Electron beam physical vapor deposition (EB-PVD) technology equipment [Electron beam physical vapor deposition for protective layer (MCrAlY) and thermal barrier coating (TBC)]

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Presentation of the equipment's characteristics

In a vacuum environment, a high-energy-density electron beam is used to bombard the evaporated material placed in a water-cooled crucible, causing it to melt and vaporize, and then condense into a film on the substrate.

processed samples

Technical principle:
In a vacuum environment, a high-energy-density electron beam is used to bombard the evaporated material placed in a water-cooled crucible, causing it to reach a molten gasified state and condense into a film on the substrate.

Technical features:
For gas turbine engine blades, EB-PVD technology is used to prepare protective coatings, which have the following technical features:
1) Single-layer, double-layer and triple-layer coatings can be continuously manufactured within one production cycle;
2) The working life of the blade is extended by 2 to 5 times;
3) The operating temperature and efficiency of the engine are improved;
4) The engine is allowed to use low-purity fuel and can ensure the full combustion of the fuel;
5) It can be used for blade repair and extend its life.

Equipment and application areas:
The EB-PVD industrial equipment with hot cathode, EB-PVD industrial test equipment with hot cathode, and EB-PVD industrial equipment with cold cathode developed by our cooperative R&D unit can be used for aerospace products such as engine blades.

EB-PVD industrial equipment with hot cathode (annual production capacity for thermal barrier coatings on gas turbine blades: 15,000 to 30,000 pieces)

EB-PVD industrial equipment with cold cathode (annual production capacity for thermal barrier coatings on gas turbine blades: 60,000 to 120,000 pieces)

△ EB-PVD industrial equipment with hot cathode (Annual production capacity for thermal barrier coatings on gas turbine blades: 15,000 to 30,000 pieces)
△ EB-PVD industrial equipment with cold cathode (Annual production capacity for thermal barrier coatings on gas turbine blades: 60,000 to 120,000 pieces)
△ Gas engine blades 1) No coating; 2) Metal coating; 3) Double-layer metal/ceramic coating
The market places increasingly stringent demands on the efficiency of gas turbine engines used in the aerospace and power generation industries. This is driven by the need to reduce fossil fuel consumption and operating costs. The main means of improving turbine efficiency is to increase the operating temperature of the hot section of the engine turbine. The materials used must withstand higher temperatures as well as mechanical stress, corrosion, erosion and other severe operating conditions while providing the extended life required by the end user. In this field, coating processes have now made a significant contribution.
The mass production EB-PVD system of our cooperative R&D unit is equipped with a central coating chamber containing two electron beam guns and a zirconium oxide ceramic reservoir, which will allow the coating process to be performed over several days. The EB will produce a uniform vapor cloud, where the part can be rotated, tilted or both simultaneously to match the part geometry and the specified coating thickness distribution requirements.
Two-layer coating systems, such as CMAS protection and low-k applications, can be achieved with the integrated ingot translator, which allows the deposition of two different materials in one coating run. High-performance electron beam evaporation of metals and ceramics. Bonding, diffusion and thermal barrier coatings can be produced in a step-by-step process with high deposition rates.
The EB-PVD process will produce a thermal barrier coating with controlled thickness distribution, excellent dendritic structure, strong anchoring and smooth surface properties. The TBC coating will absorb high thermal stresses and increase the turbine operating temperature, thus achieving the expected benefits of reduced fuel consumption, increased efficiency and longer turbine life.
The basic design includes a coating chamber, a heating chamber and a loading/unloading chamber. The modular design allows further expansion: for example: a coating machine can be converted to 2 feeders. Our cooperative R&D unit provides more than 50 years of experience and dozens of references for coating system blades and guide vanes. The coating machine with 4 feeders enables continuous batch production of turbine components with high output and efficiency.