests and microscopy observations, an optimal coating quality was obtained under 250W laser power. The selected samples were then characterized under isothermal conditions of 1200 ? for 2000 hours. SEM observations and EDAX analysis were conducted in different stages of the oxidation process. Results indicated a formation of protective Al2O3 scale on top of the ODS coating layer at early stage, which showed long term stability throughout the oxidation test. In addition, the observed adhesion between ODS coating layer and substrate was tight and stable throughout the entire oxidation test. Present study has proved that additive manufacturing has the capability to fabricate structural and protective coating layers for turbine airfoils.

Copyright (c) 2017 by ASME
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