Development of gas mixture composition for the improvement of nickel-based cathodes for the ionic-plasma coating

Modern power plants and aero-engines work at enhanceable temperatures that may reach over 1 700 °С. Heat-resistant coatings on the basis of nickel are applied to provide the work at high temperatures. The service life of shoulder-blades, first of all, depends on the quality factors of the coatings (evenness, absence of pores, inclusions, chemical homogeneity). Quality of coating is determined by the application process and quality of cathode. As a rule, cathodes are alloys that are spread with the special geometry. There are a few technologies of making cathodes, with their advantages and defects. One of the methods is ingot melting layer by layer to produce cathodes in copper water-cooled mold with the use of unfluxible electrode. Purpose of research. To enhance the quality of nickel-based cathodes (Ni − Cr − Al − Y) by the improvement of technological modes of ingot melting. The tasks are set to reduce defects such as pores, to increase homogenity of structure and chemical composition. Methodology. The equipment, namely vacuum arc unit, was improved with helium cylinder. Test samples in a way of "pucks" (127 mm in diameter and 40-mm thick) were obtained to study the microstructure and chemical composition. The modes of remelting are worked through. Research of chemical composition was conducted with the use of SEM of РЕМ 106І equipped with microanalysis system. Scientific novelty. Optimal correlation of protective gases on ingot quality factors for further cathode production was identified. At gas correlation of 70/30 % high quality ingots were obtained. Conclusions. Based on the results of research on the effect of the concentration of gas mixture on the structure and composition of cathodes, technological melting conditions were established, which made it possible to improve the quality indicators and economic indicators of the studied cathodes. This will positively affect the number of cathode defects, serviceability of parts that contain coatings and the service life of aircraft engines in general.