Research Projects

Additive manufacturing (AM) has become a significant technology, with applications ranging from consumer electronics to large aerospace components. Its advantages include near-net shapes, reduced machining costs, and increased design flexibility. The physical and mechanical properties of additively manufactured components depend on processing parameters like material deposition orientation, layer thickness, sintering time, and scanning rate. Inconel 718 is a preferred alloy for high-temperature applications due to its poor weldability and difficult machining. Thermal barrier coatings (TBCs) were developed to improve the life of hot section components subjected to high temperatures. However, the YSZ topcoat suffers from delamination when exposed to high temperatures due to the formation of an oxide layer between bond coat and base topcoat. Covering this YSZ coating with another rare earth element coating may reduce delamination issues. Rotor turbines are susceptible to this issue, but most thermal application coatings are rarely tested for fatigue load conditions. This study proposes a novel ceramic-based thermal barrier coating with superior high-temperature fatigue properties. The adhesion properties of the coating will be investigated in different ambient temperatures, and the properties will be tested for fatigue (Low and High cycle fatigue and crack growth) for up to 106 cycles and fracture studies (JIc) for different ambient temperatures between 24? and 650?. Performance under complex variable amplitude mechanical loads will also be studied under different temperature environments. These investigations will help understand the damage mechanism of coated additively manufactured IN718 alloy under cyclic loading and contribute to improving alloy performance for desired applications.