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<p>The development of thermal barrier coating (TBC) with superior thermo-mechanical properties demands different coating techniques with optimized process parameters. In this research, an efficient columnar-structured 7YSZ TBC was developed on single-crystal CMSX-4 substrate by electron-beam physical vapor deposition (EBPVD) process using novel beam-switching technique with a low electron-beam current. The performance of the developed TBCs was subjected to solid-particle erosion (SPE) test, which is one of the most aggressive and unavoidable threats to gas turbine blades, that reduces their efficiency. The SPE study of uncoated and TBC-coated CMSX-4 was conducted at an elevated temperature of 800&#xa0;°C. The erodent-impingement angle was kept at 45 and 90°, by keeping all other parameters constant. The eroded samples were characterized by FESEM analysis and 3D digital microscope. All the results were critically analyzed, and it is observed that the material loss is higher in uncoated CMSX-4 than in TBC-coated CMSX-4 in both impingement angles of 45 and 90°. The developed EBPVD TBC exhibited satisfactory solid-particle erosion resistance owing to the tailored columnar-structured ceramic top coat. This satisfactory topcoat developed using the beam-switching EBPVD technique will serve the way to develop a functionally graded multi-layer TBCs top coat with two different materials in the EBPVD chamber.</p>

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Improvement in the High-Temperature Solid-Particle Gas Jet Erosion Life of TBC-Coated CMSX-4 Using a Novel Beam-Switching EBPVD Technique

  • 期刊论文

  • 发表日期：

    2026年5月27日

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  • Santhosh Kumar Vaiyapuri,
  • Arivarasu Moganraj,
  • Andrzej Nowotnik

摘要

The development of thermal barrier coating (TBC) with superior thermo-mechanical properties demands different coating techniques with optimized process parameters. In this research, an efficient columnar-structured 7YSZ TBC was developed on single-crystal CMSX-4 substrate by electron-beam physical vapor deposition (EBPVD) process using novel beam-switching technique with a low electron-beam current. The performance of the developed TBCs was subjected to solid-particle erosion (SPE) test, which is one of the most aggressive and unavoidable threats to gas turbine blades, that reduces their efficiency. The SPE study of uncoated and TBC-coated CMSX-4 was conducted at an elevated temperature of 800 °C. The erodent-impingement angle was kept at 45 and 90°, by keeping all other parameters constant. The eroded samples were characterized by FESEM analysis and 3D digital microscope. All the results were critically analyzed, and it is observed that the material loss is higher in uncoated CMSX-4 than in TBC-coated CMSX-4 in both impingement angles of 45 and 90°. The developed EBPVD TBC exhibited satisfactory solid-particle erosion resistance owing to the tailored columnar-structured ceramic top coat. This satisfactory topcoat developed using the beam-switching EBPVD technique will serve the way to develop a functionally graded multi-layer TBCs top coat with two different materials in the EBPVD chamber.