Electro-spark deposition technology

Conference · Thu Aug 01 04:00:00 EDT 1996

OSTI ID:458962

Johnson, R N ^[1]

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1. Pacific Northwest Lab., WA (United States)

Electro-Spark Deposition (ESD) is a micro-welding process that uses short duration, high-current electrical pulses to deposit or alloy a consumable electrode material onto a metallic substrate. The ESD process was developed to produce coatings for use in severe environments where most other coatings fail. Because of the exceptional damage resistance of these coatings, and the versatility of the process to apply a wide variety of alloys, intermetallics, and cermets to metal surfaces, the ESD process has been designated as one of the enabling technologies for advanced energy systems. Developments include producing iron aluminide-based coatings with triple the corrosion resistance of the best previous Fe{sub 3}Al coatings, coatings with refractory metal diffusion barriers and multi layer coatings for achieving functionally gradient properties between the substrate and the surface. One of the most significant breakthroughs to occur in the last dozen years is the discovery of a process regime that promises an order of magnitude increase in deposition rates and achievable coating thicknesses. Since this regime borders on and exceeds the normal operating limits of existing ESD electronic equipment, development is in progress to produce equipment that can consistently and reliably achieve these conditions for a broad range of materials. Progress so far has resulted in a consistent 500% increase in deposition rates, and greater rates still are anticipated. Technology transfer activities are a significant portion of the ESD program effort. Notable successes now include the start-up of a new business to commercialize the ESD technology, the incorporation of the process into the operations of a major gas turbine manufacturer, major new applications in gas turbine blade and steam turbine blade protection and repair, and in military, medical, metal-working, and recreational equipment applications.

• Research Organization: Oak Ridge National Lab., TN (United States)
• OSTI ID: 458962
• Report Number(s): ORNL/FMP--96/1; CONF-9605167--; ON: DE97050349
• Country of Publication: United States
• Language: English

Related Subjects

20 FOSSIL-FUELED POWER PLANTS
36 MATERIALS SCIENCE
ALUMINIUM ALLOYS
CERMETS
DEPOSITION
ELECTRIC SPARKS
INTERMETALLIC COMPOUNDS
IRON BASE ALLOYS
PROTECTIVE COATINGS
REFRACTORY METALS
WELDING