Experimental Study of Tungsten Carbide Coating on Nickel Alloy
Vaideeswary S
Under the Guidance of Dr. V. Ramesh, ME, Ph.D. Assistant Professor
Department of Mechanical Engineering
Master of Technology
Metallurgical and Material Science Engineering
School of Mechanical and Construction
ABSTRACT
Nickel-based superalloys are extensively utilized in turbine blades due to their outstanding high-temperature strength, oxidation resistance, and overall durability. Despite these advantages, they encounter significant challenges in extreme operating conditions. Limitations such as high production and processing costs, susceptibility to creep and fatigue under prolonged thermal exposure, and temperature constraints pose challenges to their performance. Additionally, while inherently resistant to oxidation and corrosion, these alloys are not entirely immune to such issues. Their relatively high density also adds to the weight of turbine components, impacting efficiency and functionality. These factors underline the need for advanced material solutions to improve turbine blade performance.
Tungsten carbide (WC) coatings offer a promising approach to address these challenges. Renowned for their exceptional hardness and resistance to wear, WC coatings can be applied to nickel alloy substrates to enhance their surface characteristics. Advanced deposition techniques, such as High-Velocity Oxygen Fuel (HVOF) spraying, enable the creation of robust tungsten carbide coatings that significantly improve surface hardness, thereby minimizing wear and erosion. This is especially beneficial in environments where mechanical wear poses a major concern. Moreover, these coatings provide a protective barrier against oxidation and corrosion, enhancing the high-temperature performance of turbine blades.
By mitigating the thermal and mechanical limitations of nickel-based superalloys, tungsten carbide coatings extend the operational lifespan of turbine blades while maintaining their structural integrity. The application of these coatings enables turbine blades to perform effectively under more extreme conditions.