Study and Characterization Effect of Nickel‐Based Composite Thermal Barrier Coating Applied by Thermal Spray Process to Protect Blades of High Pressure Turbine of the Aircraft Engine

To keep up with the times, speed is one of the features of the turbofan engine, and this means operating under harsh conditions of high temperature and pressure. This is why engine parts, especially the high pressure turbine blades (HPT- Bs), often suffer from damage due to high temperature, high pressure, foreign bodies (FOD) impact and other factors. This study aims to apply a new thermal barrier coating (TBC) to increase HPT-Bs service cycles, reduce replace and maintain cost so preserve natural resources for future generations. To achieve this, a thermal spray method was used to apply NiCrBSi (as bond coat) and Ni based reinforced with tungsten carbide (WC) (as top coat) as composite TBC system with thickness 200-300 ?m, onto nickel based alloy substrate under conditions selected using the Taguchi program. By the microstructure, micro-hardness, thermal cycling and hot erosion tests, the TBC layer performance was investigated. Moreover, results were studied and discussions using a SEM, Optical microscopy and XRD analysis.