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utility of ceramic components for long term microturbine applications (discussed in section 2). The three layer BSAS-based EBC, developed in earlier NASA and CSGT programs, was found to be unsuitable for application to monolithic silicon nitride because it reduced the strength of the substrate by 50%. The reduction in the strength of the ceramic substrate caused by the CTE mismatch between the coating and substrate was not acceptable and it was clear that a new coating system was needed for Si3N4 components. This was reported in an earlier DOE/ONR EBC for Silicon Nitride contract report. Coatings tailored specifically for Si3N4 that would preserve the baseline strength of the underlying substrate were initiated under the DOE/ONR funded Enabling Technologies Program and continued under the DOE AMS program. Two papers that describe the details of the substrate strength reduction and coating development that helps overcome the problem are included in the appendix (GT 2004 -54092 and GT 2007- 27685). The manuscripts were prepared and presented at IGTI meetings during the course of the AMS contract. 4.2.1 Emphasis on non-line-of-sight coatings In the initial phase of the coating development, the complexity and small size of the monolithic silicon nitride components that needed to be coated were considered. The integral vane rings and IBRs for the ST5+ are described in Section 2. Most of the prior experience in EBC development consisted of plasma sprayed coatings and it appeared that existing thermal spray technologies might not be suitable to coat the components of interest. A feasibility study was performed to determine if an air plasma spray technique can be used to coat complex shaped engine components such as an integral vane ring. The study was based on a simple analytical approach that considered the ability of a plasma gun to coat “hidden” areas (vanes and platforms) by calculating the angle at which the spray gun approached the component using the ST5+ vane ring design developed under this contract. The quality of the coating as a function of gun angle was independently assessed by thermal spraying a cylinder. The other factors that weighed in on the final feasibility assessment included fixtures, cost, coating uniformity and existing mini-gun technologies. It was established that air plasma spray could not be used to apply environmental barrier coatings (EBCs) of acceptable quality to an integral vane ring assembly. Figure 4.2.1 is a pictorial representation of the approach used to assess the relative “accessibility” of the plasma plume to the component. Subsequent coating development for silicon nitride focused on non-line of sight coating methods, such as electrophoretic deposition, chemical vapor deposition (CVD), sol-gel, slurry coating, and pack cementation. The processing routes found most promising were slurry coatings and CVD. EBC development for silicon nitride consisted of work in four primary areas: (i) Bond coat composition and process development, (ii) Top coat composition and process development, (iii) Scale up, and (iv) Testing. Each of these areas is covered in more detail in the subsequent sections. 83PDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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