Andrzej Nowotnik, Grzegorz Maciaszek, Damian Nabel, Krzysztof Cioch, Rzeszow University of Technology, Rzeszow, Poland
In response to the growing demands of the aerospace industry, especially in the context of post-pandemic recovery, there is an urgent need to implement advanced technologies that combine energy efficiency with high-performance gas turbines. One of the critical components in this process is the development of advanced thermal barrier coatings (TBC) on superalloys.
This presentation will discuss the results of research on a new methodology for depositing ceramic coatings from yttrium-stabilized zirconia (YSZ) on newly developed PDC bond coats, which require lower deposition temperatures compared to traditional aluminide or MeCrAlY bond coats. The innovation of the proposed solution lies in the use of hollow cathode (HC) plasma in the EB-PVD process, which enables the formation of columnar ceramic coatings at temperatures up to 200°C lower than standard, while still meeting the requirements for TBC applications.
The presentation will cover both the theoretical and practical aspects of this process, including the technical challenges associated with integrating HC plasma, electron beam interactions, and magnetic field shielding. Results from 4D-Beam simulations, along with initial morphological analyses of coatings deposited at lower temperatures, will demonstrate the effectiveness of this new approach, opening up new possibilities for the advancement of thermal barrier coatings in the aerospace industry.