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000865857 1001_ $$0P:(DE-Juel1)169478$$aKalfhaus, Tobias$$b0$$eCorresponding author$$ufzj
000865857 245__ $$aEntwicklung von Reparaturmethoden für Nickel-Superlegierungen mittels thermischer Spritzverfahren$$f - 2019-11-12
000865857 260__ $$aJülich$$bForschungszentrum Jülich GmbH Zentralbibliothek, Verlag$$c2019
000865857 300__ $$aVI, 126, XXX
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000865857 4900_ $$aSchriften des Forschungszentrums Jülich Reihe Energie & Umwelt / Energy & Environment$$v470
000865857 502__ $$aDissertation, Univ. Bochum, 2019$$bDissertation$$cUniv. Bochum$$d2019
000865857 520__ $$aThe outstanding high temperature properties of Ni-based superalloys are the reason for their application in modern gas turbines. The development towards a singlecrystalline microstructure lead to a significant increase in efficiency over the past decades. Repair procedures with the potential to reduce the overall cost of these expensive components are of special interest for the gas-turbine industry. The highquality standards and the poor weldability of Ni-based superalloys limit conventional repair procedures. Thermal spray techniques are a promising method for repair applications due to their outstanding coating properties. This thesis is engaged with the potential for a possible repair application of Ni-base superalloys using vacuum plasma spray (VPS) and cold gas spray (CGS). A focus of this thesis is on the single crystalline repair of the alloy CMSX-4. A precise measurement and control of the substrate temperature during both spray techniques is important to influence the microstructural properties of the coating. Therefore, a heated substrate holder with a maximum substrate temperature of 1000 °C was constructed and build. The first part of the thesis considers the influence of an increased substrate temperature on the VPS-coatings. An epitaxial crystal growth of the polycrystalline repair coating is observed in sections on the polished single-crystalline substrate. A parameter study was used to decrease the oxide content within the coatings. The specific movement of the polycrystalline repair coatings into a hot-zone leads to directional annealing, resulting in a columnar microstructure. With the aim of stimulating grain growth from the SX substrate, a FEM-thermal-field evolution of a Bridgman furnace was simulated. The results indicate conditions within the sample to be adequate to allow hot-zone movement through a thick polycrystalline VPS-repair coating originating in the SX-substrate. In the second part of the thesis it is shown that the maximum gas temperature of the CGS-system is not sufficient to deposit CMSX-4. Therefore, the focus for CGS-repair was changed to the polycrystalline repair of IN-738 using the four alloys IN-625, IN-713, IN-738 and Rene’80. The residual stress of the coatings is characterised using a hole-drill and a curvature approach. To improve the coating thickness the elastic stored energy of the coatings is reduced using the heated sample holder and laser structuring results in a better adhesion between the substrate and the coating.It was found that subsequent HIP-heat-treatments decrease the porosity with an increasing annealing temperature. The strongly deformed microstructure of the CGScoatings attached to aged substrate can be rejuvenated with HIP-heat-treatments atoptimized annealing temperatures. Simulated Stress-Strain-Curves using Indentation data revealed similar strength properties of the IN-738-repair coating in comparison to the IN-738-substrate.
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