Real Time Measurement of Design Relevant Thermal Spray Coating Properties

ABSTRACT: ReliaCoat Technologies, LLC, a new business spin-off from Stony Brook University, together with the University and collaborators (GE, Sulzer Metco, CTS, SWI) proposes to develop and commercialize a novel in-situ coating property (ICP) technology as a real-time coating monitoring sensor, through measurement of wide ranging, design-relevant, thermal spray coating properties in a production environment such as Tinker AFB. The ICP technology is unique as it quantitatively captures critical properties such as residual stresses, linear and non-linear elastic properties and substrate-interactions. The technology also enables observation of"coating creation"with concomitant implications on application, performance and reliability. It has the potential to transform the thermal spray industry in its coating specification, design and processing strategy. ReliaCoat"s principle goal is to demonstrate the applicability of the ICP technology to industrial users and DoD maintenance facilities, and provide a framework of cross-correlations with current post-spray method of coating property evaluation. A further goal is to link in-situ derived data with component level coating characteristics through simulated experiments and models. ReliaCoat shall deliver to Tinker AFB a robust, booth level coating monitoring tool, enabling improved assessment of coating specifications and quality control as well as process variability . BENEFIT: Thermal spray coatings are widely used by original equipment manufacturer, and suppliers for repair and overhaul of turbine engine components used in propulsion and energy generation. Wide ranging coatings from thermal barriers for heat shielding to wear resistance coatings are used by both US military and civilian turbine industry and as such represents as multi-billion dollar industry. These coatings perform important functions that enhance the efficiency, safety, reliability and operational cost of advanced turbine engines. Knowledge, tools and technologies that aid in enhanced understanding of the coating generation and improved methods of coating characterization and that too in real time within the spray environment will offer significant benefits from both performance and manufacturing points-of-view. The immediate public benefit is cost savings associated with increased productivity, reduced rework and potentially increased efficiency of propulsion and energy generation turbine performances.