Operational Experience with EB-PVD Equipment and Process for Thermal Barrier Coating of Aircraft Engine Turbine Parts
(Room Room 104-B)
02 May 19
1:40 PM
-
2:20 PM
Tracks:
High-Powered Electron Beam Technology
Since 1998 Praxair Surface Technologies, Inc., and now PG Technologies, LLC, a Praxair/GE joint venture, provide high quality coating services for EBPVD TBC coating to GE Aviation, licensing GE coating technology. Beginning with a clean slate, we had the opportunity to set up a high volume coating facility specifically designed for the intended product spectrum.
State of the art multi-chamber coating machines and the related ancillary equipment were implemented in Indianapolis, IN and Singapore. A further expansion to a new coating facility in Ellisville, MS, is under way and will double the production capacity until 2020. Over the years, the EBPVD TBC process has been optimized with regard to throughput and yield in a continuous improvement process driven by Six Sigma and lean manufacturing methodology.
This presentation will focus on the EBPVD TBC process and highlight the key factors for product quality, throughput and yield. The fundamentals of the process are explained. The main features and evolution of the coating equipment over the years are highlighted. The key factors for consistent product quality, such as the thermal management of the coating process over extended coating campaigns are discussed in detail.
The essential factors for productivity enhancements are investigated, focusing on advanced coating fixture design methodology using a computer model of the process. This allows to accurately calculate the coating thickness distribution on complex part / fixture assemblies. The design process and the value of additive manufacturing for high temperature coating fixtures is demonstrated for selected examples. Process safety and key factors for operational excellence are touched upon.