Analele Universitii Constantin Brncui din Trgu Jiu, Seria Inginerie, Nr.

3/2009

TEHNICA HVOF DE ACOPERIRE

HVOF TECHNIQUE FOR

CU STRATURI MCRALY A

MCRALY LAYERS COATING OF

COMPONENTELOR

GAS TURBINES

TURBINELOR CU GAZE
University Professor Engineer Ion Mitelea
PhD, Polytechnic University from din
Timioara
Lecturer Marius-Eremia Vlaicu-Popa ,
Constantin Brncui University Tg-Jiu

Prof. Univ. Dr. Ing. Ion Mitelea ,

Universitatea Politehnica din Timioara
ef Lucrri Marius-Eremia Vlaicu-Popa ,
Universitatea Constantin Brncui Tg-Jiu
Rezumat: Lucrarea analizeaz succint condiiile de
exploatare a turbinelor cu gaz , materialele selectate
la execuia acestora i oportunitiile oferite de
tehnica pulverizrii HVOF pentru acoperirea
suprafeelor cu straturi funcionale de tip MCrAlY.
Cuvinte cheie: acoperire, turbinelor, gaze

1. Condiiile de exploatare ale turbinelor

cu gaz
Generatoarele de putere electric au utilizat i
utilizeaz turbine cu abur, turbine cu gaz i
turbine generator, tubulatur de oel,
schimbtoare de cldur i boilere, fiecare
ndeplinind o anumit funcie. Componentele
lor sunt executate din metale sau aliaje
metalice, de regul oeluri slab sau nalt aliate
cu Cr, aliaje cu baz de Ni, aliaje cu baz de
Co, alam sau Cu i, mai rar, aliaje cu baz
de Ti [1]. Selecia acestor materiale se face
lundu-se n considerare condiiile n care
urmeaz a funciona componenta respectiv:
tensiuni mecanice, deformaii sub
sarcini;
temperaturi
de
funcionare,
modificri ale temperaturii;
natura mediului de lucru;
durata operaional;
costuri.
Condiiile de funcionare ale acestor
componente pot conduce ns la discrepane
ntre design-ul funcional i materialul

Abstract: The paper briefly analyzes gas turbines

operation conditions, the materials selected for their
execution and the opportunities provided by HVOF
spraying technique for covering surfaces with MCrAlY
functional layers.
Keywords: coating, gas turbines

1. Gas turbines operation conditions

Power generators have used steam turbines,
gas turbines and generator turbines, steel
piping, heat exchangers ad boilers, each with
a certain function. Their components are
executed of metals or metallic alloys, usually
poorly or highly Cr alloyed steels, Ni based
alloys, Co based alloys, brass or Cu based
alloys and rarely Ti based alloys Ti [1]. The
selection of these materials is made by
considering the conditions for the operation
of that component:
Mechanic strength, deformations
below loads;
Operation
temperatures,
temperatures alteration;
Operation environment nature;
Operational duration;
costs.
The operation conditions of these
components may lead to discrepancies
between the functional design and the
selected material. The requirements for

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selectat. Cerinele pentru maini performante

conduc la necesitatea unor temperaturi de
operare ridicate, ceea ce implic folosirea
unor materiale speciale rezistente la aceste
solicitri. Inginerii proiectani ncearc s
tempereze impactul condiiilor de operare
asupra integritii componentelor prin dou
modaliti, fiecare dintre acestea fiind absolut
esenial n proiectarea componentelor
destinate funcionrii n seciunile fierbini.
Prima modalitate se bazeaz direct pe
tehnologia acoperirii suprafeelor pentru a
mri durata de via a componentelor. O alt
modalitate, n care straturile contribuie
indirect dar semnificativ, se bazeaz pe
reducerea temperaturii de funcionare prin
rcirea componentei de baz, straturile jucnd
i n acest caz un rol cheie.
Turbinele staionare cu gaz sunt constituite de
regul din 3 mari componente i anume:
compresor, camera de combustie i turbin
(fig. 1, 2). Aerul introdus este comprimat
pn la presiuni de 30 bar, apoi este injectat
combustibilul producndu-se combustia. Din
camera de combustie, gazele fierbini sau cele
de evacuare, cu temperaturi de cca. 1350C,
sunt conduse n turbin, unde are loc o
dilatare i apoi o rcire a gazului.
Temperatura gazelor la evacuare este de cca.
640C [2, 3]. Atunci cnd este necesar o
sporire a puterii, se poate injecta de asemenea
n compresor sau n camera de combustie, pe
lng combustibil i aer, ap sau aburi [1,4].

performant machines lead to the need for

high operation temperatures, which involves
using special resistant materials to this stress.
Designer engineers try to balance the impact
of operation conditions on components
integrity by two methods, each of them being
absolutely essential in designing the
components meant for operation in hot areas.
The first method is directly based on surfaces
coating technologies in order to increase
components operation time. Another method,
where layers contribute indirectly, but
significantly, is based on operation
temperature decrease by cooling the main
component, layers having a key role in this
case.
Standing gas turbines usually consist of 3
main
components,
namely:
breaker,
combustion chamber and turbine (fig. 1, 2).
The introduced air is compressed up to 30 bar
pressures, then fuel is injected causing
combustion. From the combustions chamber
hot or exhaust gases, with an approximate
temperature of 1350C, are lead to the
turbine, where gas is dilated and cooled.
Exhaust gases temperatures is almost 640C
[2, 3]. When power growth is required, along
with fuel, air, water or steam may be injected
in the compressor or combustion chamber
[1,4].

Fig. 1. Turbin cu gaz (Siemens Wenstinghouse)

Gas turbine (Siemens Wenstinghouse)
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Materialele din care sunt executate

componentele turbinelor cu gaz sunt supuse
permanent unor mecanisme de degradare ca
de exemplu oboseala mecano-termic,
oxidare, coroziune etc. Degradarea datorat
mediului cum este oxidarea sau coroziunea
este dependent de natura i temperatura
gazelor ce vin n contact cu materialul.

Materials included in gas turbines

components
permanently
undergo
degradation mechanisms like for instance,
mechanic-thermal wear, oxidation, corrosion
etc. Degradation due to environment like
oxidation or corrosion depends on the nature
and temperature of gases making contact to
the material.

Fig. 2. Reprezentarea schematic a unei turbine staionare cu gaz

Graphic representation of a gas standing turbine
mbuntiri semnificative s-au realizat n
domeniul straturilor de acoperire pentru a se
asigura o bun rezisten la oxidare i
coroziune la temperaturi nalte. Pentru un
asemenea scop, la ora actual, foarte des
utilizate sunt straturile de acoperire MCrAlY
(n care M = Co, Ni sau Fe) sau aluminidele
(TiAl, PtAl) [4]. Suplimentar, pentru a se
asigura o izolare termic corespunztoare a
componentelor turbinelor, se recurge la
depunerea unui strat ceramic (ZrO2 Y2O3)
peste startul MCrAlY, acesta din urm cu rol
intermediar n sistemul TBC (Thermal
Barrier Coatings straturi cu rol de barier
termic).
2. Compatibilitatea strat substrat
Straturile MCrAlY (M = Co, Ni, Fe, plus Cr,
Al, Y i uneori alte elemente de aliere Ti, Hf)
sunt aplicate ca straturi de acoperire ale
componentelor ce lucreaz la temperaturi
nalte i n medii corozive (de expl. palete de

Significant improvements have been made in

the field of coating layers in order to provide
oxidation and corrosion resistance at high
temperatures. For such a purpose, MCrAlY
coating layers are very used (where M = Co,
Ni or Fe) or alluminides (TiAl, PtAl) [4]. In
addition, in order to provide an accurate
turbines thermal isolation, a ceramic layer
(ZrO2 Y2O3) is laid over the MCrAlY layer,
the latter having an intermediary role in TBC
system (Thermal Barrier Coatings).
2. Layer-sub-layer compatibility
MCrAlY layers (M = Co, Ni, Fe, plus Cr, Al,
Y and sometimes other alloy elements Ti, Hf)
are laid as elements coating layers operating
at high temperatures and in corrosive
environments (for instance turbine pallets).
These layers have a good chemical and
thermal compatibility with the sub-layer
materials (usually Ni or Co based super-

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turbin). Aceste straturi prezint o bun

compatibilitate chimic i termic cu
materialul substratului (de regul superaliaj
pe baz de Ni sau Co), avnd un efect minim
asupra proprietilor acestuia, mbuntindui ns rezistena de oxidare i coroziune la
temperaturi nalte.
O atenie deosebit se acord compoziiei
chimice a straturilor MCrAlY, n special n
ceea ce privete coninutul de Cr i Al, aceste
dou elemente ndeplinind rolul principal n
asigurarea proteciei la oxidare (Al) i
coroziune (Cr).
Comportamentul bun la oxidare al straturilor
se datoreaz abilitii lor de a forma la
suprafa o pelicul rezistent de -Al2O3,
care are ca scop mpiedicarea oricrei
interaciuni ntre suprafaa materialului de
baz i mediul exterior corosiv. Aceast
pelicul de oxid reprezint unul dintre cele
mai bune straturi protectoare mpotriva
oxidrii n domeniul temperaturilor nalte,
oxidul fiind compact i stabil chimic.
Pelicula de -Al2O3 se consum n timp,
refcndu-se ns continuu atta timp ct
stratul MCrAlY dispune de rezerve suficiente
de Al. n condiiile n care stratul nu mai
poate furniza Al, ali oxizi se vor forma la
suprafaa straturilor MCrAlY (Cr2O3, CoO,
NiO sau oxizi micti spineli: Ni(Al,Cr)O,
Co(Ni,Cr)O etc.) dar care nu asigur protecia
dorit. La scderea coninutului de Al sub o
anumit limit (n cazul straturilor
Co/NiCrAlY de 5-6% Al), este necesar
nlocuirea stratului.
Straturile MCrAlY pot fi depuse prin
numeroase procedee (depunerea fizic n
stare de vapori cu fascicul de electroni: EBPVD, depunere prin pulverizare termic cu
jet de plasm la presiune joas LPPS sau n
vid - VPS). n ultimii ani ns, procedeul de
depunere prin pulverizare termic n flacr,
cu vitez ultrasonic HVOF (High Velocity
Oxygen Fuel), a fost adoptat pentru
depunerea acestor straturi protectoare, tehnica
respectiv devenind popular datorit

alloy), with a minimum effect on its

characteristics, improving its oxidation and
corrosion resistance at high temperatures.
Special attention is paid to the chemical
composition of MCrAlY layers, especially
regarding the Cr and Al content, these two
elements having the main role in providing
protection to oxidation (Al) and corrosion
(Cr).
Layers good oxidation behaviour is due to
their ability to form a resistance film of Al2O3, in order to prevent any interaction
between the main material basis and
corrosive exterior environment. This oxide
film is one of the best protective layers
against oxidation in the field of high
temperatures, oxide being compact and
chemically stable.
The -Al2O3 film is time consuming,
continuously recovering as long as the
MCrAlY layer has enough reserves of Al. If
the layer cannot provide Al, other oxides will
result at the surface MCrAlY layers (Cr2O3,
CoO, NiO or mixed oxides spinels:
Ni(Al,Cr)O, Co(Ni,Cr)O etc.) but which do
not provide protection expected. When the Al
content decreases below a certain limit (in
case of Co/NiCrAlY layers of 5-6% Al), the
layer needs replacing.
MCrAlY layers may be laid through
numerous procedures (physical steam deposit
with electrons beam: EB-PVD, thermal
spraying deposit with plasma jet at low
pressure LPPS or VPS). For the last few
years, thermal spraying flame coating
procedure was used with HVOF ultrasound
(High Velocity Oxygen Fuel), in order to lay
down these protective layers, the technique
becoming popular due to its flexibility, low
costs, and especially due to the quality of
resulting products, as they are dense and have
low internal porosity and oxidation.
In this paper, researches focused on the study
of HVOF coating process of various layers of
MCrAlY.

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flexibilitii, costurile reduse, dar n special

datorit calitii acoperirilor rezultate, acestea
fiind dense i prezentnd o porozitate i
oxidare intern redus.
n prezenta lucrare cercetrile au fost axate pe
studiul particularitilor procesului de
depunere HVOF a unor straturi diferite de
MCrAlY.
3.
Materialele
utilizate
pentru
componentele turbinelor cu gaz
Cerinele pentru maini performante au
condus la necesitatea de cretere a
temperaturii de operare, ceea ce implic
folosirea unor materiale speciale, rezistente la
aceste temperaturi.
Materialele utilizate pentru componentele
turbinelor cu gaz sunt: oeluri nealiniate, de
cele mai multe ori acoperite cu un strat de
vopsea pe baz de Zn pentru orificiile de
admisie ale aerului; pentru paletele sau elicile
compresorului oeluri aliate cu Cr n
anumite condiii de operare, susceptibile la
coroziune acvatic sau pitting, oeluri nalt
aliate, aliaje de Ti sau protejarea acestor pri
cu straturi de suprafa, prile rotative ale
compresorului fiind de regul acoperite cu
straturi rezistente la uzare prin abraziune [1].
Seciunile fierbini ale compresorului i
turbinei sunt realizate din aliaje cu baz de Ni
sau Co, aliaje complexe din punct de vedere
al compoziiei chimice, ce se caracterizeaz
prin proprieti superioare, o combinaie de
rezisten i ductilitate la temperaturi relativ
nalte (precipitarea fazei AlNi3 coerente
cu reeaua matricei), rezisten proprie la
mediu, tenacitate i rezisten la oboseal, ce
nu sunt n prezent disponibile n cazul altor
sisteme de aliaje. Atunci cnd problema
rezistenei la coroziune sau oxidare devine
important sau cnd apare necesitatea de
izolare termic a componentelor, pentru
protecia acestor superaliaje se utilizeaz
straturi de suprafa, metalice sau ceramice
(TBC). Difuzorul de evacuare este executat
din oel placat sau pulverizat cu Zn, coloanele

3. Materials
components

used

for

gas

turbines

The requirements for performant machines

lead to the need for high operation
temperatures, which involves using special
resistant materials to these temperatures.
Materials used for gas turbines components
are: non-alloyed steels, often covered with Zn
based paint layer for air inlet holes; for
compressor pallets or propellers Cr alloyed
steels in certain operation conditions, liable
of aquatic erosion or pitting, highly alloyed
steels, Ti alloys or by protecting these parts
with surface layers, compressor rotating parts
being usually coated with wear resistant
layers through abrasion [1].
Compressor and turbine hot sections are
made of Ni or Co based alloys, complex
alloys from point of view of chemical
composition, characterized by higher
properties, a combination of resistance and
ductility at relatively high temperatures (
phase precipitation AlNi3 coherent with
network matrix), proper resistance to the
environment, tenacity and wear resistance,
which are not currently available in the case
of other alloy systems. When the matter of
corrosion or oxidation resistance becomes
important or when components thermal
isolation needs occurs, surface metallic or
ceramic layers (TBC) are used in order to
protect these super-alloys. The exhaust outlet
is made of plated steel or Zn sprayed steel,
rotor and stator columns are made of alloy
steel, certain conditions requiring coating
with protection layers, and rotor disks are
made of Ni based alloys.
At present, over 50% of gas stand turbines
components are coated with protective layers
[1]. If other methods have been used in order
to achieve these layers, like galvanization or
chemical steam deposit, at present thermal
spraying is used. Table 1 describes gas
turbines components that may be covered
with protection layers, their main elements,

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rotorului i ale statorului sunt din oel aliat, n their related protection layers as well as the
anumite condiii fiind necesar acoperirea cu requirements that they have to meet.
straturi de protecie, iar discurile rotorului
sunt produse din aliaje pe baz de Ni.
Actualmente, peste 50% din componentele
turbinelor staionare cu gaz sunt acoperite cu
straturi protectoare [1]. Dac n trecut s-au
utilizat pentru obinerea acestor straturi
metode precum galvanizarea sau depunerea
chimic n stare de vapori (CVD), n prezent
se manifest tendina recurgerii la depunerile
prin pulverizare termic. n tabelul 1 sunt
prezentate componentele turbinelor cu gaz ce
pot fi acoperite cu straturi de protecie,
materialele de baz, straturile de protecie
aferente precum i cerinele pe care acestea
trebuie s le ndeplineasc.
Tabel 1: Componente ale turbinelor staionare cu gaz, materiale de baz i pentru strat
(ZrO2-Y2O3 Yttria Stabilized Zirconia, strat ceramic cu rol de barier termic)
Table 1: Gas standing turbines components, main materials and layer materials
(ZrO2-Y2O3 Yttria Stabilized Zirconia, ceramic layer with the role of thermal barrier)
Component

Metal de baz

Strat

Orificii imersie aer

Oel nealiat

Zn, epoxy

Palete compresor

Oel cu 12% Cr
TiAl6V4

Al, ceramic

Piese
turnate CrC, WC+Ni, Co
din oel, n
numeroase
cazuri aliaje cu
baz de Ni
Structuri turnate
Piese
turnate NiCrxx, NiAlxx
din oel slab
aliat
Alte
pri
ale Superaliaje cu NiAl, MCrAlY
compresorului
baz de Ni, Co
Structuri asamblate

Proces de
obinere a
stratului
Vopsire

Cerine rezisten

Oxidare,
eroziune,
coroziune
acvatic
Vopsire
Eroziune,
coroziune
acvatic, stres,
oboseal
Depunere
prin Uzur,
pulverizare
cu friciune,
arc, APS, HVOF sudur
HVOF

Oxidare

APS, HVOF

Strat
de
intermediar,
coroziune
i
oxidare
la
temperaturi
ridicate

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Pri de rcire ale Superaliaje cu ZrO2-Y2O3

combustorului
baz de Ni, Co
Paletele turbinelor Superaliaje cu Cr, Al
cu gaz
baz de Ni, Co
MCrAlY(+Re, Ta)
PtAl
AlSi
ZrO2-Y2O3

4. Procese de depunere prin nclzire cu

flacr
n cadrul acestui procedeu, materialul de
depunere este trecut printr-o flacr de
combustie, ajungnd astfel n stare topit.
Particulele topite sunt accelerate spre substrat
cu ajutorul unui curent de gaz sub presiune
(aer sau azot, argon, heliu). Topirea cu flacr
oxiacetilenic prezint avantajul c permite
utilizarea ca material de aport att srm,
pulbere metalic sau ceramic, ct i
materiale plastice. n acest mod se poate
realiza o mare varietate de straturi protectoare
cu aceeai instalaie. n cadrul acestui
procedeu exist trei principale variante ce
utilizeaz flacra pentru topirea materialului
de depus i anume:
a. Procesul de depunere prin pulverizare
cu flacr;
b. Procesul de pulverizare i fuziune
(retopire);
c. Procesul de pulverizare termic cu
vitez ridicat HVOF.
a. Procesul de depunere prin pulverizare
cu flacr
n acest caz, sursa de cldur necesar topirii
materialului de depus (ce poate fi sub form
de srm, vergele sau pulbere) este furnizat
de ctre o flacr de combustie. n cazul
sistemului cu srm sau vergele, mecanismul

APS, HVOF

Reducerea
temperaturii
suprafeei, TBC
CVD, cromizare, Oxidare,
coroziune
la
alitare
temperaturi
LPPS, HVOF
nalte,
strat
Galvanizare,
intermediar
alitare
Vopsire
+
sintetizare
APS, HVOF
TBC, reducerea
temperaturii
suprafeei

4. Firing warming coating processes

In this procedure, the coating material
passes through combustion flame, reaching
a melted state. Melted particles are
accelerated towards the sub-layer with the
help of gas current under pressure (air or
nitrogen, argon, helium). Oxyacetylene firing
melting has the benefit that it allows the use
of additional material like wire, metallic or
ceramic powder, as well as plastic materials.
This allows to create many protection layers
with the same plant. These procedure has
three main variants using flame in order to
melt coating material namely:
a. firing spraying coating process;
b. spraying and fusion (re-melting)
process;
c. HVOF high velocity thermal spraying
process.
a. Firing spraying coating process
In this case, the heating source necessary for
melting the coating material (either wire, rod
or powder) is provided by a combustion
flame. In the case of wire or rod system, the
supply mechanism leads the stock of material
inside the combustion chamber where the
flame melts and carries the particles (due to
high velocities of gases flowing) hence
resulting a sprayed coating. In the case of
powder variant, it is carried with the help of

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de alimentare conduce stocul de material n

interiorul camerei de combustie unde flacra
topete i propulseaz particulele (datorit
vitezelor nalte de curgere a gazelor)
rezultnd astfel o depunere pulverizat. n
cazul variantei cu pulbere, aceasta este
transportat cu ajutorul unui gaz adiional (n
mod obinuit - azotat) ctre pistol, pentru
ardere i depunere.
b. Procesul de pulverizare i fuziune
(retopire)
Acest tip de proces este o modificare a
procesului de depunere cu flacr menionat
anterior, ce utilizeaz materialul sub form de
pulbere.
Procesul este o combinaie a 2 etape n cadrul
crora, materialul de depus este mai nti
pulverizat, apoi topit ntr-un arztor
oxiacetilenic nclzit prin inducie sau tratat
la cald ntr-un cuptor (n general n condiii
de vacuum).
Temperatura de fuziune este destul de nalt,
adesea ajungnd la 1300C, producndu-se
astfel straturi cu grosimi de cca. 2000 m, cu
o duritate ridicat. Avantajul pe care l ofer
acest
proces
este
obinerea
unei
microstructuri dense i o bun aderen ntre
strat i substrat. Principalul dezavantaj l
reprezint temperatura nalt suportat de
substrat n timpul etapei de fuziune.
c. Procesul de pulverizare termic cu
vitez ridicat HVOF
Tehnica de pulverizare termic cu vitez
ridicat HVOF (High Velocity Oxygen Fuel)
intr de asemenea n categoria proceselor de
depunere cu flacr, utiliznd material de
strat numai sub form de pulbere. O larg
utilizare a sa se remarc n industria
aerospaial, unde straturi de suprafa sunt
depuse n scopul de a reduce degradarea
suprafeelor
componentelor
de
baz,
degradare ce survine datorit temperaturilor
nalte i a mediilor de funcionare.
Exist numeroase variante ale procesului,

an additional gas (usually nitrate) to the gun,

for burning and coating.
b. Spraying and fusion process (remelting)
This type of process is an alteration of the
aforementioned firing coating process which
uses material under the form of powder.
The process is a combination of 2 stages in
which the coating material is first of all
sprayed in an oxyacetylene burner, warmed
through induction or hot treated in a furnace
(vacuum conditions generally) .
The fusion temperature is relatively high,
often reaching 1300C, resulting in layers of
approximately 2000 m widths, with high
roughness. This process advantage is the
achievement
of
a
dense
adherent
microstructure between layer and sub-layer.
The main disadvantage is the high
temperature faced by the sub-layer during the
fusion stage.
c. HVOF high velocity thermal spraying
process
High Velocity Oxygen Fuel is also included
in the category of firing coating, using layer
material only under the form of powder. Its
wide use is revealed in spatial industry, where
surface layers are deposited in order to reduce
main components surfaces degradation,
which occurs due to high temperatures and
operation environments .
There are various variants of the process, the
widest known being: Detonation Gun HVOF
System and Continuous Combustion HVOF
System. The differences existing between
these variants refer to the use of various
combustion gases, various cooling systems
etc. but, in general, for all process variants,
the coating principle is the same.
Detonation Gun
The gun is easily recognized due to its front
long rod (nozzle) (fig.3).
When the gas mixture in general with
acetylene and oxygen is fired through a firing

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cele mai cunoscute fiind: Detonation Gun

HVOF System (Sistemul HVOF cu pistol de
detonaie) i Continuous Combustion HVOF
System (Sistemul HVOF cu combustie
continu). Diferenele existente ntre aceste
variante se refer la utilizarea unor diferite
gaze combustibile, diferite sisteme de rcire
etc. dar, n general, pentru toate variantele de
proces, principiul de depunere rmne
aceleai.
Detonation Gun (Pulverizarea cu pistol de
detonaie)
Pistolul poate fi uor de recunoscut datorit
tijei lungi din partea din fa a acestuia (duza)
(fig.3).
Cnd amestecul de gaze, n general coninnd
oxigen i acetilen, este aprins printr-o bujie
de aprindere, o und de detonaie (explozie)
controlat nclzete individual particulele
pn la temperaturi de cca. 4500C, le
accelereaz i apoi le expune la viteze
subsonice de cca. 800 m/s.
Structura lamelar, uniform i compact a
straturilor astfel realizate ca urmare a
temperaturii nalte i energiei cinetice a
particulelor, asigur o duritate, densitate i
for de legtur ridicate, comparabile cu cele
ale straturilor depuse prin pulverizare n jet
de plasm.

plug, a controlled detonation wave

(explosion) individually heats particles up to
temperatures of approximately 4500C,
accelerates them and then it puts them
through subsonic velocities of 800 m/s.
Lamellar, uniform and compact structure of
resulting layers due to high temperature and
particles kinetic energy provides high
connection roughness, density and strength,
comparable to those of plasma jet spraying
layers.

Fig. 3. Reprezentarea schematic a unui pistol de detonaie

Graphic representation of a detonation gun
Grosimile straturilor (de pn la 0,5 mm) sunt Layers thickness (up to 0,5 mm) are achieved
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obinute prin detonaii multiple. n timpul

procesului se produc nivele sonore nalte de
cca. 150 decibeli din acest motiv sunt
necesare incinte cu perei rezisteni, procesul
fiind controlat din exterior.
Sistemul HVOF cu combustie continu
Sistemul de pulverizare termic DJ-HVOF
este o tehnic de depunere cu flacr n
cadrul creia materialul sub form de pulbere
este topit prin utilizarea combustiei
oxigenului i a gazului combustibil, fiind apoi
propulsat cu o vitez foarte mare, prin
utilizarea aerului comprimat, deasupra
suprafeei ce urmeaz s fie acoperit (fig. 4).
n zona de combustie, materialul sub form
de pulbere este introdus n zona flcrii unde
trece n stare topit sau semitopit, n funcie
de temperatura de topire i de viteza cu care
se alimenteaz materialul.

through multiple detonations. During the

process, high sounds levels occur of
approximately 150 decibels and this is why
resistant walls buildings are required, the
process being controlled from the outside.
Continuous combustion HVOF system
DJ-HVOF thermal spraying system is a firing
coating technique in which the powder
material is melted by using oxygen and
combustible fuel and then rapidly propelled
by using compressed air, above the surface o
be covered (fig. 4).
In the combustion area, the powder material
is introduced in the firing area where it passes
in melted or semi-melted state, depending on
the melting temperature and on the material
supply velocity.

Fig. 4. Reprezentarea schematic a unui pistol de pulverizare Diamond Jet

Graphic representation of a Diamond Jet spraying gun
Temperatura flcrii este cuprins n
intervalul 2300-3000C. Particulele topite sau
semitopite sunt apoi propulsate spre exterior
prin duza pistolului, la viteze superioare de
cca. 1350 m/s, deasupra substratului.
Datorit flexibilitii sale i a costurilor
efective reduse, procedeul HVOF a fost
adoptat pentru depuneri de straturi n
numeroase industrii, fiind eficient n
producerea de straturi dense, cu porozitate
redus, putere de stratificare ridicat i o
suprafa relativ fin a stratului depus.

Flame temperature is included in 23003000C range. Melted or semi-melted

particles are then propelled towards the
exterior, through the gun nozzle, at higher
1350 m/s, above the sub-layer.
Due to its flexibility and low actual costs.
HVOF procedure was adopted for layer
coating in various industries, being also
efficient in producing dense layers, with low
porosity, high stratification power and a
relatively fine surface of the layer.

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5. Avantajele tehnicii de depunere HVOF

5. HVOF coating technique advantages

Viteza particulelor reprezint o caracteristic

important n procesul de pulverizare termic,
valorile mari ale acesteia avnd ca rezultat o
putere de stratificare nalt i porozitate
redus, ntruct particulele au un timp redus
pentru a se rci, ele lovind substratul n stare
topit sau semitopit. Procesul HVOF este
proiectat astfel nct s produc viteze nalte,
aceasta contribuind la avantajele pe care le
ofer HVOF n comparaie cu alte procese de
pulverizare termic.
Pentru acestea se menioneaz:
nclzirea uniform i eficient a
particulelor ca urmare a turbulenei lor
ridicate n interiorul camerei de
combustie;
Expunere de scurt durat n aer n timpul
deplasrii spre substrat datorit vitezelor
mari cu care sunt proiectate particulele
ceea ce conduce la o oxidare redus a
suprafeei particulelor;
Ca urmare a vitezei mari de proiectare a
particulelor, materialul depus va fi mai
puin supranclzit rezultnd temperaturi
finale ale particulelor mai reduse,
comparativ cu a altor procese (de
exemplu pulverizare cu plasm sau cu arc
opereaz la temperaturi de cca. 16000
respectiv 6000C, n opoziie, procesul
HVOF
(amestec
oxigen/propilen)
opereaz la cca. 3000C);
Permite depunerea unei mari varieti de
pulberi (ca mrime, densitate etc.);
Reprezint o variant atractiv de
obinere a straturilor de suprafa din
punct de vedere economic: depunerea se
realizeaz n aer deci nu necesit o
camer vidat, diferite componente pot fi
acoperite cu straturi de protecie chiar la
locul de operare nemaifiind astfel
necesar dezansamblarea lor.

Particles
velocity
is
a
significant
characteristic in the thermal spraying process,
its high values having high stratification
power and low porosity, because particles
have little time to cool, by touching the sublayer in melted or semi-melted state. The
HVOF process is designed in order to cause
high velocities, contributing to the advantages
that HVOF has in comparison to other
thermal spraying processes.
Among them we mention:
Uniform and efficient heating of particles
due to their high turbulence in the
combustion chamber;
Short exposure in the air during its
movement to sub-layer due to high
velocities resulting in little oxidation of
particles surface;
Due to particles high velocity of design,
the deposited material will be overheated
leading to lower particles final
temperatures, in comparison to other
processes (for instance plasma or arch
spraying operate at temperatures of
approximately 16000 and 6000C
respectively, as opposed to the HVOF
process (oxygen/polypropylene mixture)
operating at about 3000C);
It allows a great range of powders to
deposit (as far as size, density are
concerned etc.);
Has an attractive variety of surface layers
achievement from economic point of
view: depositing is made in the air but it
does not require a vacuum chamber, as
various components being able to be
covered with protection layers at the
operation site without having to
disassemble them.

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CONCLUZII

CONCLUSIONS

Acoperirea cu straturi MCrAlY a suprafeelor

componentelor turbinelor cu gaz asigur
mbuntirea durabilitii i fiabilitii
acestora.
Creterea rezistenei la oxidare i coroziune la
temperaturi nalte se justific prin formarea la
suprafa a unei pelicule aderente i compacte
de oxid -Al2O3 care mpiedic contactul cu
mediul exterior agresiv. Procesul de depunere
HVOF a straturilor MCrAlY ofer avantajul
obinerii unor straturi depuse de calitate, la
preuri de cost competitive.

MCrAlY layer coating of gas turbines

components provides improvement of their
durability and reliability.
Oxidation and corrosion resistance increase at
high temperatures is justified through the
formation of an oxide adherent and compact
film -Al2O3 which prevents contact with the
exterior aggressive environment. MCrAlY
layers HVOF depositing process has the
advantage of achieving quality layers, at
competitive cost prices.

BIBLIOGRAFIE

REFERENCE NOTES

1. K.E. Schneider a.o: Thermal spraying for

power generation components.
Wiley
VCH GmbH&Co, KgaA Weinhrim, 2006.
2. D. Eckhardt, P. Rufli: Advanced gas
turbine
technology

ABB/BBC
historical firsts. Proceeding of ASME
Turboexpo 2001,New Orleans, Lousiana,
2001
3. S. Ingistov: For system performance in
power augementation Of heavy duty
power generating gas turbines model 7EA.
Proceeding of ASMkTurboexpo 2000,
Munich, Germany.
4. P. Kopfstad: High temperature corrosion.
Elsevier Applied Science Publishers LTD,
1998.

1. K.E. Schneider a.o: Thermal spraying for

power generation components.
Wiley
VCH GmbH&Co, KgaA Weinhrim, 2006.
2. D. Eckhardt, P. Rufli: Advanced gas
turbine
technology

ABB/BBC
historical firsts. Proceeding of ASME
Turboexpo 2001,New Orleans, Lousiana,
2001
3. S. Ingistov: For system performance in
power augementation Of heavy duty
power generating gas turbines model 7EA.
Proceeding of ASMkTurboexpo 2000,
Munich, Germany.
4. P. Kopfstad: High temperature corrosion.
Elsevier Applied Science Publishers LTD,
1998.

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