The coating workshop has a full range of state-of-the-art equipment to apply metal and ceramic coatings using electron beam physical vapor deposition (EBPVD). Our major equipment includes two electron beam units, vacuum and atmospheric furnaces, shot peen unit, vibration grinding mill, air abrasion units (suction and pressure types) and offhand grinding machines, mechanical processing equipment, and chemical coating removal line.
MеCrAlY (Ni- and Co-based) coatings are used not only as independent heat-resistant coatings that protect base metals from oxidation and sulfide corrosion but also as bond coats that provide heat-resistant ceramic coatings. Sufficiently dense and defect-free MeCrAlY coatings applied using EBPVD are characterized by a uniform chemical composition throughout the entire thickness and an equiaxed duplex (g+β) structure. Evenly distributed β-NiAl intermetallic phase coatings in matrix solutions determine their functional heat resistance and increase durability of base alloys being coated. As major components of MeCrAlY coatings are diverse, this enables us to not only reduce the negative effects of high temperature and environmental influence during engine operation but also to resist salt corrosion and thermal and mechanical fatigue. The company has vast experience in applying diverse coatings based on nickel, cobalt, and their mixture.
The most widely used yttria-stabilized zirconia thermal barrier coatings (ZrO2+6-8%Y2O3) reliably protect the components of hot gas paths in gas turbine engines from high temperature by significantly reducing the temperature of metal surfaces, improving fuel efficiency, and enhancing engine reliability. EBPVD helps to apply thermal barrier coatings with a defect-free dense structure, high adhesive strength, and base/bond coats. A columnar crystalline structure of outer ceramic layers ensures safety margins during operation under varying thermal cyclic loads, which significantly increases their service life during multi-cycle engine operation. The company mastered and adapted new types of low thermal conductivity ceramic coatings for use as thermal barrier coatings to improve the efficiency and productivity of new-generation engines with a significant increase in the operating gas temperature. By using Re2Zr2O7 oxides as the main stabilizer for ZrO2 (where Re is Gd, Yb, Sm, Nd or so on) or partially replacing Y2O3 with oxides of other rare-earth metals, we can significantly reduce the thermal conductivity of thermal barrier coatings.