Tadeusz Kubaszek
@prz.edu.pl
Department of Materials Science/Faculty of Mechanical Engineering and Aeronautics
Rzeszow University of Technology
Scopus Publications
Scopus Publications
Elżbieta Jasiewicz, Beata Hadała, Tadeusz Kubaszek, Barbara Kościelniak, Agnieszka Cebo-Rudnicka, Kamil Dychtoń, and Paweł Pędrak
Elsevier BV
Jakub Jopek, Marek Góral, Barbara Koscielniak, Kamil Ochal, Marcin Drajewicz, Magdalena Mokrzycka, Tadeusz Kubaszek, Kamil Dychton, Kamil Gancarczyk, Andrzej Gradzik,et al.
Jan Evangelista Purkyne University in Usti nad Labem
Tadeusz Kubaszek, Marek Góral, Anita Słyś, Dawid Szczęch, Kamil Gancarczyk, and Marcin Drajewicz
Elsevier BV
Marek Goral, Tadeusz Kubaszek, Wieslaw A. Grabon, Karol Grochalski, and Marcin Drajewicz
MDPI AG
In the article, the new concept of plasma-sprayed coatings for the cylinder liner was presented. The new type of powder containing WC-CrC-Ni with a 5 and 10 wt. % addition of nano-YSZ powder was plasma-sprayed on aluminum 2017 alloy samples. The selection of optimal plasma-spraying parameters was made taking into account the thickness, porosity, and hardness of the coatings. For the coatings obtained according to the developed parameters, the analysis of their microstructure, chemical, and phase composition was performed. At the next stage, the friction coefficient of the developed coatings was tested and compared with the properties of a classic cast-iron cylinder liner. The obtained results suggest that the developed type of coating might be used for cylinder liner applications after a deeper friction analysis.
Krzysztof Szymkiewicz, Marek Góral, Tadeusz Kubaszek, and Kamil Gancarczyk
Central Library of the Slovak Academy of Sciences
MAREK GÓRAL
Wydawnictwo SIGMA-NOT, sp. z.o.o.
Tadeusz Kubaszek, Marek Góral, and Paweł Pędrak
Walter de Gruyter GmbH
Abstract This study investigates the optimal conditions to deposit a thermal barrier coating using micro- and nanopowders in the air plasma spraying (APS) process. The influence of the APS process parameters on the thickness, porosity and hardness of the yttria-stabilized zirconia (YSZ; ZrO2 × 8Y2O3) coatings deposited with a single-electrode plasma gun was determined. The temperature and velocity of melted particles were determined by the DPV diagnostic system to decrease the number of experimental processes. The current and H2 flow rate were changed in this research. Metco-6700 YSZ micropowder has already been used in plasma spray physical vapor deposition. The results of this study suggest the possibility of using it for APS. The particles of this powder are characterized by high temperature (2,700°C–2,900°C) and high speed (>380 m/s). The highest thickness of the coating was obtained with 6 NLPM (normal liter per minute) H2 flow and 800 A current. Difficulties were observed with the feeding of the powder particles at higher H2 flow. The results showed that using APS, deposition of Metco-6609, a nanopowder normally used in suspension plasma spraying, is possible. In this research, this powder was fed using a carrier gas. The coatings were around 40 μm thick and had high porosity. The lowest porosity of the coating was obtained at a current of 600 A and H2 flow rate of 12 NLPM. In the coatings, unmelted spherical particles were also visible.
Marcin Drajewicz, Adrianna Przybylo, Jakub Jopek, Marek Góral, Barbara Koscielniak, Kamil Ochal, Tadeusz Kubaszek, Artur Gurak, Kamil Dychton, Mateusz Wozniak,et al.
Jan Evangelista Purkyne University in Usti nad Labem
The diffusion boriding process allows increasing the abrasion and corrosion resistance of the majority of steel grades. The aim of this study was to determine the influence of the chemical composition of the substrate of various steel grades on the microstructure of boride coatings produced using two diffusion methods: pack cementation boriding using EKABOR-2 and paste-pack boriding using EKABOR-PASTE on the substrate of tool and structural steels:. The boriding processes were carried out at 1000 o C in an argon atmosphere for 4h. Microstructural investigations of the obtained coatings indicate that a high content of alloying elements increasing the FeB (Cr, Mo, W) phase, results in the formation of an external, continuous layer of FeB borides. It was found that with increasing alloying element and carbon concentration, the total thickness of the boride coatings decreases. In particular, chromium content below about 1%, with a carbon content below about 0.4%, significantly limits or prevents the formation of the FeB phase. Increasing the content of alloying elements and carbon, results in a change in the morphology of the iron borides.
M. Góral, P.C. Monteiro, P. Sosnowy, M. Woźniak, T. Kubaszek, and B. Kościelniak
Index Copernicus
In the article, the kinetic growth phenomena of aluminide coating formed by plasma spraying pure Al-Si powder and subsequent diffusion annealing on TiAl intermetallic alloy in inert atmosphere were investigated. The Al-Si powder was thermal sprayed (APS) on TiAl7Nb intermetallic alloy and annealed in Ar atmosphere during 5, 15, 30, 60, 240 and 480 min. The kinetic growth of the coating was observed using the scanning electron microscopy method (SEM), and chemical composition was analysed using the EDS method. The Kirkendall Effects pores formation, as well as titanium silicides on the grain boundary of TiAl3, was found. The oxidation resistance of the developed coating might be analysed in further work. The developed coating might be used for the production of protective aluminide coatings on TiAl intermetallic alloys. The description of aluminide coating formation in a new technological process.
P. Rokicki, M. Góral, T. Kubaszek, K. Dychton, M. Drajewicz, M. Wierzbińska, and K. Ochal
Index Copernicus
The new ceramic material for Enviromental Barrier Coatings (EBC) on ceramic material was developed. The ytterbium monosilicate was deposited using two methods: atmospheric plasma spray (APS) and plasma spray physical vapour deposition (PS-PVD). Obtained coating was characterized by dense structure and columns typically formed in PS-PVD process were not observed. In comparison with APS-deposited coating, in this method, both elements segregation and formation of ytterbium oxide occurred. The further research for production of columnar coatings will be necessary. Developed coatings migh be used for next generations of ceramic materials used for gas turbine and jet engine blades and vanes as a high temperature and corrosion protection. The first time the ytterbium monosilicate was produced bot by APS and LPPS methods.
Paweł Pędrak, Marek Góral, Kamil Dychton, Marcin Drajewicz, Malgorzata Wierzbinska, and Tadeusz Kubaszek
MDPI AG
Ytterbium zirconate (Yb2Zr2O7) is one of the most promising materials for yttria-stabilized zirconia (YSZ) replacement as a thermal barrier coating (TBCs) application. In the presented report, the experimental synthesis of Yb2Zr2O7 coating using novel Reactive Plasma Spray Physical Vapor Deposition (Reactive PS-PVD) is described. The obtained coating, irrespective of the power current (1800, 2000 and 2200 A), was characterized by a hybrid structure and a thickness of about 80–110 μm. The results of XRD phase analysis showed the formation of ytterbium zirconate in the coating but the presence of ytterbium and zirconium oxides was also detected. The oxides were not observed in calcinated powder. The decrease in thermal conductivity with power current increase was observed. It was the result of higher thickness and better columnar structure of the coating obtained using higher power current of the plasma torch.
Tadeusz Kubaszek
Wydawnictwo SIGMA-NOT, sp. z.o.o.
Marek Góral, Paweł Pędrak, Wojciech Cmela, Tadeusz Kubaszek, and Marcin Drajewicz
Trans Tech Publications, Ltd.
Plasma Spray Physical Vapour Deposition (PS-PVD) is one of the promising methods considered as an alternative to Electron Beam Physical Vapour Deposition (EB-PVD) process used for production of ceramic columnar layer for turbine blades protection against high temperature. The PS-PVD method enables to control the coating structure. In presented article the dense to columnar structure was formed during single-step PS-PVD process using yttria stabilized zirconia oxide (YSZ). The ceramic coating was deposited using LPPS-Hybrid (Oerlikon-Metco) system at Rzeszow University of Technology. The IN 713 alloy with aluminide coating produced by CVD method was used as a base material. The inner zone of the ceramic coating was characterized by dense structure and the outer was characterized by columnar structure. The influence of power current, gas composition flow, powder feed rate and coating time on thickness of both zones was investigated using Scanning Electron Microscopy method. The relationship between process parameters and thermal conductivity was also investigated using Laser Flash Method (LFA). Conducted experimental process showed that using of 1800A power current higher Ar flow (80 NLPM) as well as powder feed rate (30 g/min) enables to obtain dense structure of coating. When higher energy of plasma (power current 2200 A, plasma gasses flow (Ar-35 NLPM, He-60 NLPM) and lower powder feed rate was used the columnar zone was formed. The thickness of obtained coating was in range 140-200 μm. The formation of thick dense layer increased the overall thermal conductivity of coating in comparison with conventional columnar ceramic layer. The combination of thin 20 μm dense-zone with thick (120 μm) columnar zone reduces thermal conductivity of whole coating.
Marek Góral, Tadeusz Kubaszek, and Barbara Kościelniak
Trans Tech Publications, Ltd.
The MCrAlY overlay coatings are widely used for high-temperature protection of hot section part of gas turbines and jet engines. This type of coatings are usually thermally sprayed using APS (Atmospheric Plasma Spraying), LPPS (Low Pressure Plasma Spraying) as well as HVOF (High Velocity Oxygen Fuel) methods. In present article the newly developed ethanol based HVOF gun was used for production of this type of coatings. The stainless steel 18-8 type was used as a base material. The AMDRY 386 (Oerlikon-Metco) NiCrAlY powder was used for coatings production. In the research different oxygen (400, 500, 600 NLPM) and ethanol (16.5, 18.3, 21.3, 23.6 and 26.6 dm3/h) flow ratio were selected for experimental processes. The powder feed ratio was also changed during process. After deposition the microstructural assessment using Scanning Electron Microscopy and chemical composition analysis using EDS method were conducted. The obtained results showed that coating was above 100 μm thick depending on the process parameters. The low concentration of pores and oxides was also observed on coatings cross-section. Using of ethanol HVOF gun enables to form good quality MCrAlY coatings with 50% reduction of oxygen consumption in comparison with conventional HP/HVOF torch using kerosene such as JP 5000. The other benefit of its using is lower CO2 emission and lower concentration of carbon in coating in comparison with classic JP 5000 HVOF gun. The ethanol HVOF is a promising technology and might be considered as an replacement of LPPS and HVOF process for production of MCrAlY type of coatings.
Grzegorz Dercz, Jagoda Barczyk, Izabela Matuła, Tadeusz Kubaszek, Marek Góral, Joanna Maszybrocka, Dariusz Bochenek, Sebastian Stach, Magdalena Szklarska, Damian Ryszawy,et al.
MDPI AG
A patient’s body accepting a bone implant depends not only on the biomaterial used, but also on its surface, which allows it to properly interact with bone cells. Therefore, research has focused on improving the bioactive and tribological properties of titanium and its alloys. Commercially pure titanium (cp-Ti) is widely used as a biomedical material. However, it is characterized by unsuitable tribological properties. In this work, yttria-stabilized zirconia (YSZ) was deposited on a cp-Ti substrate via plasma spray–physical vapor deposition (PS-PVD). The structural characteristics were determined using X-ray analysis (XRD). Additionally, the lattice parameters of each phase were determined using Rietveld’s method. High-resolution scanning microscopy (HR-SEM) showed a typical column structure of coatings that can be used with PS-PVD. Depending on the process parameters, the coatings differed in thickness in the range of 2.4–9.0 µm. The surface roughness also varied. The samples were subjected to nano-indenter testing. A slight change in hardness after deposition of the coating was observed, in addition to a significant decrease in the Young’s modulus. The Young’s modulus in relation to the metallic substrate was reduced to 58 or 78 GPa depending on the parameters of the spray-coating process.
Marek Goral, Maciej Pytel, Kamil Ochal, Marcin Drajewicz, Tadeusz Kubaszek, Wojciech Simka, and Lukasz Nieuzyla
MDPI AG
In the present article the doping of aluminide coatings by Pt/Pd as well as Hf or Pd using industrial processes was developed. The different combinations of doping elements were tested as well as their influence on chemical composition of coatings was initially investigated. The Pt and Pd and both Pt + Pd was electroplated on the surface of the MAR M247 nickel superalloy. The Zr or Hf was doped during low activity CVD aluminizing process using industrial Bernex BPX Pro 325S system. The conducted research showed that Pt and Pd formed the (Ni, Pd, Pt) Al solid solution in the outer additive layer. The higher concentration of palladium in the near surface and in the whole additive layer was detected. The platinum was presented below the surface of aluminide coating. The Zr or Hf was detected mainly in the diffusion zone. The low concentration of Zr (about 0.1 wt.%) in the outer zone was observed. The hafnium was detected mainly in the diffusion zone but in the outer additive layer a small concentration of this element was measured. The obtained results showed that formation of three elements (Pd, Pt) + Zr or Hf modified aluminide coating using proposed technology is possible. The structure of all obtained aluminide coatings was typical for a low-activity, high temperature (LAHT) formation process mainly by outward diffusion of Ni from base material.
Marek Góral, Tadeusz Kubaszek, Marcin Kobylarz, Marcin Drajewicz, and Maciej Pytel
Trans Tech Publications, Ltd.
TiAl intermetallics can be considered an alternative for conventional nickel superalloys in the high-temperature application. A TBC (Thermal Barrier Coatings) with ceramic topcoat with columnar structure obtained using EB-PVD (electron beam physical vapour deposition) is currently used to protect TiAl intermetallics. This article presents the new concept and technology of TBC for TiAl intermetallic alloys. Bond coats produced using the slurry method were obtained. Si and Al nanopowders (70 nm) were used for water-based slurry preparation with different composition of solid fraction: 100 wt.% of Al, 50 wt.% Al + 50 wt.% Si and pure Si. Samples of TNM-B1 (TiAl-Nb-Mo) TiAl intermetallic alloy were used as a base material. The samples were immersed in slurries and dried. The samples were heat treated in Ar atmosphere at 1000 °C for 4 h. The outer ceramic layer was produced using the new plasma spray physical vapour deposition (PS-PVD) method. The approximately 110 μm thick outer ceramic layers contained yttria-stabilised zirconium oxide. It was characterised by a columnar structure. Differences in phase composition and structures were observed in bond coats. The coatings obtained from Al-contained slurry were approximately 30 μm thick and consisted of two zones: the outer contained the TiAl3 phase and the inner zone consisted of the TiAl2 phase. The second bond coat produced from 50 wt.% Al + 50 wt.% Si slurry was characterised by a similar thickness and contained the TiAl2 phase, as well as titanium silicides. The bond coat formed from pure-Si slurry had a thickness < 10 μm and contained up to 20 at % of Si. This suggests the formation of different types of titanium silicides and Ti-Al phases. The obtained results showed that PS-PVD method can be considered as an alternative to the EB-PVD method, which is currently applied for deposition a columnar structure ceramic layer. On the other hand, the use of nanopowder for slurry production is problematic due to the smaller thickness of the produced coating in comparison with conventional micro-sized slurries.
Marcin Drajewicz, Marek Góral, Barbara Kościelniak, Kamil Ochał, Tadeusz Kubaszek, Maciej Pytel, Patrycja Wierzba, and Robert Wojtynek
Trans Tech Publications, Ltd.
The boride coatings are characterized by attractive set of properties: high wear resistance and good high-temperature corrosion. In present research the diffusion boride coatings were obtained on X39CrMo17-1 stainless steel. The pack-boriding process was conducted using commercial Ekabor 2 powder. The influence of time of process on thickness and chemical composition was analysed. The boriding process was conducted in 2, 4, 6 hours at 1000 °C using retort furnace. The obtained coating was characterized by double layer structure and contained the FeB in outer layer and Fe2B in inner layer. The thickness of boride coatings increased with process time. The analysis of obtained results showed that the optimal thickness of coating was obtained during 4-h pack boriding.
Marcin Drajewicz, Marek Góral, Maciej Pytel, Barbara Kościelniak, Tadeusz Kubaszek, Patrycja Wierzba, and Piotr Cichosz
Trans Tech Publications, Ltd.
The nitriding process is a well-known technology for increasing of wear resistance of steel. The conventional gas nitriding process of stainless steel is difficult in the case of surface passivation and formation of Cr2O3. The using of plasma enables to form hard surface area during the nitriding process. The plasma nitriding process was developed using Ionit Metaplas device. The kinetic growth was analysed in 2, 4, 6 and 8 h processes. The plasma gasses composition was selected for formation only diffusion layer without “white area” of nitrides. The microstructure, chemical and phase composition were analysed. As a result, the diffusion layer was formed. The iron nitrides formed the precipitations in the diffusion layer. The obtained results showed that 4h process enables to form nitride layer with required composition and hardness. The relationship between process time and nitride layer thickness and its hardness was observed.
Marek Poręba, Tadeusz Kubaszek, Marek Góral, Barbara Kościelniak, Kamil Gancarczyk, and Marcin Drajewicz
Trans Tech Publications, Ltd.
In the article first tests of production of YSZ ceramic coatings using PS-PVD method on graphite were presented. The influence of hydrogen addition on structure and morphology of columns was analyzed. It was shown that width of the columns increased with the increase of hydrogen content in the plasma. The presence of re-solidified oxide vapors between ceramic columns was observed. The obtained results showed the possibility of using of YSZ ceramic layer as a protective layer for metallurgical applications.
Marek Góral, Tadeusz Kubaszek, Barbara Kościelniak, Marcin Drajewicz, and Mateusz Gajewski
Trans Tech Publications, Ltd.
Thermal barrier coatings are widely used for protection of gas turbine parts against high temperature oxidation and hot corrosion. In present work the microstructural assessment of TBCs produced by atmospheric plasma spray (APS) method was conducted. Three types of ceramic powders were used: magnesia- stabilized zirconia oxide (Metco 210), yttria stabilized zirconia oxide (YSZ -Metco 204) and fine-grained YSZ – Metco 6700. As a base material the Inconel 713 was used as well and CoNiCrAlY was plasma sprayed (APS) as a bond coat. The thickness of all ceramic layers was in range 80 – 110 μm. The elemental mapping of cross-section of magnesia-stabilized zirconia showed the presence of Mg, Zr and O in outer layer. In the YSZ ceramic layer the Y, Zr and O were observed during elemental mapping. The isothermal oxidation test was conducted at 1100 °C for 500 h in static laboratory air. On all samples the delamination and spallation of ceramic layers was observed. Chemical composition analysis of coatings showed the presence of two areas: the first one contained elements from bond coats: Ni, Cr, Al, Co and second area contained O, Cr Co and O that suggest the scale formation. The obtained results showed the total degradation of all ceramic layers as a result of internal stresses in bond-coat. Microscopic analysis showed the areas with complete degradation of bond coats and formation of thick oxides layer.
Marek Góral, Tadeusz Kubaszek, Marek Poręba, and Małgorzata Wierzbińska
Trans Tech Publications, Ltd.
Plasma Spray Physical Vapour Deposition (PS-PVD) method was designed for production of ceramic layer on nickel superalloys. In typical process before deposition the base material is heated by plasma up to 900 °C. In present article the yttria stabilized zirconia (YSZ) was deposited on low melting point materials: 2017A-type aluminium alloy and Cu-ETP copper. The influence of power current, process time and powder feed rate on structure and thickness of obtained coatings was analysed. During first deposition process the overheating of Al-sample was observed and as result the power current was decreased to 1600 A. In the next experimental the approx. 5 mm thick dense coating was formed. During experimental processes of YSZ deposition on copper the thickness of coating increased from approx. 5 to 22 mm. The copper-oxide layer was formed under ceramic layer. The microscopic assessment showed the difficulties in formation of columnar ceramic layer on use base materials. The obtained coating was characterized by dense structure as a result of lower plasma energy during process. The increasing of power current is not possible in the case of overheating of base material.
Marek Góral, Maciej Pytel, Tadeusz Kubaszek, Marcin Drajewicz, Wojciech Simka, and Łukasz Nieużyła
Walter de Gruyter GmbH
Abstract Thermal barrier coatings (TBCs) are widely used for protection of gas turbine parts from high temperature and corrosion. In the present study, the new concept of TBCs with three-element-modified aluminide coatings was presented. In the first stage, the Pt and Pd were electroplated on MAR M247 nickel superalloy. In the next stage, the low-activity CVD aluminizing process with Zr or Hf doping was conducted. The ceramic layer containing yttria-stabilized zirconia was obtained by the plasma spray physical vapour deposition (PS-PVD) method. The microscopic examination showed the formation of aluminide coating containing up to 5 at% of Pt and 10 at% of Pd in (Ni, Pt, Pd)Al solid solution. The small concentration of Hf and Zr in diffusion zone of aluminide bond coat was noted as well. The outer ceramic layer was characterized by columnar structure typically formed during the PS-PVD process. The obtained results showed that the new concept of TBCs formed using new processes might be an attractive alternative to conventional coatings produced using the expensive electron beam physical vapour deposition (EB-PVD) method.
Maciej Pytel, Tadeusz Kubaszek, Paweł Pędrak, Marek Góral, and Marcin Drajewicz
Trans Tech Publications, Ltd.
The plasma spraying is commonly used in medical application. The Atmospheric Plasma Spray (APS) method was applied for production of yttria-stabilized zirconia (YSZ) on AISI 316L stainless steel surface and also on Ti6Al4V titanium alloy surface. In present article two examples of coatings production were presented. In first experimental the YSZ was plasma sprayed (APS) on 316L stainless steel surface. The coating was deposited using A60 (Thermico) plasma torch. The initial parameters were selected and it was concluded that minimal power current was 500A. The thickness of obtained coating was in range 100-150 micrometers. The X-ray phase analysis showed the presence of tetragonal t-phase of ZrO2. The lamellar structure of coatings with large porosity was observed. In second experimental the newly developed Plasma Spray Physical Vapor Deposition method (PS-PVD) was used. The YSZ coating was deposited on titanium Grade 5 surface. The conducted research showed the formation of two types of coatings structure. When the power current was lower (2000 A) the dense lamellar-like coatings was obtained. If the power current was increased (up to 2200A) the columnar ceramic coating was observed.