Vo l . 39 N o .

1 F e b r u a r y 2006

Development of Coating and Cladding Technology, MSCoating , Using Electro-Discharge Energy

OCHIAI Hiroyuki : Chief Engineer, Manufacturing Division, Aero-Engine & Space Operations WATANABE Mitsutoshi : Manager, Production Planning Department, Manufacturing Division, Aero-Engine & Space Operations ARAI Mikiya : Manager, Materials Technology Department, Research & Engineering Division, Aero-Engine & Space Operations YOSHIZAWA Hiroki : Manager, Materials Department, Research Laboratory, Research & Development SAITOU Yoshiyuki : Manager, Reciprocating Engine Research & Development Project Group, Technical Development & Engineering Center, Research & Development

IHI and Mitsubishi Electric Corporation have developed revolutionary coating and cladding technology, named Micro Spark Coating (MSCoating), which can stably build up functional coating and cladding, and is expected to replace for plating, welding and plasma spraying. Fundamental tests for application to aero-engines were carried out. MSCoating showed better performance than existing methods. Superior anti-fretting coating over a wide temperature range was developed for low-pressure turbine blades. Many simulated samples of actual parts were processed to promote engineering managers to adopt this technology, by showing the possibility of big cost reduction.

1. Introduction
Since the jet engine was brought into practical use, incessant efforts have been made aiming at continuous improvement in the performance of the engine. Requirements for better performances focusing on fuel consumption and thrust-weight ratio as well as requirements for environmental friendliness have been becoming stronger every year. In order to meet those requirements for better performance, it is necessary to make the engines lighter and the turbines more heat resistant, and to enable compressors to create higher pressure. In order to satisfy those requirements, production technology has developed significantly, and capability in production technology determines the competitiveness. In particular, technology for surface modification (functional coating) is an important element of competitiveness. In the aircraft engine industry, the flow line production system and the cell production system have been introduced with the aim to improve productivity. Production technologies suitable for such systems became necessary for surface modification also. In the aerospace industry technologies including jet engines, CVD, PVD, plating, plasma spraying and cladding by welding have been used for building up functional coating for metal parts. Those technologies are not suitable for line production systems, because they are either for production in large lots that require a large capital investment for equipment or methods relying on workmanship. In those

methods, preprocessing such as cleaning and masking and post-treatment such as removal of masking and processing for border require too much labor. In spraying and welding, possible thermal deformation, crack and peeling are also problems. With joint efforts with Mitsubishi Electric Corporation, IHI has developed technology to build up various functional coatings at reasonable cost in the machining line.

2. History of development
Electric discharge coating technology has been introduced into actual use for surface treatment of molds and tools. Both companies jointly developed the new technology based on existing technologies. In the rubbing surface on the shroud of the low-pressure turbine (LPT) blade of the civil aircraft engine, generally used hard-face (cladding by welding of cobalt alloy with anti-fretting property in high temperature) had not been adopted. When the engine was used on the actual aircraft, however, wear was deeper than expected if hard-face is not provided, and therefore design change became necessary. Because the cost of the conventional cladding by welding was too high, it has been determined to develop new technology with the aim of reducing the cost. At first, a proposal for adoption of thin ceramic coating was made to the department in charge of engine parts development, but development of thick metal cladding similar to that by welding was requested, and a technology to clad metal rather thickly has been developed.
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3. Overview of MSCoating
MSCoating is a technology to build up stable, high quality functional coating with excellent durability and antifretting performance by electric discharge using an electrode containing coating material such as metal and ceramic. In addition, as it does not require skilled workers or preprocessing or post-treatment, it is especially suitable for automating the production line and saving labor on it, and as it does not require expensive equipment such as a coating chamber, the production process can be simplified, and a remarkable cost reduction can be expected. 3.1 Principle of MSCoating Powder of the material to be deposited as a coating shall be compressed to form an electrode. The formed electrode is dipped in insulation oil together with the base material to be coated, and a voltage is applied. A pulselike electric discharge (approximately 10 000 times per second) starts between the electrode and the base material to be coated (substrate), and the material of the electrode moves to the substrate and both materials are melted and bonded to each other (Fig. 1) . Thin ceramic coating and a thick layer of metal cladding can be built up. Furthermore, MSCoating can make metal layer dense or porous by selecting the electrode and processing conditions (Fig. 2). 3.2 Features There are several methods to coat the surface of metal, such as plating, plasma spraying and welding. MSCoating has various features compared with such methods. The main features are described below, and the comparison of technologies is shown in Table 1. (1) Deformation of the substrate is very small, and no cracking occurs. With welding, because of the large thermal shrinkage of the welded portion, there is a risk of deformation and cracking. Contrarily, with MSCoating, as fusing and bonding are conducted by repeating local minute pulse-like electric discharges with a micron level diameter, shrinkage of the substrate is limited to a very shallow range from the surface. Therefore, deformation is very small, and no cracking occurs (Fig. 3).
Minute pulse discharge Electrode Insulation oil Servo

(a) Minute texture

(b) Porous texture

Fig. 2 Micro-structure of built-up alloy by MSCoating

Table 1 Comparative table of MSCoating and others

Item Integration into the line Cost Preprocessing and post-treatment MSCoating Easy Small Almost unnecessary i Df l atin g P icult Larg e Plasma spraying Dif icult Large n Weldig Dif icult

Medim u

Masking

Masking

Fin ih s ing

Quality

Stable

Possib fi o lity peelin g None Metal

Possibility fo peeling May happen CeramicMetal

ib s oP is lity fo cracking Larg e Metal

Deformation Coating material Environment

None CeramicMetal

(Note)

: oN influence

:n I fle u ntial

(a) Welding

(b) MSCoating

Fig. 3 Comparison between TIG weld and MSCoating in deformation

Substrate

Fig. 1 Description of MSCoating

2

(2) No peeling of coating/deposited layer With plating and plasma spraying, metal simply adheres on the surface of the substrate, and therefore there is a risk of peeling of adhered metal. With MSCoating, as the metal is fused and bonded, there is no risk of peeling. (3) Processing to exact shape is possible, and no preprocessing or post-treatment is required. With MSCoating, as coating can be provided only on the place between the electrode and substrate where electric discharge occurs, coating can be made that copies exactly the shape of the electrode. Therefore, masking work that is unavoidable for plating or plasma spraying is not required (Fig. 4).

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MSCoating

Fig. 5 MSCoating (TiC) after bend peeling test

Fig. 4 Transferred electrode-shape

(4) Stable quality can be ensured without relying on workmanship. At present, the welding process is carried out manually by skilled workers in order to ensure the required quality. With MSCoating, processing can be conducted mechanically, and stable quality can be ensured without relying on skilled workers better than the currently conducted welding. (5) As small-sized equipment is used, it is possible to incorporate it in the production flow line. As welding and plasma spraying require large-sized equipment, such a process cannot be incorporated in the production flow line. But as MSCoating uses small-sized equipment, the MSCoating process can be incorporated in the production flow line.

4. Realizable functions (including certain anticipations)

Just as with plasma spraying, various functions can be implemented by developing electrodes. Functions such as anti-fretting property, the property to be abrasive (to abrade the object with which it is rubbed together), property to be abradable (to be abraded by the object with which it is rubbed together), erosion resistance, oxidation resistance and heat shielding property can be achieved by developing suitable electrodes and processing conditions.

shock test after cladding of 100% cobalt (Co) to a circular disc of INCONEL 718 and milling. In the thermal shock test, the test specimen was dipped in liquid nitrogen and hot water in sequence for 30 seconds, and this step was repeated ten times. Even after milling and the thermal shock test, no peeling was observed (Fig. 6). 5.2 Anti-fretting wear property (1) Ceramics Various materials were coated with ceramic by MSCoating, and the anti-fretting wear property was compared with that of conventional methods. Results of the fretting-wear test are shown in Table 2. Test temperature Room temperature Contact pressure 8 MPa _ 0.5 mm + Amplitude Number of cycles 100 000 times (at 40 Hz) It can be seen that coating by MSCoating has an anti-fretting wear property highly superior to that of conventional methods, chrome (Cr) plating and plasma spraying of tungsten carbide (WC). (2) Metal cladding Differently from depositing by welding, because a layer containing solid lubricant can be formed, abrasion by adhesion is small in a wide range from low temperature to high temperature. Further details will be described below.
(a) Before milling (b) After milling Border (c) Border of Co cladding after a thermal shock test

5. Fundamental performances of coating and cladding

5.1 Anti peeling property (1) Ceramic coating by MSCoating No peeling was detected after repeatedly bending a thin plate of INCONEL 718 coated with ceramic (TiC) by MSCoating until a fracture occurred. Also no peeling was detected after scratching the coating with a tool having a sharp edge after the fracture (Fig. 5). (2) Metal cladding Peeling resistance has been checked by a thermal
(d) Microstructure after a thermal shock test Co cladding 2 mm Layer of cladding (Thickness: 200 m approx.) INCONEL 718 material

Fig. 6 Co cladding after boundary layer separation test

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Table 2 Results after fretting wear

No. 1 2 3 4 5 6 Material for coating of test specimen Upper test specimen Ti-5Al-2.5Sn Ti-5Al-2.5Sn WC plasma sprayed MSC processed TiC SUS440C SUS440C Lower test specimen Cr plating (standard) MSC processed WC WC plasma sprayed (standard) MSC processed TiC WC plasma sprayed (standard) MSC processed TiC Amount of wear Upper test specimen Lower test specimen Large Large Large Very small Medium Medium Small Very small Large Very small Large Small Current design MSC Current design MSC Current design MSC (Note) : Very good : Good : No good Record Remarks Area of application in the product Prevention of galling at the fitted portion of parts in the rotor system Anti-fretting wear for the periphery of the bearing mount Upper and lower test specimens and the way of combining

Up

Down

5.3 Low cycle fatigue (LCF) life (1) Ceramic MSCoating A test specimen for LCF is shown in Fig. 7. The outer diameter of the test specimen was coated with ceramic by MSCoating, and comparison of the LCF life with another method was conducted. The test was conducted at room temperature with a cycle axial load that is close to the tensile strength of the material. Table 3 shows the results of the LCF test, and Fig. 8 shows the ruptured LCF test specimen. It can be seen that MSCoating provides a longer fatigue life compared to chrome plating and WC plasma spaying. (2) Metal cladding A test specimen for simulation of rupair is shown in Fig. 9 . A depression was provided on the outer diameter of the test specimen in order to simulate repair of surface imperfections (Fig. 9-(a)). Cladding
6.3

(a) External appearance

(b) Cut-out section

(Note) Ceramic (TiC) MSCoating

Fig. 8 Ruptured specimen after LCF test

(a) Test specimen for simulation of removal of defect

(b) Test specimen cladding repaired with Co by MSCoating

Fig. 7 Test specimen for LCF (unit : mm)

Fig. 9 Repair-simulated test specimen for LCF (unit : mm)

Table 3 Results in LCF test on coated specimens

Substrate Processing Unprocessed bar Cr plating (standard) MSC processed WC WC plasma spayed (standard) MSC processed TiC Number of cycles until ruptured 16 500 18 01 10 58 59 69 62 8 10 12 900 14 200 (Note) Cyclic axial load of 1 372 M 45 48 75 82 Withot u peening With peening Withot u peening With peening 9 060 1 400 10 300 7 900 10 700 Life ratio (%) Remarks

INCONEL 718

Pa at the room temperature

of 100% cobalt (Co) was carried out to this depression by MSCoating (Fig. 9-(b)), and the outer diameter was finished by polishing without being heat-treated. This test specimen was used for the LCF test at the room temperature. The results of comparison of fatigue life are shown in Table 4. The ruptured state is shown in Fig. 10. The test specimen without cladding to the depression was ruptured at the bottom of the depression (stress concentration zone) (Fig. 10-(a)). The test specimen with 100% Co cladding by MSCoating was ruptured at the surface of the cladding ( Fig. 10-(b) ). The fatigue life was shortened to 50 to 60% by cladding.

6.3

Depression (S 10, depth 0.35)

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Table 4 Results in LCF test on repair-simulated test specimen

Type of test specimen Test specimen for simulation of removal of defect (standard) Test specimen repaired by Co cladding by MSCoating Number of cycles until ruptured 9 300 10 700 10 Life ratio (%)

Fan blade

Compressor blade

Turbine blade

5 01

6 800

55 60

(Note) Cyclic axial load of 1 372 MPa at room temperature

(a) Test specimen for simulation of removal of defect

External appearance Cut-out section

Labyrinth seal
(b) Test specimen cladding repaired with Co by MSCoating

Shaft

Turbine stationary vane

Fig. 11 Possible applications in aero-engines

External appearance Cut-out section

(a) Surface treated by anti-fretting wear cladding

(b) Welding (conventional method)

Fig. 10 Ruptured specimen after LCF test

6. Examples and their performances

Possible applications in aero-engines are shown in Fig. 11, and the details are described below. Some of them are processes for trial and are being verified in actual machines. 6.1 Example of the anti-fretting property of metal cladding at high temperature Cladding with cobalt (Co) alloy containing chrome (Cr) was carried out on the rubbing surface on the shroud of a blade of a low-pressure turbine ( Fig. 12 ). In the test specimen by welding, a large surplus material was generated (Fig. 12-(b)), and it needs to be removed by manual work. In the test specimen treated by MSCoating (Fig. 12-(c)), a cladding of the necessary thickness is built up at the required range. As the dimensions are ensured in thin layers, no finishing work is necessary for ensuring dimensions. A fretting wear test, tensile test at room temperature, impact wear test, oxidation resistance test, and thermal fatigue test were conducted. (1) Fretting wear test The anti-fretting property of the layer of cladding is shown in Fig. 13. The amount of wear of layers by conventional welding and MSCoating are shown.

(c) MSCoating

Fig. 12

Anti-fretting wear cladding on LPT blade (unit : mm)

Hardly any wear by abrasion is observed in the range from the low temperature to the high temperature zone by MSCoating. Test conditions Contact pressure 3 to 7 MPa 1 mm Amplitude Number of times of abrasion 1 000 000 times (at 40 Hz)

0.5
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: Co alloy (welding) : Co alloy (MSCoating) : TiC (MSCoating) 100

: Welding - Welding (standard) : MSC-MSC 100

State in which the test specimen contacts 7 MPa Anvil

Amount of wear (---)

Amount of wear (---)

80 60 40 20 0 0 250 500 750 1 000 1 250

80 60 40 20 0 0 200 400 600

Striker

800

1 000

1 200

1 400

Temperature (;) (Note) Contact pressure : 3 to 7 MPa _ 0.5 mm Amplitude :+

Temperature (;)

Fig. 13 Fretting wear to temperature

Fig. 15 Impact wear to temperature

(2) Tensile test at the normal temperature Figure 14 shows how to execute the tensile test at the normal temperature. A thick cladding is provided on the substrate, loading fixtures are bonded on them by adhesive and they are pulled by the tester. If the result of the tensile test is between 7 MPa to 35 MPa, the result of the wearing test is good. If it is above the range, lubricity decreases, resulting in adhesive wear. If it is heated to high temperature in the atmosphere, the tensile strength increases significantly, and the anti-fretting wear property is also improved. (3) Impact wear test A surface of the striker collides against a surface of the anvil at an angle and then rubbed with a certain pressure to check the amount of wear and the existence/non-existence of an internal crack. The amount of wear is shown in Fig. 15. The test specimen by MSCoating showed better performance compared to the conventional welded one. The impact wear surface when worn is shown in Fig. 16. Fig. 16-(a) shows the surface with large wear and Fig. 16-(b) shows the surface with little wear. (4) Oxidation resistance test After maintaining the test specimen at 1 000; in the atmosphere for 100 hours, the tensile strength was measured. The tensile strength had been increased remarkably. This is due to the fact that diffusion progresses by oxidation, and the texture is

(a) External appearance of the surface with large wear

(b) External appearance of the surface with small wear

Fig. 16 Appearance of sliding surface after impact wear test

Jig

Substrate

Surface of cladding

Bonded surfaces

Fig. 14 Tensile test

changed to a stronger one. If heated to a high temperature, the oxide inside the layer works as a solid lubricant, and the anti-fretting wear property under a medium temperature increases. Hardly any wear occurs in the fretting wear test. (5) Thermal fatigue test The deposited test specimen is heated for approximately 11 minutes to 870; and retained for one minute. Then, it is air-cooled for approximately three minutes to 250;. This cycle was repeated 500 times. As no peeling by oxidation occurred, the thickness of the deposited layer did not change. Also, no boundary separation occurred. 6.2 Example of abrasive coating at the tip of turbine blade A tip seal on a low-pressure turbine blade was coated with ceramic by MSCoating (Fig. 17). The shape of the tip with a thickness of 0.7mm was coated without any deformation.

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Ceramic MSCoating

Fig. 17 Abrasive coating on tip seal on LPT blade

When the tip seal on the shroud of the blade rubbed the honeycomb seal of the stationary part, the tip seal was expected to abrade the honeycomb seal, but without wear on the tip seal itself. In the current state, no coating is applied, and therefore wearing occurs and the metal adheres to the honeycomb and, in certain cases, metal transfer occurs. 6.3 Example of abrasive coating for parts for compressor A curved surface on the concave side of the tip of the compressor blade was coated with 15 m thick ceramic by MSCoating (Fig. 18). Also, a tip (0.3 mm thick) of a labyrinth seal for air seal was coated with ceramic by MSCoating (Fig. 19). When rubbed with the seal of the stationary part, no wear is expected to occur to each part except the mating

part to be abraded. As the performance of the engine is degraded if the tip is worn, periodic inspection has been conducted and cladding repair has been carried out. It is expected that the number of times of cladding repair can be reduced remarkably by adopting this coating. 6.4 Example 1 of cladding repair A tip of a blade made of nickel alloy of a compressor was deposited for 0.4 mm by MSCoating (Fig. 20). At the tip of the blade, the thickness was very thin, only 0.2 mm, at the front and rear edges, but it was possible to clad the tip with the wall thickness as it was. 6.5 Example 2 of cladding repair A tip of a directionally solidified nickel-base alloy turbine blade was deposited with cobalt alloy for 0.8 mm by MSCoating (Fig. 21). For directionally solidified nickelbase alloy, welding is very difficult. But, by MSCoating, cladding could be carried out keeping the shape of the tip as it is without weld cracking. 6.6 Example 3 of cladding repair A side surface of the positioning groove of a low-pressure turbine static vane made of nickel-base alloy was deposited with cobalt alloy for 0.5 mm in thickness by MSCoating (Fig. 22). If the electrode can be brought close, cladding and coating can be conducted even in the narrow groove. This part was sent to an endurance test, and at present, it is waiting for evaluation. 6.7 Example 4 of cladding repair Using a small electrode and rotating a part, the part, made of nickel-base alloy, is deposited uniformly with cobalt alloy on the outer diameter by MSCoating (Fig. 23). This method is quite useful for repair of parts for which no deformation can be acceptable.

Fig. 18 Abrasive coating at airfoil near tip on compressor blade

Labyrinth seal

Fig. 20 Metal cladding on tip of thin blade (unit : mm)

MSCoating TIG weld

0.8

Ceramic MSCoating

Fig. 19 Abrasive coating on labyrinth seal of rotating part

Fig. 21 Metal cladding on tip of DS casting blade (unit : mm)

MSCoating 0.4 thick

Ceramic MSCoating

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MSCoating

1 mm

Fig. 22 Cladding repair on LPT vane

versatile and all-purpose technology that shows the possibility of opening new fields for coating and welding. Various applications have been tried with parts for jet engines, and their performance was investigated. As a result of this work, possibilities of achieving coatings with various functions could be demonstrated. Coating and cladding with excellent anti-fretting wear performance was achieved over a wide temperature range, in which it was previously not possible to carry out such coating or cladding. This technology is a new technology that has been born quite recently. Participation in its development by many research institutes is desired. Acknowledgments Development and application of this technology was implemented by joint development with Dr. Akihiro Goto of Mitsubishi Electric Corporation, and many other persons participated in the development activity. Also, support from various parties concerned with this project, such as the Technical Development Division, were indispensable for this achievement. We would like to tender our acknowledgment for their support. REFERENCES (1) N. Mouri, N. Saito, Y. Tsunekawa, H. Momiyama and A. Miyagawa : Metal Surface Modification by Electrical Discharge - Machining with Composite Electrode, Journal of The Japan Society for Precision Engineering Vol.59 1993 pp.625-630 (2) A. Goto, T. Magara, H. Miyake, Y. Imai, N. Saito and N. Mouri : Surface Modification by EDM, Journal of Japan Society of Electrical-Machining Engineers Vol.31 No.68 1998 pp.26-31

MSCoating After grinding

Fig. 23 Cladding repair on outer diameter of ring

7. Future development
In the field of the aerospace industry, aircraft engine manufacturers around the world will be aggressively approached for adoption of this technology and parts processed by this technology. Also it is planned to expand the range of application to fields other than aerospace, for example, automobile and medical instruments.

8. Conclusion
This new technology, MSCoating, is a revolutionary