Savisha Mahalingam

Hybrid turbine blade protection systems, which combine thermal barrier coatings (TBCs) and cooling mechanisms, are essential for safeguarding turbine blades in advanced gas turbine applications. However, conventional furnace evaluation methods are inadequate for accurately simulating the complex thermal conditions experienced by TBCs in these environments. Initial testing revealed substantial degradation of TBCs when subjected to high temperatures without the necessary cooling support. To address this limitation, the furnace setup was modified to incorporate a cooling air system. This system channeled 400 °C air to the back surface of the TBC while subjecting the front to 1400 °C furnace air, effectively replicating the thermal gradient encountered in hybrid protection systems. The modified furnace setup demonstrated a remarkable improvement in the performance of yttria-stabilized zirconia TBCs. By cooling the back surface of the TBC, the metal substrate temperature decreased, thereby improving the thermal gradient on the coating and its durability. The thermal gradient achieved by the modified furnace was verified to simulate accurately the conditions experienced by TBCs in advanced gas turbines. The conventional furnace setup, lacking a cooling mechanism, overestimated the heat transfer on the TBCs, leading to inaccurate results. The modified furnace, with its integrated cooling system, more accurately simulated the conditions experienced by TBCs in real-world advanced gas turbine applications and more reliably assessed their performance.

Cold spray has become a prominent deposition technology for coating, repair, and restoration in many industries, such as the aerospace, automotive, and power generation industries. It also has the potential to be used as an alternative overlay restoration for power plant components as it has minimal thermal distortion phase changes, as compared to conventional welding and thermal spray. This article aims to bridge the gap in the scientific literature by presenting a comprehensive review of cold spray in the context of power plant components. Firstly, this review examines the challenges of cold spray and subsequently elucidates effective mitigation strategies. Secondly, the review analyses the recent development of cold spray in the field of coating application. Moving forward, it investigates the integration of cold spray technology in repair applications, focusing on practical implementation and effectiveness. Finally, the review presents the overall impact of cold spray, its current outlook, and discusses future prospects. As such, the review will provide the community with a broad understanding of cold spray applications in the power plant sector.

Cold spray is a promising approach to repair all damages and defects in aluminum (Al) constituent elements. The study aims to investigate the mechanical and tribological properties of Al coatings deposited using high-pressure cold-spray (HPCS) and low-pressure cold-spray (LPCS) techniques. Al powder was sprayed on a cold-rolled plate of aluminum 1100, which was used as the substrate. The results showed that the micro-hardness of the LPCS Al coating reached up to 196.6 HV before the wear test compared to that of HPCS (174.3 HV). Moreover, more low friction coefficients obtained by LPCS (0.798) than HPCS (0.807) indicated good tribological properties with a high amount of oxide composition. Meanwhile, the wear studies reveal that the specific wear rate of the Al coating of LPCS (0.008) was lower than the HPCS (0.009) as the load increased from 3 N to 5 N, thus providing excellent wear resistance. Therefore, the results exhibited greater mechanical and tribological characteristics for Al coatings produced by the LPCS process than by the HPCS process.