Development of Low-Oxide MCrAlY Coatings for Gas Turbine Applications

Advanced high-energy plasma systems are being used to achieve the benefits of the high-velocity oxy-fuel (HVOF) system without losing the inherent advantages of plasma for coating of gas turbine parts. MCrAlY coatings play a very important role in the performance and reliability of gas turbine components. One of the important considerations for next generation of gas turbines, which have more demanding conditions and need to withstand ever increasing operating temperatures, is that they should possess very low oxygen content levels in the coating. Low oxygen content coatings are applied by the expensive low-pressure plasma spray (LPPS)/vacuum plasma spray (VPS) technique for critical components in aero- and land-based gas turbines. This work deals with the development of low-cost LPPS equivalent coatings (having low oxygen content) using the high-energy high-velocity plasma spray (HEHVPS) gun and inert gas shroud. A comparison has also been made with CoNiCrAlY coatings by HVOF.