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integral vane rings) in order to closely understand the challenges of coating complex geometries. Dip coating the single silicon nitride blades helped in optimization of slurries and designing fixtures to hold and manipulate the components during the dip coating process. Figure 4.2.12(a) is a picture of an EBC coated blade before burner rig testing. The blade was burner rig tested in the UTRC burner rig facility to qualitatively assess the adherence of the coating via thermal cycling. The flame from the burner impinged on the blade and the material temperature on the leading edge was in excess of 2400F (1315C). The approximate hot time was 2 minutes and the blade was subsequently cooled for 1 minute. As is seen from Figure 4.2.12(b), there was no observable damage after 50 thermal cycles. Similar burner rig testing will be used to qualify the coating as the final coating architecture and process is down selected. (b) (a) Figure 4.2.12: Slurry coated SN282 blade. (a) Before and (b) After burner rig testing to 2400 F (50 cycles) When integral vane rings or rotors were dipped, the drip issues were found to be much less severe than in the single blade. Because of this observation, it was decided to focus scale-up on the integral components since they are more relevant to the program. A dip coated integral vane ring prototype similar to one described in Figure 4.2.1 is shown in Figure 4.2.13. Note that the holes in the airfoils are from an earlier set of experiments performed on the vane ring to determine material strength in full-sized components. The focus of the current dipping studies has been vanes A and B (see markings in Figure 4.2.13). It can be seen from the figure that the airfoils and platforms have fairly uniform coverage by the coating. In order to understand the variability of coating thickness on the component and “quantify” coating quality, the white light fringe projection technique (described previously) was used extensively to map the contours of the component before and after coating application. Figure 4.2.13(e) shows sections across blade A (A1, A2 A3) and across the various points along the blade where measurements were recorded. Table 4.2.1 tabulates the coating thickness at the locations 1 through 6 on sections A1, A2 and A3. The high thickness on the leading edge (position 4) is due to a drip that collected on the leading edge. Of concern is the low amount of coating in the fillet areas (position 3) – it was repeatedly found through more analysis that the coating is lean in the areas adjacent to the attachment portions between the vane and the substrate. Further work needs to be done to understand the reason for the lack of coating in these areas and methods to mitigate it. In most areas with coverage the coating thickness varied between ~ 10- 50 μm. (a) (b) 93PDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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