Authors

Muchammad

Mechanical Engineering Department, Faculty of Engineering, Diponegoro University, Jl. Prof. H. Soedarto, SH, Tembalang-Semarang 50275, Indonesia

Budi Setiyana

Mechanical Engineering Department, Faculty of Engineering, Diponegoro University, Jl. Prof. H. Soedarto, SH, Tembalang-Semarang 50275, Indonesia

Puti Findyra Chaulia Karim

Mechanical Engineering Department, Faculty of Engineering, Diponegoro University, Jl. Prof. H. Soedarto, SH, Tembalang-Semarang 50275, Indonesia

Abstract

Blades of gas turbines operate at high temperatures and in hot gas environments that can trigger oxidation, corrosion, and degradation of protective layers. This study compares the microstructural characteristics of nickel-based coating High Velocity Oxy Fuel (HVOF) and zirconia-based coating plasma spray on gas turbine blades at power generation industry in Indonesia. Data were obtained through metallographic observation of coating cross-sections before and after operation. Initial observations showed that the coating system consisted of a superalloy substrate, a nickel-based HVOF layer with a thickness of 0,220 mm, and a zirconia-based plasma spray layer with a thickness of 0,499 mm. After operation, the HVOF thickness decreased to 0,094 mm, while the plasma spray decreased to 0,284 mm. These changes were followed by microcracks, oxidation, indications of delamination, and layer degradation. The nickel-based HVOF coating showed a denser structure and served as a bond coat that supported adhesion and corrosion protection. The zirconia layer produced by plasma spray had a lamellar and porous structure, making it effective as a thermal barrier coating, but more vulnerable as a path for oxygen ingress when exposed to thermal cycles. These results emphasize the importance of periodic coating evaluation to maintain the reliability of hot gas path components.

Keywords

Coating HVOF plasma spray zirconia gas turbine blade microstructure

Citation of this Article

Muchammad, Budi Setiyana, & Puti Findyra Chaulia Karim. (2026). Analysis of Differences in Characteristics of Coating HVOF Based on Nickel and Coating Plasma Spray Based on Zirconia on Gas Turbine Blades. International Current Journal of Engineering and Science (ICJES), 5(10), 8-12. Article DOI: https://doi.org/10.47001/ICJES/2026.510002

Licence Copyright (c) 2026 International Current Journal of Engineering and Science. This work is licensed under a Creative Commons Attribution Non Commercial 4.0 International Licence.

References

  1. Buehler. (n.d.). Standardization of metallographic practices. https://www.buehler.com/assets/solutions/technotes/vol5issue5.pdf
  2. Clarke, D. R., & Levi, C. G. (2003). Materials design for the next generation thermal barrier coatings. Annual Review of Materials Research, 33, 383-417. https://doi.org/10.1146/annurev.matsci.33.011403.113718
  3. Fauchais, P., Vardelle, M., & Vardelle, A. (2013). Reliability of plasma-sprayed coatings: Monitoring the plasma spray process and improving the quality of coatings. Journal of Physics D: Applied Physics, 46(22), 224016. https://doi.org/10.1088/0022-3727/46/22/224016
  4. Padture, N. P., Gell, M., & Jordan, E. H. (2002). Thermal barrier coatings for gas-turbine engine applications. Science, 296(5566), 280-284. https://doi.org/10.1126/science.1068609
  5. PT PLN Nusantara Power UMRO JP-1 Muara Karang. (2026). Observation data on the microstructure of gas turbine blade coating in practical work activities.
  6. Qian, C., Kou, X., Pei, C., & Chen, Z. (2022). Topcoat thickness measurement of thermal barrier coating using grating laser acoustic spectrum method. Ceramics International, 48(3), 3676-3684. https://doi.org/10.1016/j.ceramint.2021.10.149
  7. Ramezani, M., Mohd Ripin, Z., Pasang, T., & Jiang, C.-P. (2023). Surface engineering of metals: Techniques, characterizations and applications. Metals, 13(7), 1299. https://doi.org/10.3390/met13071299
  8. Sampath, S., Schulz, U., Jarligo, M. O., & Kuroda, S. (2012). Processing science of advanced thermal-barrier systems. MRS Bulletin, 37(10), 903-910. https://doi.org/10.1557/mrs.2012.233
  9. Vaßen, R., Jarligo, M. O., Steinke, T., Mack, D. E., & Stöver, D. (2010). Overview on advanced thermal barrier coatings. Surface and Coatings Technology, 205(4), 938-942. https://doi.org/10.1016/j.surfcoat.2010.08.151
  10. Wu, M., Pan, L., Duan, H., Wan, C., Yang, T., Gao, M., & Yu, S. (2021). Study on wear resistance and corrosion resistance of HVOF surface coating refabricate for hydraulic support column. Coatings, 11(12), 1457. https://doi.org/10.3390/coatings11121457