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Turbine Blade Coating
EB/PVD Production Systems
ALD Vacuum Technologies
	 High Tech is our Business
Benefits of TBC
TBC absorb high thermal stress
and enable higher turbine operating
temperatures
OO Reduced fuel consumption
OO Higher efficiency
OO Longer turbine life-time
TBC have a broad application range in
OO Aerospace
OO Power generating units
Benefits of EB/PVD
EB/PVD produces superior coating
quality thanks to
OO Homogeneous cloud of vapour
	 responsible for
OO Controlled thickness distribution of
	 layers with
OO Superior dendritic structure and
OO Firmly anchored roots and
OO Smooth surface properties
The EB/PVD process is virtually
exclusively approved in aero-
space for high temperature
turbine blades and vanes
The high performance electron beam
evaporates metals as well as ceramics
OO Bond, diffusion and thermal
	 barrier coatings
OO can be produced in a step by
	 step process
OO With high deposition speeds
The EB/PVD process
is exclusively approved
in aerospace because
of its unique structure
EB/PVD
Production Process
Electron Beam Physical
Vapour Deposition (EB/PVD)
of Thermal Barrier Coatings (TBC)
The SL XXL Coater
with 1 Feeder
The starting model into mass
production with pilot size capacity
Large chamber volume and bigger gate
valves enable
OO Coating of bigger parts
OO Handling of 4 axes in 1 feeder
The modular design allows further
extensions	
OO e.g. retrofit to a 2-feeder coater
	 is possible
The DL XXL Coater
with 2 Feeders
Production system with two loading
stations and medium size capacity
OO Embedded are 40 years of experience
	 and dozens of references
OO Coating of blades and vanes
High Volume
Production Systems
XXL Coater
Throughput of turbine
blades up to 200.000 pcs/p.a.
coated with YSZ*
*Yttria Stabilized Zirkonia
The DTL XXL Coater
with 4 Feeders
The top model of the XXL product line
The four feeders
OO Enable continuous mass production of
	 turbine components with
OO High throughput and efficiency
1
2
3
1 32
EB/PVD
Pilot, Repair and
R&D System
The New SMART Coater
The new SMART Coater –
Proven components
Based on ALD´s approved standard
and XXL concepts the new SMART
Coater incorporates their proven
components	
OO highly reliable EB guns
OO vapour cloud management
OO controlled part movements
OO sophisticated quality control
New features
	
OO Short campaign times and
OO Small investment costs
OO High part flexibility
OO Small floor space
	 requirements/no pit
OO One man operation and
	service
OO Small volumes
Further options
OO 2 layer coating systems (2 crucibles)
OO Multi layer coating systems
	 (special crucible)
OO Metal coatings
OO Advanced layer monitoring
OO by integration of a Residual Gas 	
	 Analyzer in coating chamber
OO Advanced quality management
	systems
EB/PVD Systems
from ALD
ALD – Solution provider with
market leading EB/PVD technology
n	 First EB/PVD system introduced already in the 1960‘s
n	 Dozens of systems are installed in the field
n	 ALD offers a complete model range
	 n	 From XXL Coater for mass production
	 n	 Up to SMART Coater for repair/ R&D/ pilot production
Corporate features of
ALD´s EB/PVD systems
High coating quality by fully
reproducible control over vapour
cloud and parts movements
OO Computer controlled scan of the
	 electron beam over the molten
	 pools (ECOSYS)
OO Optimal rotating and tilting of parts
	 in the vapour deposition cloud
Heating with advanced
graphite heater
OO Accurate pressure control during
preheating
Shortest down time by fast
evacuating/venting cycles
OO Rough pumping by mechanical pumps
OO Fine pumping by high performance
	 diffusion pumps
OO Dynamic seal pumping
Market leading technology
features of ALD´s EB/PVD
systems
EB/PVD
2 3
4 5
1 2 3
Sophisticated quality control
OO Identification, pre- and post- weighing
	 of parts
OO Recipe handling and quality reporting
OO Integration into host computer
	environment
Proven electron beam gun
design for high performance and
reliability
OO Double pressure stage pumping
OO Pressure control at gun pressure stage
OO High beam power thanks to proprietary
	 HV transformers
4
5
1
Typical Dimensions SMART Coater 2-Feeder XXl Coater
Width, approx.: [m] 7.1 12
Length, approx.: [m] 8.4 20
Height, approx.: [m] 4.2 8.2
Weight, approx.: [t] 33 90
Installed Power: [kVA] 500 1400
Cooling water: [m³/h] 75 125
No of floor levels Single Dual
Typical Technical Parameters SMART Coater 2-Feeder XXL Coater
Total evaporation power installed: 1 EB-Gun 250 kW 2 EB-Guns, 500 kW total
Coating uniformity: [min]
< ± 10 % of the average deposited thickness for planar panels over the length
of the coating area
Coating window: [mm] 210 x 140 420 x 140
Substrate temperature/Coating: [°C] max. 1,000 - 1,100 max. 1,000 - 1,100
Substrate temperature/Preheating: [°C] 550 to max. 1,200 adjustable
Ingot Capacity [m] 2 m 20 m
(including high
voltage supply unit)
ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1
D-63457 Hanau, Germany
Phone +49 (0) 6181 307-0
Fax +49 (0) 6181 307-3290
E-Mail info@ald-vt.de
Internet www.ald-vt.com
You can find the addresses of all our sales partners and
subsidiaries on www.ald-vt.com.
MetaCom/EB-PVD/11.14

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Turbin Blade Coating

  • 1. Turbine Blade Coating EB/PVD Production Systems ALD Vacuum Technologies High Tech is our Business
  • 2. Benefits of TBC TBC absorb high thermal stress and enable higher turbine operating temperatures OO Reduced fuel consumption OO Higher efficiency OO Longer turbine life-time TBC have a broad application range in OO Aerospace OO Power generating units Benefits of EB/PVD EB/PVD produces superior coating quality thanks to OO Homogeneous cloud of vapour responsible for OO Controlled thickness distribution of layers with OO Superior dendritic structure and OO Firmly anchored roots and OO Smooth surface properties The EB/PVD process is virtually exclusively approved in aero- space for high temperature turbine blades and vanes The high performance electron beam evaporates metals as well as ceramics OO Bond, diffusion and thermal barrier coatings OO can be produced in a step by step process OO With high deposition speeds The EB/PVD process is exclusively approved in aerospace because of its unique structure EB/PVD Production Process Electron Beam Physical Vapour Deposition (EB/PVD) of Thermal Barrier Coatings (TBC)
  • 3. The SL XXL Coater with 1 Feeder The starting model into mass production with pilot size capacity Large chamber volume and bigger gate valves enable OO Coating of bigger parts OO Handling of 4 axes in 1 feeder The modular design allows further extensions OO e.g. retrofit to a 2-feeder coater is possible The DL XXL Coater with 2 Feeders Production system with two loading stations and medium size capacity OO Embedded are 40 years of experience and dozens of references OO Coating of blades and vanes High Volume Production Systems XXL Coater Throughput of turbine blades up to 200.000 pcs/p.a. coated with YSZ* *Yttria Stabilized Zirkonia The DTL XXL Coater with 4 Feeders The top model of the XXL product line The four feeders OO Enable continuous mass production of turbine components with OO High throughput and efficiency 1 2 3 1 32
  • 4. EB/PVD Pilot, Repair and R&D System The New SMART Coater The new SMART Coater – Proven components Based on ALD´s approved standard and XXL concepts the new SMART Coater incorporates their proven components OO highly reliable EB guns OO vapour cloud management OO controlled part movements OO sophisticated quality control New features OO Short campaign times and OO Small investment costs OO High part flexibility OO Small floor space requirements/no pit OO One man operation and service OO Small volumes Further options OO 2 layer coating systems (2 crucibles) OO Multi layer coating systems (special crucible) OO Metal coatings OO Advanced layer monitoring OO by integration of a Residual Gas Analyzer in coating chamber OO Advanced quality management systems
  • 5. EB/PVD Systems from ALD ALD – Solution provider with market leading EB/PVD technology n First EB/PVD system introduced already in the 1960‘s n Dozens of systems are installed in the field n ALD offers a complete model range n From XXL Coater for mass production n Up to SMART Coater for repair/ R&D/ pilot production Corporate features of ALD´s EB/PVD systems High coating quality by fully reproducible control over vapour cloud and parts movements OO Computer controlled scan of the electron beam over the molten pools (ECOSYS) OO Optimal rotating and tilting of parts in the vapour deposition cloud Heating with advanced graphite heater OO Accurate pressure control during preheating Shortest down time by fast evacuating/venting cycles OO Rough pumping by mechanical pumps OO Fine pumping by high performance diffusion pumps OO Dynamic seal pumping Market leading technology features of ALD´s EB/PVD systems EB/PVD 2 3 4 5 1 2 3 Sophisticated quality control OO Identification, pre- and post- weighing of parts OO Recipe handling and quality reporting OO Integration into host computer environment Proven electron beam gun design for high performance and reliability OO Double pressure stage pumping OO Pressure control at gun pressure stage OO High beam power thanks to proprietary HV transformers 4 5 1
  • 6. Typical Dimensions SMART Coater 2-Feeder XXl Coater Width, approx.: [m] 7.1 12 Length, approx.: [m] 8.4 20 Height, approx.: [m] 4.2 8.2 Weight, approx.: [t] 33 90 Installed Power: [kVA] 500 1400 Cooling water: [m³/h] 75 125 No of floor levels Single Dual Typical Technical Parameters SMART Coater 2-Feeder XXL Coater Total evaporation power installed: 1 EB-Gun 250 kW 2 EB-Guns, 500 kW total Coating uniformity: [min] < ± 10 % of the average deposited thickness for planar panels over the length of the coating area Coating window: [mm] 210 x 140 420 x 140 Substrate temperature/Coating: [°C] max. 1,000 - 1,100 max. 1,000 - 1,100 Substrate temperature/Preheating: [°C] 550 to max. 1,200 adjustable Ingot Capacity [m] 2 m 20 m (including high voltage supply unit) ALD Vacuum Technologies GmbH Otto-von-Guericke-Platz 1 D-63457 Hanau, Germany Phone +49 (0) 6181 307-0 Fax +49 (0) 6181 307-3290 E-Mail info@ald-vt.de Internet www.ald-vt.com You can find the addresses of all our sales partners and subsidiaries on www.ald-vt.com. MetaCom/EB-PVD/11.14