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"ABSTRAK

Thermal spray sering diaplikasikan pada leading edge bilah turbin uap untuk meningkatkan ketahanan abrasi. Stellite adalah salah satu material yang sering digunakan dikarenakan ketahanannya yang baik terhadap aus. Penelitian ini bertujuan untuk mengkomparasi properti metode flame spray, plasma spray, dan HVOF dalam mendeposisikan lapisan Stellite ke bilah turbin baja tahan karat martensitik 410. Hasil lapisan plasma spray dan HVOF menunjukkan deposisi lapisan yang rata sedangkan flame spray tidak. Ketiga proses thermal spray memenuhi spesifikasi kuat lekat minimum manufaktur. Rata-rata kuat lekat dan kekerasan tertinggi didapat dari proses HVOF dengan nilai masing-masing 33,1 MPa dan 719 HV. Berdasarkan standar deviasi kuat lekat dan kekerasan, proses HVOF memiliki hasil lapisan paling homogen. Kekerasan substrat di bawah antarmuka pasca proses pelapisan flame spray, plasma spray, dan HVOF masing-masing naik sebesar 236%, 56%, dan 65% dari spesifikasi substrat. Lapisan HVOF memiliki tampilan penampang yang paling baik. Persentase porositas, diameter porositas, dan rata-rata panjang unbonding terkecil didapat pada proses HVOF dengan nilai masing-masing 0,2%, 7,2 μm, dan 31%. Struktur mikro lapisan pasca pengetsaan menghasilkan fasa-fasa yang berhubungan dengan masukan panas. Struktur dendritik terbentuk pada lapisan proses flame spray dan plasma spray pasca pengetsaan, namun tidak pada proses HVOF. Oksida dan karbida kobalt maupun krom mungkin terbentuk pada lapisan.

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ABSTRACT

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Thermal spray is often applied on steam turbine blade leading edge to increase abrasion resistance. Stellite is one of the commonly used material as it is known to wear protection against abrasion, oxidation, and corrosion at elevated temperature. Thermal spray method generally used in industry are flame spray, plasma spray, and HVOF. This research is intended to compare properties of those methods in depositing Stellite coating on 410 martensitic stainless steel turbine blade. Plasma spray and HVOF coating show even deposition while flame spray coating not. Those three coatings meet manufacture minimum bond strength requirement. On the flame spray process, higher preheat temperature resulted in higher bond strength. Preheat temperature variation relatively not affect coating hardness. Highest average bond strength and hardness are got by HVOF process with a value of 4.799 psi (33,1 MPa) and 719 HV respectively. According to bond strength and hardness standard deviation, the HVOF process gives the most homogeneous coating. Substrate hardness just below the coating interface after flame spray, plasma spray, and HVOF process are raised by 236%, 56%, and 65% each from the specification. HVOF coating has the best cross section compared to others with little splat and porosity. Flame spray coating has the most significant and highest amount of porosity.  In terms of percentage and size, HVOF gives the best result with a value of 0,2% and 7,2 μm respectively. The smallest coating interface unbonding is got by the HVOF process, with an average of 31%. Flame spray, plasma spray, and HVOF coating microstructure after etching show phases related to heat input during application. The dendritic structure is observed on flame spray and plasma spray coating after etching but not on HVOF process. Oxides like Cr₂O₃, CoCr₂O₄, CoO, and carbides like CoC, Cr₇C₃, Co₆W₆C, or Cr₂₃C₆ probably formed in the coating based on EDS result. Moreover, chemical composition result also indicates the formation of silicon oxide on coating and iron oxide at the coating interface. 

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"Thermal spray is a coating process that provides functional surface to protect or improve the performance of a substrate or component. Almost any kind and form of material can be thermally sprayed which is why thermal spray is used worldwide to provide protection from corrosion, wear, and heat, to restore and repair components, and for a variety of other applications. This reference handbook is the complete guide to thermal spray technology. It covers principles, processes, types of coatings, applications, performance, and testing/analysis. Developed under the guidance of the Thermal Spray Society Training Committee, the handbook provides an excellent introduction and guidebook for those who are new to thermal spray. It also provides enough in-depth coverage and data that it should be of great value to specifiers and users of thermal spray coatings and to thermal spray experts who need additional background in certain areas."

"Contents : - Quo Vadis Thermal Spraying ? - HVOF-Sprayed Quasicrystal Composite Coatings for Bearing Applications - Functional Ceramic and Metallurgical Coatings on Magnesium Components - Study on Zircon-Based Ceramic Coating for High Temperature Oxidation Resistant Application - Tungsten Coatings for Divertor Wings - Double Doped Ceria Electrolyte Synthesized by Solution Plasma Spraying with Induction Plasma Technology - Replacement for Hard Chrome Plating in Printing Machinery - A contribution to Engine pistons Life Time Improving by Means of Thermal Spray Coatings - Plasma Spraying of Tin on to a Monocrystalline Lithium Fluoride Window - Fabrication and Properties of TiO2 Plioto-Catalytic Coatings by Thermal Spraying with TiO2-AI Agglomerated Powder - XRD and Rietveld Quantitative Pliase Analysis of Radio Frequency Suspension Plasma Sprayed Nano-hydroxyapatite Powders - HVOF Sprayed Hydroxyapatite Coatings: Powders' Melting State and Mechanical Properties - In Vitro Changes on High-Pressure Plasma Sprayed Hydroxyapatite (HA) Caotings - Corrosion Resistant Coatings for Gas Turbine Exhaust Stack Applications - Ceramic Abradable Coatings for Applications up to 1100°C - Production of Superplastic Foils by Thermal Spraying - The Internal Plasma Spraying on Powerful Technology for the Aerospace and Automotive Industries - A Contribution to the Production and Characterization of HVOF coatings for Application in the Petrochemical Field - Process Modelling to Optimise the Structure of Hollow Zirconia Particles for use in Plasma Sprayed Thermal Barrier Coatings - Comparative Study of Different Sealing Methods for Thick Thermal Barrier Coatings - Influence of a Multi-Gas Mixture on the on the Performance of a HPPS Plazjet System for a Thermal Barrier Coating - Effect of Bond Coat Processes and Surface Characteristics on the Failure Mechanism of Thermal Barrier Coatings - Thermal Shock Characteristics of Functionally Graded Thermal Barrier Coatings - Kinetics of Thermally Grown Oxide at Interface Between Thermal Barrier Coatings and MCrAlY Bond Coatings - Reaction Diffusion Behavior of Thermally Sprayed MCrAlY Coatings on Ni-Based Super Alloys - Optimization of Shop Practices for Thermal Barrier Coatings - Removal of Thermal Barrier Coatings from Turbine Blades: A Comparison of Machanical and Chemical Methods - Induction Plasma Synthesis of MoSi2 Ultrafine Powders - Improvements in HVOF Sprayed Cermet Coatings Produced from SHS Powders - Composites Made of Metal Foams With Thermally Sprayed Coatings - Plasma Spray Dissociation ZrSiO4 As The Basis of Forming ZrO2-Mullite Composites from a ZrSiO4 + AI2O3 Mixture - HVOF Sprayed Hydroxyapatite/Titania Composite Coatings - Manufacture of SiC Composite Coatings by HVOF - Hight Temperature Behaviour of Plasma Sprayed ZrB2-SiC Composite Coatings - Abradable Coatings for Low-Temperature Applications - Developments of Plasma Sprayed Ceramic Coatings - Properties of Al203 coatings sprayed by HFPD - On the Tailoring of Spray Dried Thermal Spray Powders - Spray Powders and Coatings on the Basis of Titanium Suboxides - A Comparative Study of the Deposition of Chromium Carbide Based Metal Matrix Composites by Axial Plasma Spray, Air Plasma Spray and High Velocity Oxygen Fuel - Heating Effect of Flame Impingement on polymer Coatings - Mechanical Properties of Thermal Spray PEEK Coatings - Characterization and Mechanical Properties of Flame Sprayed Hydroxyapatite/Polymer Composite Coatings - Structure and Thermal Conductivity of Flame Sprayed Polyamide 11 Coatings Filled with AI2O3, AIN and BN Ceramics - Surface Modification of Recycled PET Plate by Particle Implantation and Deposition with Plasma Spraying - Sprayed Composite Coating of High Performance Thermoplastics - Processing and Characterization of Nanostructured Cermet Coatings - Synthesis and Properties of Multimodal WC-12 Co Coatings - Structure and Properties of HVOF Sprayed Amorphous Polymer Matrix Nanocomposite Coatings - Properties of HVOF Sprayed Multi-Scale Polymer/Silica Nanocomposite Coatings - Control of the Injection of an Alumina Suspension Containing Nanograins in a dc Plasma - Cold Sprayed Nanostructured WC-Co - Low Pressure Plasma Spraying of Sol-Gel Al203/SiC Nanocomposite Coatings - Effects of Shock Waves on Impact Velocity of Cold Spray Particles - Optimization of the Cold Spray Process - Kinetic Powder Compaction Applying the Cold Spray Process A Study on Parameters - Experimental Study of Interaction of Supersonic Gas Jet With a Sub"

"This proceedings volume representing the second International Thermal Spray Conference (May 2004, Osaka, Japan) contains 232 papers and 93 poster presentations. Arrangement is in sections on applications, characterization methods for coating properties, coating technologies for vehicle engines, cold spray, consumables for thermal spraying, corrosion protection, economics and quality, HVOF processes and materials, innovative equipment and process technology, modeling and simulation, nanostructured materials, photocatalytic materials, process diagnostics, protective coatings against wear and erosion, and thermal barrier coatings."

"Contents :- Verfasserverzeichnis / List of authors - WSP-sprayed boron carbide coatings for fusion applications - Composite functional thermal sprayed coatings for the parabolic aerials - HVOF sprayed WC-Co-Cr as a generic coating type for replacement of hard chrome plating - HVOF facility qualification at an airline ? importance and benefits for landing gear applications - Thermisch gespritzte korrosionsschutzschichten für sulfidierende atmosphären - Wire arc spraying of zinc as effective method to produce anodes for the corrosion protection of reinforced concrete structures - Heating of porous particles in the plasma flame - Effect of surface morphology of substrate on flattening behavior of freely fallen metal droplet - Simulation of the influence of spray parameters on particle properties in APS - Particle flux imaging (PFI) und particle shape imaging (PSI) ? two innovative diagnostics for thermal coating - Optisches prozessanalysesystem für das thermische spritzen - Preliminary studies of a closed-loop for a feedback control of air plasma spray processes - The industrial use of diagnostic technology for plasma spraying - Low cost industrial type diagnostic system for powder jet visualisation, particlesubstrate interaction and coating growth - Application of digital CCD camera for monitoring of particle-in-flight parameters in plasma and HVOF spraying - Prozessdiagnostik an thermischen Beschichtungsverfahren ? Neue Erkenntnisse aus den laufenden Arbeiten der DFG-geförderten Forschungsgruppe - On-line-monitoring control of stainless steel coatings obtained by APS processes - Volumetric and size characterization of void morphologies in thermally sprayed metallic deposits using scattering techniques - Zusammenhänge zwischen dem gefüge und den eigenschaften der tic- haltigen spritzschichten - Microstructures and properties of nanocrystalline composite coatings - Evaluation of plasma deposited Alumina-Titania ceramic composite coatings - YSZ film deposition by thermal plasma assisted chemical vapor deposition in open air - Vacuum plasma sprayed YSZ electrolyte for solid oxide fuel cell application - High energy ball milling prepared Al2O3-NiCr dispersion powders for thermal spray coatings - Nanostructured ceramic coatings obtained by thermal spraying - Plasma sprayed nano-structured oxide ceramic coatings - Coatings of powders based on iron aluminides - Erosion behavior of WCP-Fe3Al composite coating produced by high velocity arc spray at elevated temperature - Thermal spray moulding ? production of microcomponents - Herstellung von kleinserienwerkzeugen für die blechumformung durch gespritzte schichten in schalenbauweise - Thermal sprayed coatings for thixoforming tools - Internal plasma spraying for new generation of automotive engine , etc."

"Proceedings, 15th International Thermal Spray Conference Nice, France, 25-29 May 1998. The 271 papers presented in this two-volume set cover the theory of thermal spray, the properties of coatings, the different spraying processes, their quality control, and their practical application. The conference was organised by the Commissariat a l'Energie Atomique and five other French organizations, and was co-sponsored by the ASM Thermal Spray SocietySM, The German Welding Society, and the High Temperature Society of Japan. Contents: Oxidation, Wear, and Corrosion Jets and Deposits Properties and characterization Processes and Quality Control Applications Composite Structures Free-Standing Shapes Polymer Coatings Feedstock Spraying Thermal Barriers."

"Proceedings of the 1st International Thermal Spray Conference, Montreal, Quebec, Canada, May 8-11, 2000. Conference assembled nearly 300 experts from academia, research, and industry from 35 countries to discuss the challenges and opportunities facing the thermal spray community now and into the 21st century."