Effect of Ultrasonic Shot Peening on Morphology and Structure of NiCrAlYSi Coatings on Superalloys for Blade Applications
Abstract
:1. Introduction
2. Materials and Methods
3. Results and Discussion
3.1. Morphology of NiCrAlYSi Bond Coats
3.2. Effect of USP on Surface Roughness of the Bond Coats
3.3. Elemental Distribution and Coating Thickness of NiCrAlYSi Bond Coats
4. Conclusions
- (1)
- In terms of macroscopic morphology, the surface brightness of the bond coat is reduced after USP treatment, and the coating surface exhibits a more uniform particle distribution. At the microscopic morphology level, the bond coat becomes denser, with a reduced porosity and a smoother surface after USP treatment, leading to better adhesion between the bond coat and the substrate. Meanwhile, as the intensity increases, the bond coat thickness decreases, even with a reduction range of 12.5% to 50%.
- (2)
- After USP treatment, the surface of the bond coat incorporates Cr elements from the GCr15 spheres and the surface Cr content increases with increasing intensity. At an intensity of 0.1 A, localized enrichment of Cr elements is observed in the bond coat region near the substrate, indicating the presence of Cr oxides in addition to Al oxides within the bond coat after USP treatment, hindering the diffusion of O elements into the substrate.
- (3)
- The impact of coating thickness and roughness on the aerodynamic performance of turbine blades is discussed. USP has been well validated in reducing coating thickness and roughness, which is expected to significantly enhance the aerodynamic efficiency of coated turbine blades, as evidenced by the previous literature. However, it is regrettable that the present study did not conduct experimental or computational analysis on the effects of roughness and thickness on blade aerodynamic performance but only provided a discussion and analysis. This will be the focus of further research aiming to establish a complex setup tailored for USP application on turbine blades. Through computational and experimental methods, the influence of coated blade surface variations on aerodynamic performance will be analyzed.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
- Bose, S. High Temperature Coatings; Butterworth-Heinemann: Oxford, UK, 2017. [Google Scholar]
- Padture, N.P.; Gell, M.; Jordan, E.H. Thermal barrier coatings for gas-turbine engine applications. Science 2002, 296, 280–284. [Google Scholar] [CrossRef] [PubMed]
- Aktaa, J.; Sfar, K.; Munz, D. Assessment of TBC systems failure mechanisms using a fracture mechanics approach. Acta Mater. 2005, 53, 4399–4413. [Google Scholar] [CrossRef]
- Chen, L.; Meng, G.H.; Li, C.J.; Yang, G.J. Critical scale grain size for optimal lifetime of TBCs. J. Mater. Sci. Technol. 2022, 115, 241–250. [Google Scholar] [CrossRef]
- Nowak, W.; Naumenko, D.; Mor, G.; Mor, F.; Mack, D.E.; Vassen, R.; Quadakkers, W.J. Effect of processing parameters on MCrAlY bondcoat roughness and lifetime of APS–TBC systems. Surf. Coat. Technol. 2014, 260, 82–89. [Google Scholar] [CrossRef]
- Giolli, C.; Scrivani, A.; Rizzi, G.; Borgioli, F.; Bolelli, G.; Lusvarghi, L. Failure mechanism for thermal fatigue of thermal barrier coating systems. J. Therm. Spray Technol. 2009, 18, 223–230. [Google Scholar] [CrossRef]
- Karaoglanli, A.C.; Doleker, K.M.; Demirel, B.; Turk, A.; Varol, R. Effect of shot peening on the oxidation behavior of thermal barrier coatings. Appl. Surf. Sci. 2015, 354, 314–322. [Google Scholar] [CrossRef]
- Itoh, Y.; Saitoh, M.; Takaki, K.; Fujiyama, K. Effect of high-temperature protective coatings on fatigue lives of nickel-based superalloys. Fatigue Fract. Eng. Mater. Struct. 2001, 24, 843–854. [Google Scholar] [CrossRef]
- Gabb, T.P.; Rogers, R.B.; Nesbitt, J.A.; Puleo, B.J.; Miller, R.A.; Telesman, I.; Locci, I.E. Powder Metallurgy Disk Superalloy. 2017. Available online: https://ntrs.nasa.gov/citations/20170005889 (accessed on 2 July 2024).
- Kumar, S.; Chattopadhyay, K.; Singh, V. Effect of ultrasonic shot peening on LCF behavior of the Ti–6Al–4V alloy. J. Alloys Compd. 2017, 724, 187–197. [Google Scholar] [CrossRef]
- Akebono, H.; Komotori, J.; Suzuki, H. The effect of coating thickness on fatigue properties of steel thermally sprayed with Ni-based self-fluxing alloy. Int. J. Mod. Phys. B 2006, 20, 3599–3604. [Google Scholar] [CrossRef]
- Stoll, I.; Helm, D.; Polanetzki, H.; Wagner, L. Ultrasonic Shot Peening (USP) on Ti-6Al-4V and Ti-6Al-2Sn-4Zr-6Mo Aero Engine Components. ICSP-11 2011. Available online: https://www.shotpeener.com/library/pdf/2011062.pdf (accessed on 2 July 2024).
- Karaoglanli, A.C.; Altuncu, E.; Ozdemir, I.; Turk, A.; Ustel, F. Structure and durability evaluation of YSZ+ Al2O3 composite TBCs with APS and HVOF bond coats under thermal cycling conditions. Surf. Coat. Technol. 2011, 205, S369–S373. [Google Scholar] [CrossRef]
- Sohn, Y.H.; Kim, J.H.; Jordan, E.H.; Gell, M. Thermal cycling of EB-PVD/MCrAlY thermal barrier coatings: I. Microstructural development and spallation mechanisms. Surf. Coat. Technol. 2001, 146, 70–78. [Google Scholar] [CrossRef]
- Moridi, A.; Hassani-Gangaraj, S.M.; Vezzú, S.; Trško, L.; Guagliano, M. Fatigue behavior of cold spray coatings: The effect of conventional and severe shot peening as pre-/post-treatment. Surf. Coat. Technol. 2015, 283, 247–254. [Google Scholar] [CrossRef]
- Suder, K.L.; Chima, R.V.; Strazisar, A.J.; Roberts, W.B. The effect of adding roughness and thickness to a transonic axial compressor rotor. J. Turbomach. 1995, 117, 491–505. [Google Scholar] [CrossRef]
- Si, C.; Sun, W.; Tian, Y.; Cai, J. Cavitation erosion resistance enhancement of the surface modified 2024T351 Al alloy by ultrasonic shot peening. Surf. Coat. Technol. 2023, 452, 129122. [Google Scholar] [CrossRef]
- Curry, N.; Tang, Z.; Markocsan, N.; Nylén, P. Influence of bond coat surface roughness on the structure of axial suspension plasma spray thermal barrier coatings—Thermal and lifetime performance. Surf. Coat. Technol. 2015, 268, 15–23. [Google Scholar] [CrossRef]
- Voorwald, H.J.C.; Padilha, R.; Costa, M.Y.P.; Pigatin, W.L.; Cioffi, M.O.H. Effect of electroless nickel interlayer on the fatigue strength of chromium electroplated AISI 4340 steel. Int. J. Fatigue 2007, 29, 695–704. [Google Scholar] [CrossRef]
- Zhang, X.H.; Liu, D.X.; Tan, H.B.; Wang, X.F. Effect of TiN/Ti composite coating and shot peening on fretting fatigue behavior of TC17 alloy at 350 C. Surf. Coat. Technol. 2009, 203, 2315–2321. [Google Scholar] [CrossRef]
- Pawlak, W.; Kubiak, K.J.; Wendler, B.G.; Mathia, T.G. Wear resistant multilayer nanocomposite WC1−x/C coating on Ti–6Al–4V titanium alloy. Tribol. Int. 2015, 82, 400–406. [Google Scholar] [CrossRef]
- Richard, C.; Kowandy, C.; Landoulsi, J.; Geetha, M.; Ramasawmy, H. Corrosion and wear behavior of thermally sprayed nano ceramic coatings on commercially pure Titanium and Ti–13Nb–13Zr substrates. Int. J. Refract. Met. Hard Mater. 2010, 28, 115–123. [Google Scholar] [CrossRef]
- Tan, L.; Ren, X.; Sridharan, K.; Allen, T.R. Effect of shot-peening on the oxidation of alloy 800H exposed to supercritical water and cyclic oxidation. Corros. Sci. 2008, 50, 2040–2046. [Google Scholar] [CrossRef]
- Ni, L.-Y.; Wu, Z.-L.; Zhou, C.-G. Effects of surface modification on isothermal oxidation behavior of HVOF-sprayed NiCrAlY coatings. Prog. Nat. Sci. Mater. Int. 2011, 21, 173–179. [Google Scholar] [CrossRef]
- Faksa, L.; Daves, W.; Ecker, W.; Klünsner, T.; Tkadletz, M.; Czettl, C. Effect of shot peening on residual stresses and crack closure in CVD coated hard metal cutting inserts. Int. J. Refract. Met. Hard Mater. 2019, 82, 174–182. [Google Scholar] [CrossRef]
- Wu, Y.; Christensen, K.T. Spatial structure of a turbulent boundary layer with irregular surface roughness. J. Fluid Mech. 2010, 655, 380–418. [Google Scholar] [CrossRef]
- Acharya, S.; Mahmood, G. Turbine blade aerodynamics. Gas Turbine Handb. 2006, 1, 364–380. [Google Scholar]
- Hamakhan, I.; Korakianitis, T. Aerodynamic performance effects of leading-edge geometry in gas-turbine blades. Appl. Energy 2010, 87, 1591–1601. [Google Scholar] [CrossRef]
Material | Fe | Ni | Co | Mo | Al | Ti | Cr | C | Y | Si |
---|---|---|---|---|---|---|---|---|---|---|
GH4169 | Bal. | 50–55.0 | 1.0 | 2.8–3.3 | 0.3–0.7 | 0.8–1.2 | 17.0–21.0 | 0.08 | - | - |
NiCrAlYSi | 0.3 | Bal. | - | - | 8.0–10.0 | - | 18.0–22.0 | 0.05 | 0.5–0.8 | 0.5–0.8 |
Treatment Process | Roughness (μm) | Average | Standard Deviation |
---|---|---|---|
Coated | Ra | 1.25 | 0.045 |
Rz | 6.52 | 0.363 | |
Coated + USP 0.1 A | Ra | 0.79 | 0.023 |
Rz | 3.65 | 0.152 | |
Coated + USP 0.15 A | Ra | 0.83 | 0.027 |
Rz | 3.83 | 0.173 | |
Coated + USP 0.2 A | Ra | 0.85 | 0.032 |
Rz | 4.24 | 0.182 |
Point | O | Al | Cr | Ni |
---|---|---|---|---|
M | 28.68 | 18.72 | 34.44 | 18.16 |
N | 12.93 | 12.93 | 27.82 | 29.03 |
Disclaimer/Publisher’s Note: The statements, opinions and data contained in all publications are solely those of the individual author(s) and contributor(s) and not of MDPI and/or the editor(s). MDPI and/or the editor(s) disclaim responsibility for any injury to people or property resulting from any ideas, methods, instructions or products referred to in the content. |
© 2024 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
Share and Cite
Cai, J.; Wu, H.; Shi, X. Effect of Ultrasonic Shot Peening on Morphology and Structure of NiCrAlYSi Coatings on Superalloys for Blade Applications. Coatings 2024, 14, 949. https://doi.org/10.3390/coatings14080949
Cai J, Wu H, Shi X. Effect of Ultrasonic Shot Peening on Morphology and Structure of NiCrAlYSi Coatings on Superalloys for Blade Applications. Coatings. 2024; 14(8):949. https://doi.org/10.3390/coatings14080949
Chicago/Turabian StyleCai, Jin, Hao Wu, and Xihui Shi. 2024. "Effect of Ultrasonic Shot Peening on Morphology and Structure of NiCrAlYSi Coatings on Superalloys for Blade Applications" Coatings 14, no. 8: 949. https://doi.org/10.3390/coatings14080949