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4.2.4 Slurry Coating Process Scale-up Preliminary scale-up of the coating process to more complex turbine geometries was initiated using turbine airfoils of NT154 silicon nitride. These single airfoils were used to develop the coating process for eventual coating of more complex turbine components such as rotor and vane ring components. Initial dip coating trials were performed to deposit the yttrium silicate interlayer coating on an NT154 silicon nitride airfoil. Characterization of the coating showed uniform coverage of the YS2 layer over the majority of the airfoil cross section including the leading edge (Figure 4.2.11). The main trouble spot in terms of coating coverage was on the trailing edge of the airfoil and this was addressed in subsequent scale-up activity. Si3N4 Interlayer Coating Figure 4.2.11 .A yttrium silicate coating was applied to a NT154 silicon nitride airfoil via dip coating. The optical micrograph on the right shows a section of the leading edge with a uniform layer of the coating. Further developments reiterated that coating coverage and uniformity at the coupon level could not be used to guide slurry optimization as component geometries played an important role in determining coating quality. It was also clear from this first scale-up trial that a non-destructive tool to evaluate coating uniformity needed to be used to guide scale up because it was not realistic to cut-up prototype components after each coating trial. In recognition of this need, a white light fringe projection technique was identified to characterize coating thickness as a function of position and geometry through the series of steps as the coating builds up. The blade (or other prototype component) is first scanned without the coating to obtain a baseline contour measurement. The blade is again scanned after the coating is applied. The difference between the coated and uncoated contours results in the contour of the coating on the blade. The white light fringe projection method was found to be a very powerful tool to understand coating uniformity and how uniformity is governed by slurry characteristics, component characteristics, and firing cycles. Efforts at scale-up were focused on two classes of components: (1) single SN282 blades for burner rig tests, and; (2) integral turbine components (integrally bladed rotors and 92PDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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