Browsing by Author "Shetty, G."

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    High temperature erosion performance of NiCrAlY/Cr2O3/YSZ plasma spray coatings
    (Taylor and Francis Ltd., 2023) Reddy, G.M.S.; Prasad, C.D.; Patil, P.; Shetty, G.; Naresh, N.; Ramesh, M.R.
    The current investigation's objective was to assess the air jet erosion tester's ability to measure the erosive behaviour of plasma sprayed coatings on titanium-15 alloy. 65% NiCrAlY, 30% Cr2O3, and 5% YSZ make up the coating's chemical composition. A study of microstructure and phases was carried out. Microhardness and adhesive strength have both been measured in this work. With impact angles of 30° and 90° at 300°C, 500°C, and 700°C, Al2O3 erodent was utilised in a solid particle erosion test. An optical profilometer was used to calculate the erosion volume loss. The coating erosion resistance was found to be higher than the substrate sample for the test temperature that was employed, and this was more obvious at higher impact angles and higher temperatures The ductile character of the coating is seen in the contour of the deteriorated coating surface. © 2023 Institute of Materials Finishing Published by Taylor & Francis on behalf of the Institute.
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    High-temperature oxidation behavior of plasma-sprayed NiCrAlY/TiO2 and NiCrAlY/Cr2O3/YSZ coatings on titanium alloy
    (Springer Science and Business Media Deutschland GmbH, 2022) Reddy, G.M.S.; Prasad, C.D.; Shetty, G.; Ramesh, M.R.; Rao, T.N.; Patil, P.
    The 70% NiCrAlY + 30% TiO2 and 70% NiCrAlY + 25% Cr2O3 + 5% YSZ metallic coatings are sprayed on titanium-15 alloy of ASTM B338, Grade 2, by using the plasma spray coating technology. Cyclic oxidation studies are conducted on the uncoated and coated alloys at 700 °C under static air environment. The kinetics of oxidation is studied by using the thermo-gravimetric method. Phase, microstructural, and chemical analysis tests are performed on as-sprayed and oxidized coatings. The coated alloys are found to be more resistant when compared to the uncoated alloys. The NiCrAlY + Cr2O3 + YSZ coating is found to be more protective when compared to NiCrAlY + TiO2 coating. It is concluded that the formation of Cr2O3, NiCr2O4, and Al2O3 is attributed to the development of oxidation resistance in the coatings. © 2022, International Institute of Welding.
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    High-Temperature Oxidation Studies of Plasma-Sprayed NiCrAlY/TiO2 and NiCrAlY/Cr2O3/YSZ Cermet Composite Coatings on MDN-420 Special Steel Alloy
    (Springer, 2021) Madhu Sudana Reddy, G.; Prasad, C.D.; Shetty, G.; Ramesh, M.R.; Rao, T.N.; Patil, P.
    The plasma spray process was used to form 70%NiCrAlY + 30%TiO2 and 70%NiCrAlY + 25%Cr2O3 + 5%YSZ cermet coatings on MDN-420 special steel alloy. Cyclic oxidation testing was conducted on coated and uncoated specimens at 700°C under a static air environment. Thermogravimetric analysis was applied to establish the oxidation kinetics. X-ray diffraction (XRD), scanning electron microscopy (SEM)/energy-dispersive x-ray spectroscopy (EDS), and electron probe microanalysis (EPMA) techniques were used to analyze the oxidized products. The NiCrAlY + Cr2O3 + YSZ coating was found to be most resistive when compared with the NiCrAlY + TiO2 coating in the aggressive oxidation environment. Net weight loss was observed for bare MDN-420 alloy due to sputtering. The oxidation resistance of the coatings was due to formation of Cr2O3, NiCr2O4, NiO, and Al2O3 phases. © 2021, ASM International.
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    Investigation of thermally sprayed NiCrAlY/TiO2and NiCrAlY/Cr2O3/YSZ cermet composite coatings on titanium alloys
    (Institute of Physics, 2022) Madhu Sudana Reddy, G.; Prasad, C.D.; Patil, P.; Shetty, G.; Ramesh, M.R.; Nageswara Rao, T.
    The present work investigates the hot corrosion behavior of thermally sprayed 65 pct NiCrAlY + 35 pct TiO2 and 65 pct NiCrAlY + 30 pct Cr2O3 + 5 pct YSZ coatings on titanium 15 alloys. The coatings on the titanium 15 alloy substrates exhibit a near-uniform, dense, and adherent microstructure with a porosity of 2.7 to 2.9%. Thermogravimetric studies are made to examine the hot corrosion performance of coatings in a molten salt environment of Na2SO4 + 60%V2O5 at the temperature of 700 °C for 50 cycles. One cycle is carried out by heating for a period of one hour and cooling the sample at ambient conditions. The corrosion products are analyzed based on scanning electron microscopy, energy dispersive analysis, and X-ray diffraction techniques to study the morphology, phase composition, and abundance of the high-temperature corrosion constituents. The bare titanium-15 alloy, 65 pct NiCrAlY + 35 pct TiO2 coating and 65 pct NiCrAlY + 35 pct Cr2O3 + 5 pct YSZ coating produced a weight gain of 307.92 mg cm-2, 42.16 mg cm-2 and 44.02 mg cm-2 respectively after the period of 50 cycles. The effective resistance of the coatings is due to the formation of Ni3V2O8, NiCr2O4, Cr2O3 & AlV2O4 phases. © 2022 IOP Publishing Ltd.
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    Studies on the role of HVOF coatings to combat erosion in turbine alloys
    (2018) Prasanna, N.D.; Siddaraju, C.; Shetty, G.; Ramesh, M.R.; Reddy, M.
    Erosive wear is caused by the action of sliding or impact of solids, liquids, gases or the combination of these. Solid particle erosion is an important material degradation mechanism encountered in a number of engineering systems such as gas turbine engines, thermal power plants, coal slurry pipe lines. Erosive action results from the impact of particulates, such as coal ash, dolomite and un-burnt carbon particles on the surface of turbine. Super alloys developed for high temperature applications suffer from the drawback that the strength and the erosion-corrosion resistance at high temperature exhibited are poor. To improve the resistance property, one way would be the use of coatings on the super alloy component. Coatings take care of the problems related to erosion whereas the super alloys take care of the requirement of strength at elevated temperature. Various coatings have been highly attractive; however, High Velocity Oxy-fuel (HVOF) process, a family of thermal spray techniques uses kinetic energy of the burnt gases to soften and to propel the spray powder producing dense very low porosity, good inter-particle cohesion and well bonded coatings. In the present study successful attempts have been made to spray Stellite-6, 10%Al2O3+90%CoCrAlTaY and 25%Cr3C2-20(Ni-Cr)+75%NiCrAlY on three kinds of turbine alloys, namely Ti-6Al-4V, Co-based super alloy (Super co 605) and Fe-based special steel (MDN121).Microstructure and mechanical properties of the coatings have been characterized. Erosion tests for different conditions using Air-jet erosion test rig for different impingement angles have been studied in detail. From these studies it is observed that satellite-6 coating exhibits lower erosive rate compared to other two coating materials. The morphology of the eroded surface shows craters, groove formation in the binder matrix and carbide pull-out as the existing erosion mechanism. Higher erosion loss is observed for Al2O3+CoCrAlTaY coating. � 2018 Elsevier Ltd.
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    Studies on the role of HVOF coatings to combat erosion in turbine alloys
    (Elsevier Ltd, 2018) Prasanna, N.D.; Siddaraju, C.; Shetty, G.; Ramesh, M.R.; Reddy, M.
    Erosive wear is caused by the action of sliding or impact of solids, liquids, gases or the combination of these. Solid particle erosion is an important material degradation mechanism encountered in a number of engineering systems such as gas turbine engines, thermal power plants, coal slurry pipe lines. Erosive action results from the impact of particulates, such as coal ash, dolomite and un-burnt carbon particles on the surface of turbine. Super alloys developed for high temperature applications suffer from the drawback that the strength and the erosion-corrosion resistance at high temperature exhibited are poor. To improve the resistance property, one way would be the use of coatings on the super alloy component. Coatings take care of the problems related to erosion whereas the super alloys take care of the requirement of strength at elevated temperature. Various coatings have been highly attractive; however, High Velocity Oxy-fuel (HVOF) process, a family of thermal spray techniques uses kinetic energy of the burnt gases to soften and to propel the spray powder producing dense very low porosity, good inter-particle cohesion and well bonded coatings. In the present study successful attempts have been made to spray Stellite-6, 10%Al2O3+90%CoCrAlTaY and 25%Cr3C2-20(Ni-Cr)+75%NiCrAlY on three kinds of turbine alloys, namely Ti-6Al-4V, Co-based super alloy (Super co 605) and Fe-based special steel (MDN121).Microstructure and mechanical properties of the coatings have been characterized. Erosion tests for different conditions using Air-jet erosion test rig for different impingement angles have been studied in detail. From these studies it is observed that satellite-6 coating exhibits lower erosive rate compared to other two coating materials. The morphology of the eroded surface shows craters, groove formation in the binder matrix and carbide pull-out as the existing erosion mechanism. Higher erosion loss is observed for Al2O3+CoCrAlTaY coating. © 2018 Elsevier Ltd.