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Standards Development
This document specifies the evaluation of thermal spray ceramic protective coatings applied to additively manufactured nickel-based superalloy components. This document also defines test methods and performance criteria for key characteristics of the coating, including surface roughness, porosity, thermal conductivity, thermal cyclability, adhesion/cohesion, and scratch test.
High-pressure turbine components in aero-engines and stationary gas turbines operate under extreme thermal and mechanical conditions. Thermal barrier coatings (TBCs) are essential for reducing thermal loads, enhancing component durability, and enabling higher operating temperatures.
Additive manufacturing (AM) of nickel-based superalloys has rapidly expanded its applications because it enables complex internal cooling structures and lightweight geometries. However, AM substrates exhibit unique properties—such as residual porosity, anisotropic microstructures, and surface irregularities—that significantly influence TBC adhesion, durability, and thermal performance. Existing standards address thermal spray processes, coating characterization, and general TBC performance, but the document that defines requirements specifically for TBCs applied to additively manufactured nickel-based superalloys is not available. This gap leads to inconsistent substrate preparation, coating processes, and performance evaluation methods, limiting global comparability, qualification efficiency, and industrial adoption.
This document aims to provide harmonized requirements and test methods tailored to AM substrates, supporting reliable qualification, improved coating performance, and safer implementation of AM components in aerospace and energy applications.
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