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@PHDTHESIS{Letang:1055067,
author = {Letang, Maike},
title = {{E}ntwicklung von {R}eparaturmethoden für einkristalline
{B}auteile mittels thermischer {S}pritzverfahren},
volume = {692},
school = {Bochum},
type = {Dissertation},
address = {Jülich},
publisher = {Forschungszentrum Jülich GmbH Zentralbibliothek, Verlag},
reportid = {FZJ-2026-01844},
isbn = {978-3-95806-883-4},
series = {Schriften des Forschungszentrums Jülich Reihe Energie $\&$
Umwelt / Energy $\&$ Environment},
pages = {X, 211},
year = {2026},
note = {Dissertation, Bochum, 2025},
abstract = {Single-crystal turbine blades made of nickel-based
superalloys, such as CMSX-4, are of great importance for gas
turbines due to their excellent high-temperature properties,
however, they are subject to various damage mechanisms.
Repairing these costly components is desirable for both
ecological and economic reasons; however, it poses a
challenge as the single-crystal microstructure in the repair
area must be restored. This study, conducted as part of
Transfer Project 5 within Collaborative Research Center 103,
investigates the thermal spray processes Cold Gas Spraying
(CGS), Vacuum Plasma Spraying (VPS), and High Velocity Air
Fuel Spraying (HVAF), in combination with directional
recrystallization, as potential repair methods for
single-crystal CMSX- 4 turbine blades. Thermal spray
processes show great potential for this application due to
their low oxidation and high density. Differences in the
process conditions lead to varying coating properties. CGS
and VPS achieve the lowest values for porosity and oxygen.
HVAF coatings have the highest values for oxygen content and
porosity. The residual stress state of the different
coatings is also investigated. In the coatings that were
produced using CGS and HVAF, compressive residual stresses
can be determined, while the VPS coatings exhibit tensile
stresses up to a stress-free state. The analysis of the
adhesive tensile strength shows that HVAF coatings with the
highest compressive stresses fail the earliest. Directional
recrystallization to set a columnar microstructure of the
repair coatings shows clear differences in the resulting
microstructures, with the VPS coating having the most
pronounced columnar structure, while the CGS coating
develops predominantly equiaxed grains. The differences can
mainly be attributed to the different initial
microstructures, whereby the presence of the γ’ phase and
the degree of work hardening are decisive influencing
factors. Despite the process-related limitations of the
experimental setup, the fundamental feasibility of columnar
grain growth has been demonstrated, paving the way for
future optimizations with improved process control.},
cin = {IMD-2},
cid = {I:(DE-Juel1)IMD-2-20101013},
pnm = {899 - ohne Topic (POF4-899)},
pid = {G:(DE-HGF)POF4-899},
typ = {PUB:(DE-HGF)3 / PUB:(DE-HGF)11},
doi = {10.34734/FZJ-2026-01844},
url = {https://juser.fz-juelich.de/record/1055067},
}