G. E. Kim, Perpetual Technologies, Inc., Ile des Soeurs, QC, Canada; P. Richer, B. Jodoin, University of Ottawa, Ottawa, ON, Canada; T. Addona, n-WERKZ, Ile des Soeurs, QC, Canada
Thermal barrier coatings with nanostructured bond coats have shown significant thermal cycling enhancements over its conventional microstructured counterpart; however, the high cost inherent to the cryomilling processing of the MCrAlY powder restricts from commercial application. Hence, this study characterizes and evaluates nanostructured bond coats derived from non-cryogenically milled MCrAlY powder with emphasis placed on reduced processing cost and scale-up capability. After extensive development of both a high-energy planetary mill and its operating parameters, fine-grained equiaxed NiCrAlY powder has been produced. XRD and SEM characterization of the milled powder will be presented. Microstructural analyses of the coatings sprayed via the HVOF and cold spray processes will also be carried out in addition to some preliminary static oxidation test results of conventional and milled NiCrAlY.
A custom-built high-energy planetary mill has been optimized to produce fine-grained equiaxed NiCrAlY powder. This processing route, unlike the cryomilling process used in previous studies, exerts significantly higher energy (over 20x) into the process and does not require the use of liquid nitrogen. Preliminary characterization and evaluation of the milled NiCrAlY powder and its coatings will be presented.
