समीक्षा
Electron Beam Physical Vapor Deposition (EBPVD) technology is widely recognized for producing coatings with a columnar microstructure, which imparts enhanced strain tolerance and erosion resistance at high temperatures. This unique feature makes EBPVD coatings ideal for thermal barrier coatings (TBCs) with extremely low thermal conductivity.
One of the most common TBC configurations is an yttria-stabilized zirconia (YSZ) topcoat applied over a suitable bond coat on aero-engine gas turbine blades and vanes. In addition, EBPVD is highly versatile, enabling deposition of a wide range of metallic, alloy, and composite materials, including MCrAlY (M = Ni or Co) bond coats on superalloy substrates for improved functional performance.
ARCI has established a state-of-the-art EBPVD unit in collaboration with the International Centre for Electron Beam Technologies, Kiev, Ukraine, to serve the Indian industry. The system uses multiple electron beam guns to melt and evaporate ingot materials under controlled vacuum conditions, ensuring precise deposition on substrates. Specialized jigs and optimized processing parameters enable high-quality TBCs for components operating in extreme environments.
Furthermore, ARCI has developed an innovative methodology for refurbishing and repairing blades and vanes during engine overhauls, significantly reducing costs and saving foreign exchange for strategic sectors.
Key Features
- Coatings can range from highly dense to porous, with uniform and fine finishes.
- Capability to achieve gradient compositions, tailored structures, and properties as required.
- High deposition rate of 50 – 200 µm/hr with productivity up to 10 – 15 kg/hr.
- Wide coating thickness range: 10 µm to 2 mm.
- Ability to coat thin foils, strips, sheets, and heavy blanks.
EBPVD System
Potential Applications
By adjusting processing parameters (ingot composition, part manipulation, EB energy), EB-PVD can deposit:
- Functional gradient coatings
- Multilayered thick ceramic coatings
- Textured multilayer coatings
- Biological coatings
- Hot corrosion and oxidation-resistant coatings
- Uniform thermal barrier coatings (TBCs)
- Damping and wear-resistant coatings
- Thick repair coatings up to 1 – 2 mm
अवस्था
- Application development for aero-engine and power sector turbine blades.
- Sponsored projects on TBC coating for HP rotor turbine blades in helicopter engines are in progress at ARCI.
Intellectual Property Development Index (IPDI)
Level
1
2
3
4
5
6
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10
उल्लेख
Basic concepts and understanding of underlying scientific principles
Shortlisting possible applications
Research to prove technical feasibility for targeted application
Coupon level testing in simulated conditions
Check repeatability/consistency
Prototype testing in real-life conditions
Check repeatability/consistency
Reassessing feasibility (IP, competition technology, commercial)
Initiate technology transfer
Support in stabilizing production
अवस्था
| Level | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
|---|---|---|---|---|---|---|---|---|---|---|
| उल्लेख | Basic concepts and understanding of underlying scientific principles | Shortlisting possible applications | Research to prove technical feasibility for targeted application | Coupon level testing in simulated conditions | Check repeatability/consistency | Prototype testing in real-life conditions | Check repeatability/consistency | Reassessing feasibility (IP, competition technology, commercial) | Initiate technology transfer | Support in stabilizing production |
| अवस्था |
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- Krishna Valleti et al., Processing-Structure-Property Relationships in EB-PVD Yttria Stabilized Zirconia (YSZ) Coatings, Journal of Vacuum Science & Technology A, 29 (2011).
- Dipak K. Das, D. Srinivasa Rao et al., Microstructure, Texture and Thermal Cycling Performance of EB-PVD TBCs Deposited under Different Processing Conditions, Journal of High Temperature Materials and Processes, Vol. 30 (2011), pp. 539–548.