Enhanced Oxide Layer Formation through Plasma Electrolytic Diffusion Processing of Hot Section Components

As operating temperatures of marine propulsion systems increase, oxidation and hot corrosion of compressor, combustor and turbine section components are becoming increasingly acute, limiting the effectiveness of current coating systems on hot section components. Salt-deposit-induced hot corrosion in particular has become an intensive area of emphasis for OEMs, as at increased temperatures, combined with mechanical stresses, new chemical reactions with both environmental coatings and metal substrates creates an accelerated corrosion condition. In order to provide a more complete solution for both oxidation and hot corrosion performance of IBC Materials and Technologies in conjunction with our industry partners Rolls-Royce Corporation, CompuTherm LLC, and Purdue University, will develop a revolutionary new protective coating based on the Plasma Electrolytic Diffusion (PED) process. The PED process will yield an improved diffusion and oxide layer capable of improved resistance to Type I and II hot corrosion, oxidation, and mechanical stresses for advanced aero-derivative marine propulsion systems. The focus of IBC?s effort is to create and understand unique, non-equilibrium surface chemistries and microstructures that provide superior oxide layers and increase resistance to oxidation, hot corrosion, and coating/substrate interface issues. PED processing will be used to treat disk/blade alloy substrates for hot corrosion testing.