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Fraunhofer UMSICHT

Institutsteil Sulzbach-Rosenberg – Sommersymposium am 27. Juni 2013

Dr. HDR Patrick J. Masset

Hochtemperaturanwendungen Herausforderungen für Beschichtungstechnologien

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Folie 2

Agenda

1. Energy situation

2. Challenges for materials for power engineering

3. Coatings as alternative

4. Conclusion / outlook

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Folie 3

Technologic developments

Foto: DIHK

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Folie 4

Evolution of the world population

Estimated world population, 1950-2000, and projections: 2000-2050

Source: UN World Population to 2300

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Folie 5

Evolution of the energy needs

The combined increase of the individual / industrial needs and population growth leads

to high requirements for power engineering within a short time

Global energy demand rises by over one third in the period to 2035, underpinned by rising living standards in China, India & the Middle East

Source: OECD/IEA 2012

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Folie 6

Agenda

1. Energy situation

2. Challenges for materials for power engineering

3. Coatings as alternative

4. Conclusion / outlook

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Folie 7

Materials and power engineering

Applications

− Mining

− Materials processing

− Production, transport

− Conversion processes

Large variety of “raw materials”

− Coal, fuels, biomass, wastes, ores

− Sun, wind, hydraulic

Economy

− Geographic and geopolitical aspects

− Cost, availability

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Folie 8

Costs of corrosion

− All economic sectors

− 4% of GDP

− Consumption of raw materials

− Safety and environmental issues

Combined loads

− Thermal, chemical, mechanical, radiation

− Gaseous, liquid, solid phases

− High temperatures, pressures

Challenges for coatings for power engineering

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Folie 9

Agenda

1. Energy situation

2. Challenges for materials for power engineering

3. Coatings as alternative

4. Conclusion / outlook

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Folie 10

Why coatings are so interesting?

Technologies: electrochemistry, PVD, CVD, thermal spraying, laser cladding

Complementary properties to bulk properties

Low cost compared to bulk materials (low thickness)

Composition and / or properties on request

Often reparable

Combination of properties (corrosion / wear)

molding process

light alloys (TiAl)

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Folie 11

Chemical densification of thermal sprayed oxide coatings

4% HCl, 700 °C, 3d

100 µm

2% HCl, 800 °C, 1d

2% HCl, 600 °C, 3d 2% HCl, 800 °C, 3d

0% HCl, 700 °C, 3d

YSZ

NiCr-alloy

2% HCl, 700 °C, 3d

100 µm 100 µm

100 µm 100 µm 100 µm

Densification front from the oxide / alloy interface outwards

Densification process depends on temperature and solvo-thermal parameters

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Folie 12

treated

untreated

Tribological properties

Reduction of the friction coefficient

Improvement of the tribological properties

Cycles Fr

icti

on

co

effi

cien

t µ

Line scan

Untreated Treated

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Folie 13

Porosity and hardness

Decrease of the residual porosity after solvo-thermal post-treatment

Increase of the hardness of the coating

Temperature (°C) Temperature (°C) untreated untreated

Poro

sity

(%

)

Har

dn

ess

HV

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Folie 14

Resistance to mechanical impacts

Better resistance to impacts, reduced formation of cracks

Improvement of the oxide layer cohesion

trace of scratch test

200 µm

200 µm

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Folie 15

Adhesion properties

Increase of the adhesion of the Top-Coat to the Bond-Coat

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Folie 16

Resistance to thermal shocks

Cycles in liquid Al 4 min in the melt at 800°C 1 min cooling in air till 420 °C

420°C 800°C

800

C 20

C

Steel 1.2343

met./cer. composite

ZrO2 on Ni-based bond-coat +solvothermal

Cycles

cer./cer. composite on Ni-based Bond-coat

MgO + Al2O3-TiO2

Improvement of the chemical stability vs. liquid metals

Increased resistance against thermal shocks Cycles in air 20 min at 800°C 40 min cooling in air till 20 °C

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Folie 17

TiAl alloys: evidence of environmental embrittlement

Accelerated oxidation

100h in air at 600 °C

100h in air at 900 °C

5 µm

5 µm

Accelerated embrittlement

100 h, air

Accelerated oxidation of TiAl above 700 °C

Significant ductility loss (environmental embrittlement)

Decrease of mechanical properties (strength)

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Folie 18

Thermal spraying techniques 0 – 45 µm

45 – 63 µm

63 – 90 µm

32 – 45 µm15 – 32 µm

Example of thermal spraying process. Powder size < 45 µm

High velocity spraying of molten metallic powder. Powder composition: Ti-51Al-2Cr-2Nb and Ti-54Al-2Cr-2Nb

FhG

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Folie 19

Coated samples

1 cm

MO-CVD PVD HVOF

Source: Report project IGF-Nr. 24 EBG

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Folie 20

Coating of industrial components

TNB + Al-CVD oxidised 50 h at 1 100 °C

+ F

TNB + Al-CVD + F oxidised 100 h at 900 °C

Al2O3

TNB + Al-CVD + F oxidised 50 h at 1 100 °C

Al2O3

TNB + Al-CVD oxidised 100 h at 900 °C

Al2O3

TiO2

Blades TNB alloy (as received)

TNB + Al-CVD (0.5 – 1 µm)

Oxidation protection up to 1 100 °C + improved mechanical resistance (coating)

Applicability of the CVD route on technical parts

Untreated blades do not withstand oxidation tests

Source: Report project IGF-Nr. 24 EBG

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Folie 21

Improvement of the mechanical properties

×2

×2

×3

Goal

Higher ductility

Hig

her

stre

ng

th

90%

Halogen effect

no protection

Source: Report project IGF-Nr. 24 EBG

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Folie 22

Mechanical properties: overview

Source: P. Masset et al, Oral communication, ECS Fall Meeting, Honolulu (Oct. 2012)

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Folie 23

Agenda

1. Energy situation

2. Challenges for materials for power engineering

3. Coatings as alternative

4. Conclusion / outlook

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Folie 24

Conclusion

Suitable protection even under complex loads and / or environments

Economic benefit

Coating development specific to the applications

Meet challenges of power engineering

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Folie 25

Outlook

Nano-materials

− Lower thickness of coatings

− Less materials

− Specific properties (catalysis)

Interdisciplinary approach

− Combination of technologies

− Be inspired by other applications / disciplines

Versatile technologies

− Adaptable coatings for different applications

− Family of coatings

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Folie 26

FRAUNHOFER UMSICHT

Vielen Dank für Ihre Aufmerksamkeit! Thank you for your attention! Merci de votre attention!

Institutsteil Sulzbach-Rosenberg

Kontakt Fraunhofer UMSICHT Fraunhofer-Institut für Umwelt-, Sicherheits- und Energietechnik UMSICHT Institutsteil Sulzbach-Rosenberg Dr. HDR Patrick J. Masset E-Mail: info-suro@umsicht.fraunhofer.de Telefon: 09661-908 472 Internet: http://www.umsicht-suro.fraunhofer.de E-Mail: patrick.masset@umsicht.fraunhofer.de