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<p>This study investigates the use of the internal diameter high-velocity oxygen fuel (ID-HVOF) technology for the deposition of bond coats in thermal barrier coatings, targeting potential applications in enhancing high-temperature protection of internal surfaces of gas turbine engines components. NiCoCrAlY and NiCoCrAlYHfSi powders, in both fine and coarse particle sizes, were applied using a kerosene-fueled ID-HVOF torch. Nitrogen was introduced into the combustion fuel at flow rates up to 150&#xa0;lpm to extend the deposition window by promoting solid-state particle deposition, thus minimizing nozzle buildup, a key challenge in spraying fine metallic powders with ID-HVOF systems. An atmospheric plasma spray (APS) flash layer was applied to selected bond coats to enhance surface roughness and adhesion to the ceramic top coat. High-temperature performance was evaluated through isothermal and furnace cycle testing at 1150&#xa0;°C. The combination of nitrogen addition and APS flash layer significantly improved TBCs performance, achieving 900 h in isothermal tests and 390 cycles in cyclic tests, surpassing the 248 cycle lifespan of a conventional APS benchmark coating. These findings highlight the strong potential of ID-HVOF for producing high-performance bond coats in next-generation TBC systems, offering a viable solution for coating internal surfaces in advanced gas turbine engines.</p>

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Unlocking the Potential of ID-HVOF in NiCoCrAlX (X = Y, Hf, and Si) Bond Coat Deposition for Thermal Barrier Coatings

  • 期刊论文

  • 发表日期：

    2025年12月29日

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  • Maniya Aghasibeig,
  • Cristian V. Cojocaru

摘要

This study investigates the use of the internal diameter high-velocity oxygen fuel (ID-HVOF) technology for the deposition of bond coats in thermal barrier coatings, targeting potential applications in enhancing high-temperature protection of internal surfaces of gas turbine engines components. NiCoCrAlY and NiCoCrAlYHfSi powders, in both fine and coarse particle sizes, were applied using a kerosene-fueled ID-HVOF torch. Nitrogen was introduced into the combustion fuel at flow rates up to 150 lpm to extend the deposition window by promoting solid-state particle deposition, thus minimizing nozzle buildup, a key challenge in spraying fine metallic powders with ID-HVOF systems. An atmospheric plasma spray (APS) flash layer was applied to selected bond coats to enhance surface roughness and adhesion to the ceramic top coat. High-temperature performance was evaluated through isothermal and furnace cycle testing at 1150 °C. The combination of nitrogen addition and APS flash layer significantly improved TBCs performance, achieving 900 h in isothermal tests and 390 cycles in cyclic tests, surpassing the 248 cycle lifespan of a conventional APS benchmark coating. These findings highlight the strong potential of ID-HVOF for producing high-performance bond coats in next-generation TBC systems, offering a viable solution for coating internal surfaces in advanced gas turbine engines.