Plasma-assisted (PA) PVD coating of tools and components with hard ceramic thin films is now a commonly accepted means to reduce wear and improve productivity; however, technical challenges remain in extending PVD/CVD-based treatment techniques to a wider range of commercial substrate materials and operating conditions. Three main examples are: i) treatment of non-ferrous engineering substrate materials (eg. nickel alloys, light-alloys and composite materials) – where coating load support is low; ii) addressing known problems of reduced fatigue life when applying hard, stiff ceramic films to soft, compliant metal substrates, and iii) improved durability in “extreme environments” – for example in conditions of high temperature erosion and/or thermal cycling. An industrial example of the urgent need to jointly address all three of these challenges is the coating of aero-engine compressor blades for improved performance, both in normal use and in extreme conditions (e.g. in desert environments).
This project harnesses the combined expertise of TECVAC, a UK Surface Engineering company which routinely coats aero-engine compressor blades; TECMAT, Technion - Israel Institute of Technology with novel surface treatment capabilities and SHEFFIELD UNIVERSITY, of international repute for research in materials science, plasma-assisted processing and coating characterisation & testing. The main objective is to develop new ‘duplex’ surface treatment techniques – and relevant erosion-testing capabilities – for improved Ni-alloy and Ti-alloy compressor blade performance. The project will be centred on the commercial up-scaling and duplex PVD/CVD process integration of TECMAT’s innovative Powder Immersion Reaction Assisted Coating (PIRAC) technique, to provide a low-cost treatment for (e.g.) non-ferrous substrate materials, providing functionally-graded surface properties to improve significantly the performance of subsequently-applied plasma-assisted coatings and treatments.
The project outcomes will meet the strong demand by aero-engine manufacturers and end-users (airlines and defence ministries) for new technologies that improve reliability, durability, energy efficiency and reduce environmental impact. The combined PIRAC / PA-PVD/CVD duplex treatment technology also has, in the medium term, truly exciting prospects to be exploited on a diverse range of materials for commercial application in transport, biomedical, energy supply (land-based turbine generators & renewable) and other, ‘multifunctional’ areas, with significant benefits to society in the UK, Israel and the wider European community.