Papers by Author: M. Mollard

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Authors: G. Bonnet, M. Mollard, B. Rannou, J. Balmain, F. Pedraza, X. Montero, M. Galetz, Michael Schütze
Abstract: Novel, unconventional type of high temperature coating systems can be elaborated by depositing Al micro-particles on nickel base substrates, using an appropriate binder, and converting them into a thermal barrier type coating by a two-step heat treatment under argon. Final result is a coating structure consisting of a quasi-foam top coat, constituted by spherical hollow alumina particles, surmounting a β-NiAl diffusion layer able to form during high-temperature oxidation a protective alumina scale. In this work, pure nickel was employed as a model material to evaluate the effects of moderate temperatures (550-700°C), dwelling times and Al particle size on the final characteristics of the coatings. Almost no diffusion occurred below 600°C. In contrast, a Ni2Al3 layer very quickly formed at 650 or 700°C. The rapidity of coating formation was attributed to the appearance of a liquid phase at the coating/substrate interface. The increase of dwelling time did not provide any significant thickness increase as the Al particles got practically emptied after 2h. In addition, the use of different micro-sized particles resulted in similar Al diffusion coatings under the investigated conditions.
Authors: B. Rannou, M. Mollard, B. Bouchaud, J. Balmain, G. Bonnet, Vladislav Kolarik, F. Pedraza
Abstract: The use of thermal barrier coating systems allows superalloys to withstand higher operating temperatures in aeroengine turbines. Aiming at providing oxidation protection to such substrates, an aluminum-rich layer is deposited to form the α-Al2O3 scale over which a ceramic layer (i.e. YSZ layer) is applied to provide thermal insulation. A new approach is now being investigated within the FP7 European project « PARTICOAT », in which a single step process is employed by applying micro-sized aluminum particles. The particles are mixed in a binder and deposited by brushing or spraying on the substrate surface. During a heat treatment, the particles sinter and oxidize to form a top coat composed of hollow con-joint alumina spheres and simultaneously, an Al-rich diffusion zone is formed in the substrate. For a better understanding of the diffusion / growth processes, preliminary tests were carried out on pure nickel and Ni20Cr model alloys prior to further application on commercial superalloys. The effect of the heat treatment on the coating characteristics (number of layers, thickness, composition, homogeneity, etc.) was particularly investigated to emphasize the mechanisms of diffusion governing the growth of the coatings. The establishment of the diffused layers occurred very readily even at intermediate temperatures (650 and 700°C). However, the layers formed did not match perfectly with the thermodynamic modeling because of the quick incorporation of Ni into molten Al at intermediate temperatures (650°C). In contrast, at higher temperatures (700 and 1100°C) the phases predicted by Thermocalc are in good agreement with the observed thickness of the diffused layers. The incorporation of Cr as an alloying element restrained Al ingress by segregation of Cr even at very low temperatures aluminizing temperatures (625°C).
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