Solutions Flash Reduce processing cost and time using

Solutions Flash
Reduce processing cost and time using TriplexPro-210
to apply abradable coatings
SF-0005.2 – September 2016
Today’s situation
Thermal sprayed abradable coatings have long been considered an effective method to achieve clearance control in turbine engines, and in particular, aircraft turbine engines, offering the following advantages:
nn A friable structure that does not cause excessive wear on
rubbing components within the clearance control system
or particulate damage to components downstream.
nn Coating thickness that can be tailored to suit the application and can be machined to dimension using single point
tools.
nn A variety of available coating chemistries suitable for different operating conditions.
Relatively
simple application, with the ability to be renn
moved and reapplied as needed at overhaul.
The matrix materials used for abradable materials are, in
general, relatively inexpensive; however, the additives used to
induce friability and other abradable properties are more
costly rare earths or plastics. Furthermore, many of the parts
coated with abradable materials are large, such as compressor casings and fan casings, and the coatings are applied
quite thick. Using conventional spray guns, the spray rate
can be improved, thereby reducing processing time, but at
the expense of deposit efficiency. Even at optimum spray
rates, the deposit efficiency that can be achieved using conventional spray guns and still achieve the desired coating
structure is limited by the efficiency of these guns.
The Oerlikon Metco solution
A plasma spray system incorporating the Oerlikon Metco
TriplexPro™-210 gun addresses the need for improved deposit efficiency for abradable coatings as well as faster application rates. Abradable coatings applied using TriplexPro-210 have optimal hardness and porosity and exhibit
closely packed, homogeneous structures.
TriplexPro-210 is also economical when it comes to the consumption of spray process consumables, such as gas, gun
parts that wear, and electricity. The bond coat and the top
coat materials of the abradable coating system are sprayed
using the same gun hardware, so changeover from one material to another is also fast and efficient.
The Oerlikon Metco TriplexPro-210 plasma spray gun with high enthalpy flame.
Extremely stable, the TriplexPro-210 is capable of spraying
for more than 200 hours without process drift and without
the need to change gun wear parts.
Solution description and validation
TriplexPro-210 saves time and reduces cost
The Oerlikon Metco TriplexPro-210 Plasma Spray Gun can
spray standard abradable materials with greater deposit efficiency and at higher spray rates, reducing both the cost of
materials and processing time. This can result in a very significant savings to turbine engine component manufacturers
and overhaul facilities.
Deposit efficiency and spray rates
Abradable coating materials sprayed using TriplexPro-210
exhibit substantially higher deposit efficiencies compared to
the same materials applied using the Oerlikon Metco 9MB
plasma spray gun.
SF-0005.2 – Abradable Coatings with TriplexPro™-210
© 2016 Oerlikon Metco
Of equal importance is that TriplexPro-210 can maintain
these higher deposit efficiencies and the quality of the coating at feed rates that are as much as three times higher than
the Oerlikon Metco 9MB gun.
A more complete picture emerges through an evaluation of
coating throughput improvement (spray rate vs. deposit Efficiency), yet the power levels for TriplexPro-210 are comparable to other plasma guns.
2
100
90
200
200
9MB
TriplexPro-210
Throughput [g / min]
(Spray Rate x Deposit Efficiency)
Spray rate [g / min]
Deposit efficiency [%]
180
9MB
TriplexPro-210
180
80
160
160
70
140
140
60
120
120
50
100
100
40
80
80
30
60
60
20
40
40
10
20
20
0
0
Metco
313NS
Metco
320NS
TriplexPro-210 parameters
Primary flow – Ar
Secondary flow – N2
Current
Power (approx.)
Metco
601NS
9MB
TriplexPro-210
Percent Improvement [%]
0
Metco
313NS
Metco
320NS
Metco 313NS
90 NLPM
205.5 SCFH
–
–
350 A
34 kW
Metco
601NS
Metco
313NS
Metco 320NS
76 NLPM
173.5 SCFH
–
–
250 A
22 kW
Metco
320NS
Metco
601NS
Metco 601NS
160 NLPM
365 SCFH
2 NLPM
4.5 SCFH
330 A
42 kW
nn Deposit efficiency and throughput data reported as mean values. Small variations (± 3.5 %) should be expected.
nn Parameters may vary as a result of differences in system setup, material and quality / specification requirements.
nn Metco 313NS and Metco 320NS results not optimized for total throughput. Additional optimization may produce even better results.
Additional processing considerations
nn With TriplexPro-210, many spray parameters can be
achieved using only argon for the process gas. In some
instances, small amounts of nitrogen can be used to increase overall energy. There is no need for complex ternary gas parameters and the infrastructure to support them.
nn Bond coats are usually applied using the same gun configuration as the top coat, so material changeover from
bond coat to top coat can be automated.
nn The TriplexPro-210 maintains the spray process window
with stable output for long periods without gun component wear. The cost of gun components are approximately US $2.00 per hour.
nn The TriplexPro-210 achieves the process window again
and again, without the need to adjust parameters.
nn Validation testing has proven that the TriplexPro-210 can
spray Metco 601NS for more than 200 hours with no
change in coating quality or microstructure.
Coating quality
The coatings produced by the TriplexPro-210 plasma spray
gun easily meet specifications. It can achieve the parameter
window repeatedly and maintains it over long spray runs,
even with numerous gun starts and stops.
Metco 313NS
Macrohardness (R15Y): 65 – 75
Fugitive Phase + Porosity: 45 – 50
Metco 320NS
Macrohardness (R15Y): 56 – 62
Fugitive Phase + Porosity: 51 – 57
SF-0005.2 – Abradable Coatings with TriplexPro™-210
© 2016 Oerlikon Metco
Metco 601NS
Macrohardness (R15Y): 62.5 – 70.5
Fugitive Phase + Porosity: 54.5 – 57
3
Processing costs
Total cost to use the TriplexPro-210 spray Metco 601NS indicates an overall savings of 24 % compared to the Metco
9MB series guns and a 27 % savings compared to the
Metco F4 series guns.
Comparative coating costs for Metco 601NS
9MB
F4
TriplexPro-210
0
10
20
30
40
50
Capital cost
(10 year amortized depreciation)
Operator
(Grade 7 per U.S. Dept. of Commerce)
Coating material (Standard pricing)
Spare parts
(Average hourly rate)
Utilities
(U.S. Dept. of Commerce national averages)
Maintenance
(Grade 11 per U.S. Dept. of Commerce)
Facilities
(U.S. Dept. of Commerce national averages)
60
70
80
90
100
110
Notes:
nn Based on cost to apply 1 kg of material using standard parameters and
normalized against the Metco 9MB plasma spray gun.
nn Calculations based on fully utilized, single-shift operation.
nn Costs will vary according to the Customer’s location and system
configuration.
Customer benefits
Effective
nn Produce high quality abradable coating systems that
meet or exceed OEM requirements for coating structure,
hardness, porosity and abradability.
Highly
stable process ensures coating requirements are
nn
met with little or no process drift during long spray
campaigns.
nn Simplified infrastructure requirements and coating development resulting from single (argon only) or binary (argon
with nitrogen bleed) process gas parameters.
Economical
nn Save material costs with higher deposit efficiencies.
nn Save production time with higher spray rates, throughput
values and a stable process that does not require constant adjustment.
nn Inexpensive gun consumable cost, estimated at only US
$2.00 per hour.
nn Economical power and gas consumption.
nn Save on spray run qualification costs resulting from higher
process reproducibility.
Efficient
nn Significantly increase production throughput with higher
deposit efficiencies and / or spray rates.
nn Quick changeover from bond coat to top coat using the
same gun configuration.
nn Highly stable process with no parameter adjustment required from part to part or day to day for more than 200
hours of spray time.
Environmental benefits
nn Reduce waste with higher deposition efficiency
parameters.
nn Low gun decibel level reduces shop noise levels.
nn No thoriated tungsten components used, reducing a hazardous waste disposal issue.
Information is subject to change without prior notice.
SF-0005.2 – Abradable Coatings with TriplexPro™-210
© 2016 Oerlikon Metco
www.oerlikon.com/metco
info.metco@oerlikon.com4
Download PDF