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Creating nanostructure coatings to work in high temperature conditions

Number of pages: 69 File Format: word File Code: 32296
Year: 2014 University Degree: Master's degree Category: Facilities - Mechanics
Tags/Keywords: activity - Aluminization - Aluminizing - Aluminum coating - Coating oxidation - Hedging practices - Nano structure coatings - Penetration coatings - Sedimentary
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  • Summary of Creating nanostructure coatings to work in high temperature conditions

    Dissertation for receiving M.Sc degree

    in the field of mechanical-construction and production engineering

    Abstract

    Aluminide penetrating coatings for the protection of gas turbines used in power plants, aviation and marine industries, and oil and gas industries and Petrochemicals are mainly attacked by high temperature oxidation and hot corrosion phenomena. In this research, in order to use the effect of oxygen-loving elements, how to strengthen the aluminide permeable coating with zirconium oxide nanoparticles has been investigated. To create a coating of a nickel layer and a nanocomposite layer of nickel-nanozirconia, it was created by electroplating method on the nickel-based superalloy separately, followed by a two-step high activity aluminumization process. First, aluminizing operation was performed at 760 degrees Celsius, and then at 1080 degrees Celsius, additional infiltration operations were performed in order to form the desired phases. The coating formation mechanism was evaluated through microstructure examination by optical microscope, scanning electron microscope and energy dispersive spectroscopy chemical analysis. The results showed that cerium oxide nanoparticles were successfully involved in aluminide coating.

    Key words: co-deposition-aluminization-penetrating aluminide coatings-two-step process-high activity.

    The purpose of applying a suitable coating is to obtain long-term resistance against the corrosive environment. High temperature coatings are among the coatings that are used to increase the lifespan of gas turbine parts, including blades. In order to obtain more efficiency in gas turbines, according to thermodynamic calculations, it is necessary to increase the temperature of the gas exiting from the blades. With the increase in temperature, due to the greater activity of the environment and dynamic changes in the construction of objects, problems such as creep, thermal fatigue, oxidation and hot corrosion arise, which requires the development and production of better materials. Also, considering that the resistance to oxidation and corrosion at high temperature decreases with the increase in strength, it is tried to produce an alloy with high strength first and then cover their surfaces to protect them from the mentioned factors. One of the ways to increase the efficiency and effectiveness of gas turbines is to increase the inlet temperature. The need to increase the working temperature of the blades, increase the performance and lifetime of the components used in the gas turbine has led to the advancement of material science technology. This performance improvement can be achieved through the design of new materials and better manufacturing methods. For this purpose, nickel-based superalloys have been developed from heated work to casting, directional casting, and single crystal, and then coated spokes replaced uncoated spokes.

    Resistance to oxidation of coatings at high temperature is possible in two ways: one is by creating a neutral coating against the corrosive environment that does not react with that environment, and the other is coatings that change the surface composition by an active element. and its reaction with the environment to obtain a protective layer that can protect the surface from the environment. The first category includes TBC coatings and the second category includes penetrating coatings such as aluminizing, chromizing, and siliconizing.

    The powder mixture method (aluminization) is a relatively cheap engineering method for forming high temperature coatings. The simplicity of the required technology, the acceptable repeatability and the ability to cover parts with various shapes and sizes have put this method at the top of the technologies used in high temperature industries, especially turbines. Aluminide permeation coatings are obtained by enriching the surface of the alloy with aluminum, which forms a protective layer against oxygen penetration by creating aluminum oxide on the surface of the coating in the environment. The growth of this layer is low compared to other oxides, and the base alloy can be protected at high temperatures with this method, because this oxide is resistant to temperatures close to 1100 degrees Celsius.

    Various researches have been done on the effect of various elements on the properties of simple Al penetrating coatings.Most of these researches have been conducted on improving the adhesion of the shell in cyclic oxidation and improving the hot corrosion behavior of the coating. One of the most important methods known to improve the adhesion of the oxide shell is the effect of oxygen-loving elements such as yttrium, cerium, hafnium and the like. A small concentration of these elements or their oxides can modify the morphology of the alumina oxide layer and its interface with the aluminide coating and significantly increase the adhesion of the alumina shell to the aluminide coating. The methods that have been used so far to introduce oxygen-loving elements or their oxides in high temperature coatings are mainly laboratory and their practical implementation is difficult for industries. Examples include ion implantation, chemical vapor deposition, and sol-gel methods.

    In this research, a nickel electroplating layer was used as a support for ceria nanoparticles. In this method, first a thick layer of nanocomposite is created by nickel electroplating in a bath containing ceria nanoparticles on the surface of the substrate, and in the next step, an aluminide penetrating coating with inward growth (Inward Growth) is applied to the substrate and the electroplated layer. The development of this method due to the establishment of electroplating processes and penetrating coating in the industry can be well received by high temperature industries. In this field, no similar research history was found inside the country, and there are differences in materials and methods in the present work compared to similar foreign articles. oil & gas and petrochemical industries that are mainly attacked by high temperature oxidation and hot corrosion phenomena.  In this research, in order to take advantage of the effect of reactive elements, how Strengthening aluminide diffusion coating with Zirconium Oxide Nanoparticles is investigated. For creating coating, on nickel-base superalloy by electrodeposited nickel layer and the electrodeposited Ni-ZrO2 nanoparticles composite layer was separately followed by high activity pack aluminizing with a two-step process. First, high activity aluminizing is carried out at a temperature of 760°C and which is then followed by a diffusion treatment at 1080°C to achieve the desired phases. Coating formation mechanism was evaluated via Optical Microscope, Scanning Electron Microscopy structural studies and Energy Dispersive Spectroscopy analysis. The results showed that cerium oxide nanoparticles have been successfully involved in the aluminide coating.

    Keywords: co-deposition, Aluminizing or aluminization, aluminide diffusion coatings, two-step process, high activity.

  • Contents & References of Creating nanostructure coatings to work in high temperature conditions

    List:

    1. Chapter 1: Introduction 1

    1-1- Introduction. 2

    2. The second chapter: an overview of the research done 4

    1-2-Composition of superalloys 5

    2-2 Coatings used in superalloys 6

    3-2- Deposition processes. 7

    2-3-1- Electrodeposition. 7

    2-4- Important points in the design of nano composites 12

    2-4-1- Dispersion. 12

    2-4-2- Makeup. 12

    2-4-3- economic value. 13

    2-4-4- Electrodeposition. 13

    2-5- Powder cementation process to produce aluminide coatings. 13

    2-5-1- Advantages of powder cementation process. 15

    2-5-2- limitations of powder cementation process. 15

    2-6- Aluminide coatings on nickel and nickel-based superalloys. 16

    2-6-1- Coatings obtained from the process with high aluminum activity 17

    2-6-2- Coatings produced by low activity aluminum processes 22

    2-6-2-2-Nickel-based superalloys. 23

    2-7- Pre-treatment before aluminizing. 24

    2-8- Surface morphology of aluminide coatings. 25

    2-9- Alumina systems. 27

    2-10- Mechanisms of the effect of reactive elements in alumina-forming alloys. 28

    2-11- The effect of reactive elements on the alumina shell 29

    2-11-1- The effect of reactive elements on the growth and adhesion of the alumina shell 30

    2-11-2- Strengthening the alloy/shell bond and the separation phenomenon. 30

    3. Chapter 3: Research method 32 3-2- Raw materials and equipment for coating. 34

    3-2-1- Sublayer alloy. 34

    3-2-2- Electroplating process. 34

    3-2-2-1- Materials used in electroplating process. 34

    3-2-2-2- Equipment used in electroplating process. 36

    3-2-2-3- applying electroplating coating. 37

    3-2-3- Penetration coating process. 40

    3-2-3-1- Powders used in the penetration coating process. 40

    3-2-3-2- The equipment used in the infiltration coating process. 40

    3-2-3-3- Application of penetration coating. 41

    3-3- Characterization of samples 42

    3-3-1- Metallography. 42

    3-3-2- Observing the microstructure. 42

    4. Chapter 4: Laboratory findings 44

    4-1- Electroplating of nickel. 45

    4-2- Nanocomposite nickel plating. 45

    4-3- Penetration aluminization. 48

    4-4- Final covers. 52

    5. The fifth chapter: analysis of findings 57

    6. Chapter Six: Conclusion and Suggestions 60

    6-1- Conclusion. 61

    6-2- Suggestions. 62

    References 63

    Source:

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    [13] G. Goward and L. Cannon, "Pack cementation coatings for superalloys: a review of history, theory, and practice," Journal of engineering for gas turbines and power, vol. 110, pp. 150-154, 1988.

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    [17] R. Streiff, J. N'Gandu Muamba, and D. Boone, "Surface morphology of diffusion aluminide coatings," Thin solid films, vol. 119, pp. 291-300, 1984.

    [18] F. H. Stott and G. C. Wood, "Growth and adhesion of oxide scales on Al2O3-forming alloys and coatings," Mater. Sci. Eng, vol. 87, pp. 267-274, 1987.

    [19] N. Lindblad, "A review of the behavior of aluminide-coated superalloys," Oxidation of Metals, vol. 1, pp. 143-170, 1969.

    [20] W. E. Boggs, "The Oxidation of Iron-Aluminum Alloys from 450° to 900° C," Journal of the Electrochemical Society, vol. 118, pp. 906-913, 1971.

    [21] R. Prescott and M. Graham, "The formation of aluminum oxide scales on high-temperature alloys," Oxidation of Metals, vol. 38, pp. 233-254, 1992.

    [22] G. C. Wood, "High-temperature oxidation of alloys," Oxidation of Metals, vol. 2, pp. 11-57, 1970.

    [23] G. Wood and F. Stott, "The influence of aluminum additions on the oxidation of Co-Cr alloys at 1000 and 1200°C," Oxidation of Metals, vol. 3, pp. 365-398, 1971.

    [24] F. Stott, G. Wood, and M. Hobby, "A comparison of the oxidation behavior of Fe-Cr-Al, Ni-Cr-Al, and Co-Cr-Al alloys," Oxidation of Metals, vol. 3, pp. 103-113, 1971.

    [25] P. Choquet, C. Indrigo, and R. Mevrel, "Microstructure of oxide scales formed on cyclically oxidized M Cr Al Y coatings," Materials Science and Engineering, vol. 88, pp. 97-101, 1987.

    [26] J. Tien and F. Pettit, "Mechanism of oxide adherence on Fe-25Cr-4Al (Y or Sc) alloys," Metallurgical Transactions, vol. 3, pp. 1587-1599, 1972.

    [27] D. Delaunay, A. Huntz, and P. Lacombe, "Impurities influence on oxidation kinetics of Fe-Ni-Cr-Al alloys," Corrosion science, vol. 24, pp. 13-25, 1984.

    [28] A. Kumar, M. Nasrallah, and D. L. Douglass, "The effect of yttrium and thorium on the oxidation behavior of Ni-Cr-Al alloys," Oxidation of Metals, vol. 8, pp. 227-263, 1974.

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