Abstract
Recognizing the fundamental cost advantage, technical capabilities, and compositional flexibility of reduced pressure (vacuum) plasma spraying compared to other overlay coating methods, an advanced, second generation, closed chamber deposition process called VPX (a Howmet trademark) was developed. An automated experimental facility for coating gas turbine engine components was also constructed. This paper describes several important features of the process and equipment. It shows that the use of optimized spray parameters combined with an appropriate schedule of relative orientations between the gun and work-piece can be used to produce dense and highly reproducible coatings of either uniform or controlled thickness distributions. The chemical composition, microstructure, and interfacial characteristics of typical MCrAlY coatings are reported. Some effects of operating procedures and MCrAlY chemical composition on coating density are noted. The results of mechanical property and burner rig tests of coated material are also described.
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