The Deformation Effects of Aluminide Over the Pack Coatings Diffusion Cycles on an Inconel 600 Coating Boat Lid (Rectangular Plate) by Sergio L. Moren.

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The Deformation Effects of Aluminide Over the Pack Coatings Diffusion Cycles on an Inconel 600 Coating Boat Lid (Rectangular Plate) by Sergio L. Moren An Engineering Project Submitted to the Graduate Faculty of Rensselaer Polytechnic Institute in Partial Fulfillment of the Requirements for the degree of MASTER OF MECHANICAL ENGINEERING

Problem: An Inconel 600 coating vessel lid deforms (potato chips) after a certain amount of coating cycles. Purpose: The purpose of this Engineering project is to obtain an approximate life expectancy for the Inconel 600 vessels based on the deformation of the Lid. Not actual tooling

Above-the-pack diffusion coating process: Aluminide coatings rely on the formation of βNiAl on the surface of the component alloys. There are three processes by which aluminide vapor coating can be performed: Pack process Above-the-pack process Chemical Vapor Deposition This project addresses tooling issues related to the above-the-pack coating process: Process Temperature ºF Activator – Halide (NaCl, CrCl 2, NH 4 Cl, or AlF 3 ) Source Element – Aluminum Compound Process type – “Low Activity” and “Outward Diffusing” Ni

Why does the Inconel 600 deform? The stresses and strains involved in the thermal fatigue in bimetallic specimens is a contribution of the CTE (Coefficient of Thermal Expansion) mismatch between the coating and the alloy. NiAl 1600 ºF (871 ºC) ≈ 8.33 / ºFInconel ºF ≈ 9.0 / ºF Further analysis will be conducted to calculate the CTE at 2000 ºF

Deformation Mechanism of a Bimetallic: After integrating the strain equations twice over the area the deformation equation is obtained:

Project Status: Format – customized the template provided Research – obtained all reference required to do the background and methods Methodology – - need to conduct ANSYS analysis of the sample problems and apply it to the Inconel 600 plate - first coating run on Inconel 600 samples started on 3/10/2008 (no manufacturing window until that date) - send specimens to the lab to measure coating thickness Should be able to complete all tasks by the required date. Looking to obtain at least 6 coating runs for the six samples.