WorldWideScience

Sample records for barrier coating system

  1. Advanced thermal barrier coating systems

    Science.gov (United States)

    Dorfman, M. R.; Reardon, J. D.

    1985-01-01

    Current state-of-the-art thermal barrier coating (TBC) systems consist of partially stabilized zirconia coatings plasma sprayed over a MCrAlY bond coat. Although these systems have excellent thermal shock properties, they have shown themselves to be deficient for a number of diesel and aircraft applications. Two ternary ceramic plasma coatings are discussed with respect to their possible use in TBC systems. Zirconia-ceria-yttria (ZCY) coatings were developed with low thermal conductivities, good thermal shock resistance and improved resistance to vanadium containing environments, when compared to the baseline yttria stabilized zirconia (YSZ) coatings. In addition, dense zirconia-titania-yttria (ZTY) coatings were developed with particle erosion resistance exceeding conventional stabilized zirconia coatings. Both coatings were evaluated in conjunction with a NiCr-Al-Co-Y2O3 bond coat. Also, multilayer or hybrid coatings consisting of the bond coat with subsequent coatings of zirconia-ceria-yttria and zirconia-titania-yttria were evaluated. These coatings combine the enhanced performance characteristics of ZCY with the improved erosion resistance of ZTY coatings. Improvement in the erosion resistance of the TBC system should result in a more consistent delta T gradient during service. Economically, this may also translate into increased component life simply because the coating lasts longer.

  2. Combustion chemical vapor desposited coatings for thermal barrier coating systems

    Energy Technology Data Exchange (ETDEWEB)

    Hampikian, J.M.; Carter, W.B. [Georgia Institute of Technology, Atlanta, GA (United States)

    1995-10-01

    The new deposition process, combustion chemical vapor deposition, shows a great deal of promise in the area of thermal barrier coating systems. This technique produces dense, adherent coatings, and does not require a reaction chamber. Coatings can therefore be applied in the open atmosphere. The process is potentially suitable for producing high quality CVD coatings for use as interlayers between the bond coat and thermal barrier coating, and/or as overlayers, on top of thermal barrier coatings.

  3. Combustion chemical vapor deposited coatings for thermal barrier coating systems

    Energy Technology Data Exchange (ETDEWEB)

    Hampikian, J.M.; Carter, W.B. [Georgia Institute of Technology, Atlanta, GA (United States). School of Materials Science and Engineering

    1995-12-31

    The new deposition process, combustion chemical vapor deposition, shows a great deal of promise in the area of thermal barrier coating systems. This technique produces dense, adherent coatings, and does not require a reaction chamber. Coatings can therefore be applied in the open atmosphere. The process is potentially suitable for producing high quality CVD coatings for use as interlayers between the bond coat and thermal barrier coating, and/or as overlayers, on top of thermal barrier coatings. In this report, the evaluation of alumina and ceria coatings on a nickel-chromium alloy is described.

  4. Article Including Environmental Barrier Coating System

    Science.gov (United States)

    Lee, Kang N. (Inventor)

    2015-01-01

    An enhanced environmental barrier coating for a silicon containing substrate. The enhanced barrier coating may include a bond coat doped with at least one of an alkali metal oxide and an alkali earth metal oxide. The enhanced barrier coating may include a composite mullite bond coat including BSAS and another distinct second phase oxide applied over said surface.

  5. Diffusion Barrier Coating System and Oxidation Behavior of Coated Alloys

    Institute of Scientific and Technical Information of China (English)

    T.NARITA

    2009-01-01

    @@ 1 Introduction Research into the formation of Re-based alloys is in progress in our laboratory to provide a diffusion barrier layer between heat-resistant alloys and Al reservoir layers, which assist in the formation and maintenance a protective Al2O3 scale for long periods. Coatings with a two-layered structure comprised of inner Re-based alloy layer and outer β-NiAl layer with or without Pt addition were successfully formed on various heat resistant alloys such as Ni-based singlecrystal superalloys, Ni-based heat resistant alloys, NiMo based alloy, Ni-Cr based alloy, and Fe-based alloys. The duplex layer coating proposed is generally termed a diffusion barrier coating system; DBC system.

  6. Thermal and Environmental Barrier Coatings for Advanced Propulsion Engine Systems

    Science.gov (United States)

    Zhu, Dong-Ming; Miller, Robert A.

    2004-01-01

    Ceramic thermal and environmental barrier coatings (TEBCs) are used in gas turbine engines to protect engine hot-section components in the harsh combustion environments, and extend component lifetimes. For future high performance engines, the development of advanced ceramic barrier coating systems will allow these coatings to be used to simultaneously increase engine operating temperature and reduce cooling requirements, thereby leading to significant improvements in engine power density and efficiency. In order to meet future engine performance and reliability requirements, the coating systems must be designed with increased high temperature stability, lower thermal conductivity, and improved thermal stress and erosion resistance. In this paper, ceramic coating design and testing considerations will be described for high temperature and high-heat-flux engine applications in hot corrosion and oxidation, erosion, and combustion water vapor environments. Further coating performance and life improvements will be expected by utilizing advanced coating architecture design, composition optimization, and improved processing techniques, in conjunction with modeling and design tools.

  7. Low Conductivity Thermal Barrier Coatings

    Science.gov (United States)

    Zhu, Dong-Ming

    2005-01-01

    Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. In this presentation, thermal barrier coating development considerations and requirements will be discussed. An experimental approach is established to monitor in real time the thermal conductivity of the coating systems subjected to high-heat-flux, steady-state and cyclic temperature gradients. Advanced low conductivity thermal barrier coatings have also been developed using a multi-component defect clustering approach, and shown to have improved thermal stability. The durability and erosion resistance of low conductivity thermal barrier coatings have been improved utilizing advanced coating architecture design, composition optimization, in conjunction with more sophisticated modeling and design tools.

  8. Thermal and Environmental Barrier Coating Development for Advanced Propulsion Engine Systems

    Science.gov (United States)

    Zhu, Dongming; Miller, Robert A.; Fox, Dennis S.

    2008-01-01

    Ceramic thermal and environmental barrier coatings (TEBCs) are used in gas turbine engines to protect engine hot-section components in the harsh combustion environments, and extend component lifetimes. Advanced TEBCs that have significantly lower thermal conductivity, better thermal stability and higher toughness than current coatings will be beneficial for future low emission and high performance propulsion engine systems. In this paper, ceramic coating design and testing considerations will be described for turbine engine high temperature and high-heat-flux applications. Thermal barrier coatings for metallic turbine airfoils and thermal/environmental barrier coatings for SiC/SiC ceramic matrix composite (CMC) components for future supersonic aircraft propulsion engines will be emphasized. Further coating capability and durability improvements for the engine hot-section component applications can be expected by utilizing advanced modeling and design tools.

  9. Advanced thermal barrier system bond coatings for use on Ni, Co-, and Fe-base alloy substrates

    Science.gov (United States)

    Stecura, S.

    1985-01-01

    New and improved Ni-, Co-, and Fe-base bond coatings have been identified for the ZrO2-Y2O3 thermal barrier coatings to be used on NI-, Co-, and Fe-base alloy substrates. These bond coatings were evaluated in a cyclic furnace between 1120 and 1175 C. It was found that MCrAlYb (where M = Ni, Co, or Fe) bond coating thermal barrier systems. The longest life was obtained with the FeCrAlYb thermal barrier system followed by NiCrAlYb and CoCrAlYb thermal barrier systems in that order.

  10. Evaluation of the Lifetime and Thermal Conductivity of Dysprosia-Stabilized Thermal Barrier Coating Systems

    Science.gov (United States)

    Curry, Nicholas; Markocsan, Nicolaie; Östergren, Lars; Li, Xin-Hai; Dorfman, Mitch

    2013-08-01

    The aim of this study was the further development of dysprosia-stabilized zirconia coatings for gas turbine applications. The target for these coatings was a longer lifetime and higher insulating performance compared to today's industrial standard thermal barrier coating. Two morphologies of ceramic top coat were studied: one using a dual-layer system and the second using a polymer to generate porosity. Evaluations were carried out using a laser flash technique to measure thermal properties. Lifetime testing was conducted using thermo-cyclic fatigue testing. Microstructure was assessed with SEM and Image analysis was used to characterize porosity content. The results show that coatings with an engineered microstructure give performance twice that of the present reference coating.

  11. Westinghouse thermal barrier coatings development

    Energy Technology Data Exchange (ETDEWEB)

    Goedjen, J.G.; Wagner, G. [Westinghouse Electric Corp., Orlando, FL (United States)

    1995-10-01

    Westinghouse, in conjunction with the Department of Energy and Oak Ridge National Laboratory, has embarked upon a program for the development of advanced thermal barrier coatings for industrial gas turbines. Development of thermal barrier coatings (TBC`s) for industrial gas turbines has relied heavily on the transfer of technology from the aerospace industry. Significant differences in the time/temperature/stress duty cycles exist between these two coating applications. Coating systems which perform well in aerospace applications may not been optimized to meet power generation performance requirements. This program will focus on development of TBC`s to meet the specific needs of power generation applications. The program is directed at developing a state-of-the-art coating system with a minimum coating life of 25,000 hours at service temperatures required to meet increasing operating efficiency goals. Westinghouse has assembled a team of university and industry leaders to accomplish this goal. Westinghouse will coordinate the efforts of all program participants. Chromalloy Turbine Technologies, Inc. and Sermatech International, Inc. will be responsible for bond coat and TBC deposition technology. Praxair Specialty Powders, Inc. will be responsible for the fabrication of all bond coat and ceramic powders for the program. Southwest Research Institute will head the life prediction modelling effort; they will also be involved in coordinating nondestructive evaluation (NDE) efforts. Process modelling will be provided by the University of Arizona.

  12. Advanced thermal barrier system bond coatings for use on nickel-, cobalt- and iron-base alloy substrates

    Science.gov (United States)

    Stecura, S.

    1986-01-01

    New and improved Ni-, Co-, and Fe-base bond coatings have been identified for the ZrO2-Y2O3 thermal barrier coatings to be used on Ni-, Co-, and Fe-base alloy substrates. These bond coatings were evaluated in a cyclic furnace between 1120 and 1175 C. It was found that MCrAlYb (where M = Ni, Co, or Fe) bond coating thermal barrier systems have significantly longer lives than MCrAlY bond coating thermal barrier systems. The longest life was obtained with the FeCrAlYb thermal barrier system followed by NiCrAlYb and CoCrAlYb thermal barrier systems in that order.

  13. Monitoring Local Strain in a Thermal Barrier Coating System Under Thermal Mechanical Gas Turbine Operating Conditions

    Science.gov (United States)

    Manero, Albert; Sofronsky, Stephen; Knipe, Kevin; Meid, Carla; Wischek, Janine; Okasinski, John; Almer, Jonathan; Karlsson, Anette M.; Raghavan, Seetha; Bartsch, Marion

    2015-07-01

    Advances in aircraft and land-based turbine engines have been increasing the extreme loading conditions on traditional engine components and have incited the need for improved performance with the use of protective coatings. These protective coatings shield the load-bearing super alloy blades from the high-temperature combustion gases by creating a thermal gradient over their thickness. This addition extends the life and performance of blades. A more complete understanding of the behavior, failure mechanics, and life expectancy for turbine blades and their coatings is needed to enhance and validate simulation models. As new thermal-barrier-coated materials and deposition methods are developed, strides to effectively test, evaluate, and prepare the technology for industry deployment are of paramount interest. Coupling the experience and expertise of researchers at the University of Central Florida, The German Aerospace Center, and Cleveland State University with the world-class synchrotron x-ray beam at the Advanced Photon Source in Argonne National Laboratory, the synergistic collaboration has yielded previously unseen measurements to look inside the coating layer system for in situ strain measurements during representative service loading. These findings quantify the in situ strain response on multilayer thermal barrier coatings and shed light on the elastic and nonelastic properties of the layers and the role of mechanical load and internal cooling variations on the response. The article discusses the experimental configuration and development of equipment to perform in situ strain measurements on multilayer thin coatings and provides an overview of the achievements thus far.

  14. Thermal barrier coating materials

    Directory of Open Access Journals (Sweden)

    David R. Clarke

    2005-06-01

    Full Text Available Improved thermal barrier coatings (TBCs will enable future gas turbines to operate at higher gas temperatures. Considerable effort is being invested, therefore, in identifying new materials with even better performance than the current industry standard, yttria-stabilized zirconia (YSZ. We review recent progress and suggest that an integrated strategy of experiment, intuitive arguments based on crystallography, and simulation may lead most rapidly to the development of new TBC materials.

  15. An investigation of enhanced capability thermal barrier coating systems for diesel engine components

    Science.gov (United States)

    Holtzman, R. L.; Layne, J. L.; Schechter, B.

    1984-01-01

    Material systems and processes for the development of effective and durable thermal barriers for heavy duty diesel engines were investigated. Seven coating systems were evaluated for thermal conductivity, erosion resistance, corrosion/oxidation resistance, and thermal shock resistance. An advanced coating system based on plasma sprayed particle yttria stabilized zirconia (PS/HYSZ) was judged superior in these tests. The measured thermal conductivity of the selected coating was 0.893 W/m C at 371 C. The PS/HYSZ coating system was applied to the piston crown, fire deck and valves of a single cylinder low heat rejection diesel engine. The coated engine components were tested for 24 hr at power levels from 0.83 MPa to 1.17 MPa brake mean effective pressure. The component coatings survived the engine tests with a minimum of distress. The measured fire deck temperatures decreased 86 C (155 F) on the intake side and 42 C (75 F) on the exhaust side with the coating applied.

  16. Creep Behavior of Hafnia and Ytterbium Silicate Environmental Barrier Coating Systems on SiC/SiC Ceramic Matrix Composites

    Science.gov (United States)

    Zhu, Dongming; Fox, Dennis S.; Ghosn, Louis J.; Harder, Bryan

    2011-01-01

    Environmental barrier coatings will play a crucial role in future advanced gas turbine engines because of their ability to significantly extend the temperature capability and stability of SiC/SiC ceramic matrix composite (CMC) engine components, thus improving the engine performance. In order to develop high performance, robust coating systems for engine components, appropriate test approaches simulating operating temperature gradient and stress environments for evaluating the critical coating properties must be established. In this paper, thermal gradient mechanical testing approaches for evaluating creep and fatigue behavior of environmental barrier coated SiC/SiC CMC systems will be described. The creep and fatigue behavior of Hafnia and ytterbium silicate environmental barrier coatings on SiC/SiC CMC systems will be reported in simulated environmental exposure conditions. The coating failure mechanisms will also be discussed under the heat flux and stress conditions.

  17. Advanced Oxide Material Systems for 1650 C Thermal/Environmental Barrier Coating Applications

    Science.gov (United States)

    Zhu, Dong-Ming; Fox, Dennis S.; Bansal, Narottam P.; Miller, Robert A.

    2004-01-01

    Advanced thermal and environmental barrier coatings (TEBCs) are being developed for low-emission SiC/SiC ceramic matrix composite (CMC) combustor and vane applications to extend the CMC liner and vane temperature capability to 1650 C (3000 F) in oxidizing and water-vapor-containing combustion environments. The advanced 1650 C TEBC system is required to have a better high-temperature stability, lower thermal conductivity, and more resistance to sintering and thermal stress than current coating systems under engine high-heat-flux and severe thermal cycling conditions. In this report, the thermal conductivity and water vapor stability of selected candidate hafnia-, pyrochlore- and magnetoplumbite-based TEBC materials are evaluated. The effects of dopants on the materials properties are also discussed. The test results have been used to downselect the TEBC materials and help demonstrate the feasibility of advanced 1650 C coatings with long-term thermal cycling durability.

  18. Blanch Resistant and Thermal Barrier NiAl Coating Systems for Advanced Copper Alloys

    Science.gov (United States)

    Raj, Sai V. (Inventor)

    2005-01-01

    A method of forming an environmental resistant thermal barrier coating on a copper alloy is disclosed. The steps include cleansing a surface of a copper alloy, depositing a bond coat on the cleansed surface of the copper alloy, depositing a NiAl top coat on the bond coat and consolidating the bond coat and the NiAl top coat to form the thermal barrier coating. The bond coat may be a nickel layer or a layer composed of at least one of copper and chromium-copper alloy and either the bond coat or the NiAl top coat or both may be deposited using a low pressure or vacuum plasma spray.

  19. Mechanisms governing the interfacial delamination of thermal barrier coating system with double ceramic layers

    Science.gov (United States)

    Xu, Rong; Fan, Xueling; Wang, T. J.

    2016-05-01

    A systematic study of factors affecting the interfacial delamination of thermal barrier coating system (TBCs) with double ceramic layers (DCL) is presented. Crack driving forces for delaminations at two weak interfaces are examined. The results show that a thicker outermost ceramic layer can induce dramatic increase in crack driving force and make the interface between two ceramic coatings become more prone to delamination. The behavior is shown to be more prominent in TBCs with stiffer outmost coating. The thickness ratio of two ceramic layers is an important parameter for controlling the failure mechanisms and determining the lifetime of DCL TBCs under inservice condition. By accounting for the influences of thickness ratio of two ceramic layers and interfacial fracture toughnesses of two involved interfaces, the fracture mechanism map of DCL TBCs has been constructed, in which different failure mechanisms are identified. The results quanlitatively agree with the aviliable experimental data.

  20. Residual stress analysis of the thermal barrier coating system by considering the plasma spraying process

    Energy Technology Data Exchange (ETDEWEB)

    Lee, Myung Jae; Lee, Byung Chai [KAIST, Daejeon (Korea, Republic of); Lim, Jang Gyun; Kim, Moon Ki [Sungkyunkwan University, Suwon (Korea, Republic of)

    2014-06-15

    The residual stress is the key factor causing the reliability problem of thermal barrier coating (TBC). The failure of plasma spray coatings due to residual stresses is a serious and recurring problem of TBC. The difference of thermal expansion coefficient between the substrate and each coating combined with temperature evolution and temperature gradients during deposition process determine the residual stress for the whole TBC system. The magnitudes and distributions of the residual stresses are affected by deposition process and deposition characteristics. Most of FEA (finite element analysis) has been performed under the assumption that the multilayer coating system is stacked at once without considering the deposition process during plasma spraying. In this research, FEA for a coupled heat transfer and elastic-plastic thermal stress was performed to obtain the more detailed and reliable result of residual stress of the TBC system using the element activation/deactivation technique. The residual stress variation from the start of plasma spraying to cooling stage with room temperature was obtained systematically considering the deposition process. It can be used as reference data to improve the performance of TBC. In addition, the relationship between residual stress and coating conditions such as cooling rate and time is also examined thoroughly.

  1. The Development of Environmental Barrier Coating Systems for SiC-SiC Ceramic Matrix Composites: Environment Effects on the Creep and Fatigue Resistance

    Science.gov (United States)

    Zhu, Dongming; Ghosn, Louis J.

    2014-01-01

    Topics covered include: Environmental barrier coating system development: needs, challenges and limitations; Advanced environmental barrier coating systems (EBCs) for CMC airfoils and combustors; NASA EBC systems and material system evolutions, Current turbine and combustor EBC coating emphases, Advanced development, processing, testing and modeling, EBC and EBC bond coats: recent advances; Design tool and life prediction of coated CMC components; Advanced CMC-EBC rig demonstrations; Summary and future directions.

  2. An overview on novel thermal barrier coatings

    Institute of Scientific and Technical Information of China (English)

    2005-01-01

    Thermal barrier coatings (TBCs) offer the potential to significantly improve efficiencies of aero engines as well as stationary gas turbines for power generation. On internally cooled turbine parts, temperature gradients of the order of 100-150℃ can be achieved. TBCs, typically consisting of an yttrium stabilized zirconia top coat and a metallic bond coat deposited onto a superalloy substrate, are mainly used to extend lifetime. Further efficiency improvements require TBCs being an integral part of the component which requires reliable and predictable TBC performance. TBCs produced by electron beam physical vapor deposition (EbPVD) or plasma spray (PS) deposition are favored for high performance applications. The paper highlights critical R&D needs for advanced TBC systems with a special focus on reduced thermal conductivity and life prediction needs. To further enhance the efficiency of gas turbines, higher temperature and a longer lifetime of the coating are needed for the next generation of TBCs. This paper presents the development of new materials, new deposition technologies, and new concept for application as novel TBCs. This paper summarizes the basic properties of conventional thermal barrier coatings. Based on our own investigation, we reviewed the progress on materials and technologies of novel thermal barrier coatings. Except yttria stabilized zirconia, other materials such as lanthanum zirconate and rare earth oxides are also promising materials for thermal barrier coatings. Nanostructure thermal barrier coating is presented as a new concept. This paper also summarizes the technologies for depositing the thermal barrier coatings.

  3. Functionally gradient materials for thermal barrier coatings in advanced gas turbine systems

    Energy Technology Data Exchange (ETDEWEB)

    Banovic, S.W.; Barmak, K.; Chan, H.M. [Lehigh Univ., Bethlehem, PA (United States)] [and others

    1995-10-01

    New designs for advanced gas turbine engines for power production are required to have higher operating temperatures in order to increase efficiency. However, elevated temperatures will increase the magnitude and severity of environmental degradation of critical turbine components (e.g. combustor parts, turbine blades, etc{hor_ellipsis}). To offset this problem, the usage of thermal barrier coatings (TBCs) has become popular by allowing an increase in maximum inlet temperatures for an operating engine. Although thermal barrier technology is over thirty years old, the principle failure mechanism is the spallation of the ceramic coating at or near the ceramic/bond coat interface. Therefore, it is desirable to develop a coating that combines the thermal barrier qualities of the ceramic layer and the corrosion protection by the metallic bond coat without the detrimental effects associated with the localization of the ceramic/metal interface to a single plane.

  4. Durability and CMAS Resistance of Advanced Environmental Barrier Coatings Systems for SiC/SiC Ceramic Matrix Composites

    Science.gov (United States)

    Zhu, Dongming

    2015-01-01

    Environmental barrier coatings (EBCs) and SiCSiC ceramic matrix composites (CMCs) systems will play a crucial role in next generation turbine engines for hot-section component applications because of their ability to significantly increase engine operating temperatures with improved efficiency, reduce engine weight and cooling requirements. This paper will emphasize advanced environmental barrier coating developments for SiCSiC turbine airfoil components, by using advanced coating compositions and processing, in conjunction with mechanical and environment testing and durability validations. The coating-CMC degradations and durability in the laboratory simulated engine fatigue-creep and complex operating environments are being addressed. The effects of Calcium-Magnesium-Alumino-Silicate (CMAS) from road sand or volcano-ash deposits on the degradation mechanisms of the environmental barrier coating systems will be discussed. The results help understand the advanced EBC-CMC system performance, aiming at the durability improvements of more robust, prime-reliant environmental barrier coatings for successful applications of the component technologies and lifing methodologies.

  5. DETERMINATION OF CREEP PROPERTIES OF THERMAL BARRIER COATING(TBC) SYSTEMS FROM THE INDENTATION CREEP TESTING WITH ROUND FLAT INDENTERS

    Institute of Scientific and Technical Information of China (English)

    B. Zhao; B.X. Xu; J. Liu; Z.F. Yue

    2004-01-01

    Indentation creep behavior with cylindrical flat indenters on the thermal barrier coating (TBC) was studied by finite element method (FEM). On the constant applied indentation creep stress, there is a steady creep rate for each case studied for different creep properties of the TBC system. The steady creep depth rate depends on the applied indentation creep stress and size of the indenters as well as the creep properties of the bond coat of the TBC and the substrate. The possibilities to determine the creep properties of a thermal barrier system from indention creep testing were discussed. As an example, with two different size indenters, the creep properties of bond coat of the TBC system can be derived by an inverse FEM method. This study not only provides a numerical method to obtain the creep properties of the TBC system, but also extends the application of indentation creep method with cylindrical flat indenters.

  6. Pratt & Whitney thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Bornstein, N. [United Technologies Research Center, East Hartford, CT (United States); Marcin, J. [Pratt & Whitney Aircraft Co., East Hartford, CT (United States)

    1995-10-01

    The objective of the Advanced Turbine Systems (ATS) Program is to develop ultra-high efficient, environmentally superior, and cost competitive gas turbine systems. The operating profiles of these industrial gas turbines are long, less cyclic with fewer transients-compared with those for aircraft gas turbine engines. Therefore, creep rather than thermal fatigue, becomes primary life-limiting for hot section components. Thermal barrier coatings (TBCs) will be used to achieve the objectives of the program. TBCs allow surface temperatures to increase without compromising the structural properties of the alloy. TBCs typically consist of a ceramic insulating layer, deposited onto the substrate with an intervening metallic layer, which imparts oxidation protection to the substrate and provides a surface to which the ceramic layer can adhere.

  7. Evaluation of Erosion Resistance of Advanced Turbine Thermal Barrier Coatings

    Science.gov (United States)

    Zhu, Dongming; Kuczmarski, Maria A.; Miller, Robert A.; Cuy, Michael D.

    2007-01-01

    The erosion resistant turbine thermal barrier coating system is critical to aircraft engine performance and durability. By demonstrating advanced turbine material testing capabilities, we will be able to facilitate the critical turbine coating and subcomponent development and help establish advanced erosion-resistant turbine airfoil thermal barrier coatings design tools. The objective of this work is to determine erosion resistance of advanced thermal barrier coating systems under simulated engine erosion and/or thermal gradient environments, validating advanced turbine airfoil thermal barrier coating systems based on nano-tetragonal phase toughening design approaches.

  8. Thermal/residual stress in an electron beam physical vapor deposited thermal barrier coating system

    Energy Technology Data Exchange (ETDEWEB)

    Cheng, J.; Jordan, E.H.; Barber, B.; Gell, M. [Univ. of Connecticut, Storrs, CT (United States)

    1998-10-09

    Elastic-plastic finite element models are used to define the thermal/residual stress state responsible for the observed failure behavior of an electron beam physical vapor deposited yttria stabilized zirconia thermal barrier coating on a Pt-Al bond coat. The failures were observed to start at grain boundary ridges, some of which evolved into oxide filled cavities. Finite element models are made of the actual interface geometries through the use of metallographic sectioning and imaging processing. There is a one to one correspondence of calculated tension in the oxide layer and the observed localized damage. Purely elastic analysis failed to show some important tensile regions associated with the observed failure.

  9. Residual Stresses in Thermal Barrier Coatings for a Cu-8Cr-4Nb Substrate System

    Science.gov (United States)

    Ghosn, Louis J.; Raj, Sai V.

    2002-01-01

    Analytical calculations were conducted to determine the thermal stresses developed in a coated copper-based alloy, Cu-8%(at.%)Cr-4%Nb (designated as GRCop-84), after plasma spraying and during heat-up in a simulated rocket engine environment. Finite element analyses were conducted for two coating systems consisting of a metallic top coat, a pure copper bond coat and the GRCop-84. The through thickness temperature variations were determined as a function of coating thickness for two metallic coatings, a Ni-17%(wt%)Cr-6%Al-0.5%Y alloy and a Ni-50%(at.%)Al alloy. The residual stresses after low-pressure plasma spraying of the NiCrAlY and NiAl coatings on GRCop-84 substrate were also evaluated. These analyses took into consideration a 50.8 mm copper bond coat and the effects of an interface coating roughness. The through the thickness thermal stresses developed in coated liners were also calculated after 15 minutes of exposure in a rocket environment with and without an interfacial roughness.

  10. Thermal barrier coatings for heat engine components

    Science.gov (United States)

    Levine, S. R.; Miller, R. A.; Hodge, P. E.

    1980-01-01

    A comprehensive NASA-Lewis program of coating development for aircraft gas turbine blades and vanes is presented. Improved ceramic layer compositions are investigated, along the MCrAlY bond films and the methods of uniform deposition of the coatings; the thermomechanical and fuel impurity tolerance limits of the coatings are being studied. Materials include the ZrO2-Y2O3/NiCrAlY system; the effects of the bond coat and zirconia composition on coating life and Mach 1 burner rig test results are discussed. It is concluded that Diesel engines can also utilize thermal barrier coatings; they have been used successfully on piston crowns and exhaust valves of shipboard engines to combat lower grade fuel combustion corrosion.

  11. Influence of Heat Treatment on the Bond Coat Cyclic Oxidation Behaviour in an Air-plasma-sprayed Thermal Barrier Coating System

    Institute of Scientific and Technical Information of China (English)

    W.R.Chen; X.Wu; B.R.Marple; P.C.Patnaik

    2004-01-01

    It is generally believed that a thermally grown oxide (TGO) layer of alumina provides enhanced protection to the metallic bond coat in thermal barrier coating (TBC) systems at elevated temperatures. However, in an air-plasma-sprayed (APS) TBC system with Co-32Ni-21Cr-8A1-0.5Y (wt%) bond coat, the TGO layer formed upon thermal exposure in air was predominantly chromia and spinels, which would not effectively protect the bond coat at above 1000℃. In addition, mixed oxides of chromia, spinel and nickel oxide formed heterogeneously between the ceramic coating and CoNiCrA1Y bond coat, which would promote crack initiation and lead to premature TBC failure. A heat treatment in a low-pressure condition was applied to the as-sprayed TBC system, with the aim to produce an alumina layer as well as reduce the amount of detrimental oxides. The influence of this low-pressure oxidation treatment (LPOT) on the bond coat cyclic oxidation behaviour of the TBC system was also investigated.

  12. Influence of Heat Treatment on the Bond Coat Cyclic Oxidation Behaviour in an Air-plasma-sprayed Thermal Barrier Coating System

    Institute of Scientific and Technical Information of China (English)

    W.R. Chen; X. Wu; B.R. Marple; P.C. Patnaik

    2004-01-01

    It is generally believed that a thermally grown oxide (TGO) layer of alumina provides enhanced protection to the metallic bond coat in thermal barrier coating (TBC) systems at elevated temperatures. However, in an air-plasma-sprayed (APS) TBC system with Co-32Ni-21Cr-8A1-0.5Y (wt%) bond coat, the TGO layer formed upon thermal exposure in air was predominantly chromia and spinels, which would not effectively protect the bond coat at above 1000℃. In addition,mixed oxides of chromia, spinel and nickel oxide formed heterogeneously between the ceramic coating and CoNiCrAlY bond coat, which would promote crack initiation and lead to premature TBC failure. A heat treatment in a low-pressure condition was applied to the as-sprayed TBC system, with the aim to produce an alumina layer as well as reduce the amount of detrimental oxides. The influence of this low-pressure oxidation treatment (LPOT) on the bond coat cyclic oxidation behaviour of the TBC system was also investigated.

  13. Simulation of residual stresses and their effects on thermal barrier coating systems using finite element method

    Science.gov (United States)

    Zhu, JianGuo; Chen, Wei; Xie, HuiMin

    2015-03-01

    Thermal barrier coating (TBC) systems are widely used in industrial gas-turbine engines. However, premature failures have impaired the use of TBCs and cut down their lifetime, which requires a better understanding of their failure mechanisms. In the present study, experimental studies of isothermal cycling are firstly carried out with the observation and estimation of microstructures. According to the experimental results, a finite element model is established for the analysis of stress perpendicular to the TBC/BC interface. Detailed residual stress distributions in TBC are obtained to reflect the influence of mechanical properties, oxidation, and interfacial roughness. The calculated results show that the maximum tensile stress concentration appears at the peak of TBC and continues to increase with thermal cycles. Because of the microstructural characteristics of plasma-sprayed TBCs, cracks initialize in tensile stress concentration (TSC) regions at the peaks of TBC and propagate along the TBC/BC interface resulting in the spallation of TBC. Also, the inclusion of creep is crucial to failure prediction and is more important than the inclusion of sintering in the simulation.

  14. Effect of Residual Stresses and Prediction of Possible Failure Mechanisms on Thermal Barrier Coating System by Finite Element Method

    Science.gov (United States)

    Ranjbar-Far, M.; Absi, J.; Mariaux, G.; Shahidi, S.

    2010-09-01

    This work is focused on the effect of the residual stresses resulting from the coating process and thermal cycling on the failure mechanisms within the thermal barrier coating (TBC) system. To reach this objective, we studied the effect of the substrate preheating and cooling rate on the coating process conditions. A new thermomechanical finite element model (FEM) considering a nonhomogeneous temperature distribution has been developed. In the results, we observed a critical stress corresponding to a low substrate temperature and high cooling rate during spraying of the top-coat material. Moreover, the analysis of the stress distribution after service shows that more critical stresses are obtained in the case where residual stresses are taken into account.

  15. New Generation Perovskite Thermal Barrier Coating Materials

    Science.gov (United States)

    Ma, W.; Jarligo, M. O.; Mack, D. E.; Pitzer, D.; Malzbender, J.; Vaßen, R.; Stöver, D.

    2008-12-01

    Advanced ceramic materials of perovskite structure have been developed for potential application in thermal barrier coating systems, in an effort to improve the properties of the pre-existing ones like yttria-stabilized zirconia. Yb2O3 and Gd2O3 doped strontium zirconate (SrZrO3) and barium magnesium tantalate (Ba(Mg1/3Ta2/3)O3) of the ABO3 and complex A(B'1/3B''2/3)O3 systems, respectively, have been synthesized using ball milling prior to solid state sintering. Thermal and mechanical investigations show desirable properties for high-temperature coating applications. On atmospheric plasma spraying, the newly developed thermal barrier coatings reveal promising thermal cycle lifetime up to 1350 °C.

  16. Development Status and Performance Comparisons of Environmental Barrier Coating Systems for SiCSiC Ceramic Matrix Composites

    Science.gov (United States)

    Zhu, Dongming; Harder, Bryan

    2016-01-01

    Environmental barrier coatings (EBC) and SiCSiC ceramic matrix composites (CMCs) will play a crucial role in future aircraft turbine engine systems, because of their ability to significantly increase engine operating temperatures, reduce engine weight and cooling requirements. This paper presents current NASA EBC-CMC development emphases including: the coating composition and processing improvements, laser high heat flux-thermal gradient thermo-mechanical fatigue - environmental testing methodology development, and property evaluations for next generation EBC-CMC systems. EBCs processed with various deposition techniques including Plasma Spray, Electron Beam - Physical Vapor Deposition, and Plasma Spray Physical Vapor Deposition (PS-PVD) will be particularly discussed. The testing results and demonstrations of advanced EBCs-CMCs in complex simulated engine thermal gradient cyclic fatigue, oxidizing-steam and CMAS environments will help provide insights into the coating development strategies to meet long-term engine component durability goals.

  17. Load rate dependence of the mechanical properties of thermal barrier coating systems

    Energy Technology Data Exchange (ETDEWEB)

    Zotov, Nikolay; Eggeler, Gunther [Institut fuer Werkstoffe, Ruhr Universitaet Bochum, 44780 Bochum (Germany); Bartsch, Marion [Institut fuer Werkstoff-Forschung, DLR Koeln, 51147 Koeln (Germany)

    2009-07-01

    Thermal barrier coatings (TBC), composed of yttrium-stabilized zirconia (YSZ) ceramic top coat (TC) and intermetallic NiCoCrAlY bond coat (BC) are commonly used as protective coatings of Ni-based high temperature gas engine components. Nanoindentation techniques are increasingly applied for determining the TBC mechanical properties on a nanometre scale. However, little is known about the load-rate dependence of the mechanical properties, which is important for better understanding of cyclic thermal fatigue experiments. Nanoindentations with different load rates omega were performed on polished cross-sections of TBC, deposited by EB-PVD on IN625 substrates (S), using a XP Nanoindenter (MTS) equipped with Berkovich diamond tip. The Young's modulus (E) of the TC is independent of omega, while E for the BC and the S decreases with omega. The hardness (H) of the TC and the BC increases, while H for the S decreases with omega. From the dependence of H on omega, creep power-law exponents c = 0.24(11) and c = 0.023(6) for the TC and the BC were determined. For all TBC components, a decrease with omega of the power-law exponents n and m, describing the loading and unloading nanoindentation curves, is observed.

  18. Residual Stresses Modeled in Thermal Barrier Coatings

    Science.gov (United States)

    Freborg, A. M.; Ferguson, B. L.; Petrus, G. J.; Brindley, W. J.

    1998-01-01

    Thermal barrier coating (TBC) applications continue to increase as the need for greater engine efficiency in aircraft and land-based gas turbines increases. However, durability and reliability issues limit the benefits that can be derived from TBC's. A thorough understanding of the mechanisms that cause TBC failure is a key to increasing, as well as predicting, TBC durability. Oxidation of the bond coat has been repeatedly identified as one of the major factors affecting the durability of the ceramic top coat during service. However, the mechanisms by which oxidation facilitates TBC failure are poorly understood and require further characterization. In addition, researchers have suspected that other bond coat and top coat factors might influence TBC thermal fatigue life, both separately and through interactions with the mechanism of oxidation. These other factors include the bond coat coefficient of thermal expansion, the bond coat roughness, and the creep behavior of both the ceramic and bond coat layers. Although it is difficult to design an experiment to examine these factors unambiguously, it is possible to design a computer modeling "experiment" to examine the action and interaction of these factors, as well as to determine failure drivers for TBC's. Previous computer models have examined some of these factors separately to determine their effect on coating residual stresses, but none have examined all the factors concurrently. The purpose of this research, which was performed at DCT, Inc., in contract with the NASA Lewis Research Center, was to develop an inclusive finite element model to characterize the effects of oxidation on the residual stresses within the TBC system during thermal cycling as well as to examine the interaction of oxidation with the other factors affecting TBC life. The plasma sprayed, two-layer thermal barrier coating that was modeled incorporated a superalloy substrate, a NiCrAlY bond coat, and a ZrO2-8 wt % Y2O3 ceramic top coat. We

  19. Advanced Thermal-Barrier Bond Coatings for Alloys

    Science.gov (United States)

    Secura, Stephen

    1987-01-01

    New and improved bond coatings developed for use in thermal-barrier systems on Ni, Co-, and Fe-base alloy substrates. Use of these new bond coatings, containing ytterbium instead of yttrium, significantly increased lives of resultant thermal-barrier systems. Uses include many load-bearing applications in high-temperature, hostile environments.

  20. Evaluation of hot corrosion behavior of thermal barrier coatings

    Science.gov (United States)

    Hodge, P. E.; Miller, R. A.; Gedwill, M. A.

    1980-01-01

    Calcium silicate and yttria stabilized zirconia/MCrAlY thermal barrier coating systems on air-cooled specimens were exposed to sodium plus vanadium doped Mach 0.3 combustion gases. Thermal barrier coating endurance was determined to be a strong inverse function of ceramic coating thickness. Coating system durability was increased through the use of higher Cr + Al NiCrAl and CoCrAlY bond coatings. Chemical and electron microprobe analyses supported the predictions of condensate compositions and the determination of their roles in causing spalling of the ceramic coatings.

  1. Thermal Barrier Coatings for Advanced Gas Turbine and Diesel Engines

    Science.gov (United States)

    Zhu, Dongming; Miller, Robert A.

    1999-01-01

    Ceramic thermal barrier coatings (TBCS) have been developed for advanced gas turbine and diesel engine applications to improve engine reliability and fuel efficiency. However, durability issues of these thermal barrier coatings under high temperature cyclic conditions are still of major concern. The coating failure depends not only on the coating, but also on the ceramic sintering/creep and bond coat oxidation under the operating conditions. Novel test approaches have been established to obtain critical thermomechanical and thermophysical properties of the coating systems under near-realistic transient and steady state temperature and stress gradients encountered in advanced engine systems. This paper presents detailed experimental and modeling results describing processes occurring in the ZrO2-Y2O3 thermal barrier coating systems, thus providing a framework for developing strategies to manage ceramic coating architecture, microstructure and properties.

  2. Advanced Low Conductivity Thermal Barrier Coatings: Performance and Future Directions

    Science.gov (United States)

    Zhu, Dongming; Miller, Robert A.

    2008-01-01

    Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. In this presentation, thermal barrier coating development considerations and performance will be emphasized. Advanced thermal barrier coatings have been developed using a multi-component defect clustering approach, and shown to have improved thermal stability and lower conductivity. The coating systems have been demonstrated for high temperature combustor applications. For thermal barrier coatings designed for turbine airfoil applications, further improved erosion and impact resistance are crucial for engine performance and durability. Erosion resistant thermal barrier coatings are being developed, with a current emphasis on the toughness improvements using a combined rare earth- and transition metal-oxide doping approach. The performance of the toughened thermal barrier coatings has been evaluated in burner rig and laser heat-flux rig simulated engine erosion and thermal gradient environments. The results have shown that the coating composition optimizations can effectively improve the erosion and impact resistance of the coating systems, while maintaining low thermal conductivity and cyclic durability. The erosion, impact and high heat-flux damage mechanisms of the thermal barrier coatings will also be described.

  3. Thermal barrier coatings application in diesel engines

    Energy Technology Data Exchange (ETDEWEB)

    Fairbanks, J.W.

    1995-10-01

    Commercial use of thermal barrier coatings in diesel engines began in the mid 70`s by Dr. Ingard Kvernes at the Central Institute for Industrial Research in Oslo, Norway. Dr. Kvernes attributed attack on diesel engine valves and piston crowns encountered in marine diesel engines in Norwegian ships as hot-corrosion attributed to a reduced quality of residual fuel. His solution was to coat these components to reduce metal temperature below the threshold of aggressive hot-corrosion and also provide protection. Roy Kamo introduced thermal barrier coatings in his `Adiabatic Diesel Engine` in the late 70`s. Kamo`s concept was to eliminate the engine block water cooling system and reduce heat losses. Roy reported significant performance improvements in his thermally insulated engine at the SAE Congress in 1982. Kamo`s work stimulates major programs with insulated engines, particularly in Europe. Most of the major diesel engine manufacturers conducted some level of test with insulated combustion chamber components. They initially ran into increased fuel consumption. The German engine consortium had Prof. Woschni of the Technical Institute in Munich. Woschni conducted testing with pistons with air gaps to provide the insulation effects. Woschni indicated the hot walls of the insulated engine created a major increase in heat transfer he refers to as `convection vive.` Woschni`s work was a major factor in the abrupt curtailment of insulated diesel engine work in continental Europe. Ricardo in the UK suggested that combustion should be reoptimized for the hot-wall effects of the insulated combustion chamber and showed under a narrow range of conditions fuel economy could be improved. The Department of Energy has supported thermal barrier coating development for diesel engine applications. In the Clean Diesel - 50 Percent Efficient (CD-50) engine for the year 2000, thermal barrier coatings will be used on piston crowns and possibly other components.

  4. Cold Sprayed Intermetallic Thermal Barrier Coatings

    Science.gov (United States)

    Leshchinsky, Evgeny

    Conventional thermal barrier coating (TBC) systems consist of a duplex structure with a metallic bond coat and a ceramic heat-isolative topcoat. Several recent research activities are concentrated on the development of improved multilayer bond coat and TBC materials. This study represents an investigation performed for the aluminum based bond coats, especially those with reduced thermal conductivities. Using alternative TBC materials, such as metal alloys and intermetallics, their processing methods can be further optimized to achieve the best thermal physical parameters. One example is the ten-layer system in which cold sprayed aluminum based intermetallics are synthesized. These systems demonstrated improved heat insulation and thermal fatigue capabilities compared to conventional TBC. The microstructures and properties of the laminar coatings were characterized by SEM, EDS, XRD; micromechanical and durability tests were performed to define the structure and coating formation mechanisms. Application prospects for HCCI engines are discussed. Fuel energy can be utilized more efficiently with the concept of low heat rejection engines with applied TBC.

  5. Thermal barrier coatings application in diesel engines

    Science.gov (United States)

    Fairbanks, J. W.

    1995-01-01

    Commercial use of thermal barrier coatings in diesel engines began in the mid 70's by Dr. Ingard Kvernes at the Central Institute for Industrial Research in Oslo, Norway. Dr. Kvernes attributed attack on diesel engine valves and piston crowns encountered in marine diesel engines in Norwegian ships as hot-corrosion attributed to a reduced quality of residual fuel. His solution was to coat these components to reduce metal temperature below the threshold of aggressive hot-corrosion and also provide protection. Roy Kamo introduced thermal barrier coatings in his 'Adiabatic Diesel Engine' in the late 70's. Kamo's concept was to eliminate the engine block water cooling system and reduce heat losses. Roy reported significant performance improvements in his thermally insulated engine at the SAE Congress in 1982. Kamo's work stimulates major programs with insulated engines, particularly in Europe. Most of the major diesel engine manufacturers conducted some level of test with insulated combustion chamber components. They initially ran into increased fuel consumption. The German engine consortium had Prof. Woschni of the Technical Institute in Munich. Woschni conducted testing with pistons with air gaps to provide the insulation effects. Woschni indicated the hot walls of the insulated engine created a major increase in heat transfer he refers to as 'convection vive.' Woschni's work was a major factor in the abrupt curtailment of insulated diesel engine work in continental Europe. Ricardo in the UK suggested that combustion should be reoptimized for the hot-wall effects of the insulated combustion chamber and showed under a narrow range of conditions fuel economy could be improved. The Department of Energy has supported thermal barrier coating development for diesel engine applications. In the Clean Diesel - 50 Percent Efficient (CD-50) engine for the year 2000, thermal barrier coatings will be used on piston crowns and possibly other components. The primary purpose of the

  6. Fracture mechanism of a thermal barrier coating

    Science.gov (United States)

    Samoilenko, V. M.; Ravilov, R. G.; Drevnyak, V. V.; Petrova, M. A.

    2016-06-01

    The fracture mechanism of the thermal barrier coating of gas turbine blades is studied. The causes of the fracture of the ceramic layer are discussed and the possible ways to increase the fatigue life of the thermal barrier coating are considered.

  7. Aircraft engine-mounted camera system for long wavelength infrared imaging of in-service thermal barrier coated turbine blades

    Science.gov (United States)

    Markham, James; Cosgrove, Joseph; Scire, James; Haldeman, Charles; Agoos, Ian

    2014-12-01

    This paper announces the implementation of a long wavelength infrared camera to obtain high-speed thermal images of an aircraft engine's in-service thermal barrier coated turbine blades. Long wavelength thermal images were captured of first-stage blades. The achieved temporal and spatial resolutions allowed for the identification of cooling-hole locations. The software and synchronization components of the system allowed for the selection of any blade on the turbine wheel, with tuning capability to image from leading edge to trailing edge. Its first application delivered calibrated thermal images as a function of turbine rotational speed at both steady state conditions and during engine transients. In advance of presenting these data for the purpose of understanding engine operation, this paper focuses on the components of the system, verification of high-speed synchronized operation, and the integration of the system with the commercial jet engine test bed.

  8. New generation perovskite thermal barrier coating materials

    Energy Technology Data Exchange (ETDEWEB)

    Ma, W.; Jarligo, M.O.; Mack, D.E.; Pitzer, D.; Malzbender, J.; Vassen, R.; Stoever, D. [Forschungszentrum Juelich GmbH, Juelich (Germany)

    2008-07-01

    Advanced ceramic materials of perovskite structure have been developed for potential application in thermal barrier coating systems, in an effort to improve the properties of the pre-existing ones like yttria stabilized zirconia. Yb{sub 2}O{sub 3} and Gd{sub 2}O{sub 3} doped strontium zirconate (SrZrO{sub 3}) and barium magnesium tantalate (Ba(Mg{sub 1/3}Ta{sub 2/3})O{sub 3}) of the ABO{sub 3} and complex A(B'{sub 1/3}B''{sub 2/3})O{sub 3} systems respectively, have been synthesized using ball milling prior to solid state sintering. Thermal and mechanical investigations show desirable properties for high temperature coating applications. On atmospheric plasma spraying, the newly developed TBCs reveal promising thermal cycle lifetime above 1300 C. (orig.)

  9. Microlaminate composites: An alternate approach to thermal barrier coatings

    Science.gov (United States)

    Bunshah, R. F.; Deshpandey, C. V.; Obrien, B. P.

    1985-01-01

    Ceramic thermal barrier coatings suffer from a major drawback, i.e., brittle behavior. An alternate approach is microlaminate composite coatings consisting of alternate layers of metal and oxide. As the thickness of the individual laminae decrease while keeping the total thickness of the coating constant, the thermal conductivity drops markedly. Data on the Fe-Cu system will be presented. A model is proposed for an MCrAlY-Al2O3 microlaminate coating for thermal barriers. The methods of fabrication will also be discussed.

  10. Controlled Thermal Expansion Coat for Thermal Barrier Coatings

    Science.gov (United States)

    Brindley, William J. (Inventor); Miller, Robert A. (Inventor); Aikin, Beverly J. M. (Inventor)

    1999-01-01

    A improved thermal barrier coating and method for producing and applying such is disclosed herein. The thermal barrier coating includes a high temperature substrate, a first bond coat layer applied to the substrate of MCrAlX, and a second bond coat layer of MCrAlX with particles of a particulate dispersed throughout the MCrAlX and the preferred particulate is Al2O3. The particles of the particulate dispersed throughout the second bond coat layer preferably have a diameter of less then the height of the peaks of the second bond coat layer, or a diameter of less than 5 microns. The method of producing the second bond coat layer may either include the steps of mechanical alloying of particles throughout the second bond coat layer, attrition milling the particles of the particulate throughout the second bond coat layer, or using electrophoresis to disperse the particles throughout the second bond coat layer. In the preferred embodiment of the invention, the first bond coat layer is applied to the substrate, and then the second bond coat layer is thermally sprayed onto the first bond coat layer. Further, in a preferred embodiment of die invention, a ceramic insulating layer covers the second bond coat layer.

  11. Composite layers for barrier coatings on polymers

    Science.gov (United States)

    Brochhagen, Markus; Vorkoetter, Christoph; Boeke, Marc; Benedikt, Jan

    2016-09-01

    Amorphous hydrogenated carbon (a-C:H), amorphous hydrogenated silicon (a-Si:H), and SiO2 thin films are of high interest because they can serve as a gas barrier on polymers. To understand how the coating changes the overall barrier properties of the thin film-polymer system, optical, mechanical, and barrier properties have to be studied. One of the important characteristic of such coatings is their compressive stress, which has beneficial as well as unwanted effects. The stress can cause deformation of the bulk material or de-lamination of the film. The mechanical stability can be improved and it is possible to reduce cracking due to elongation, as the compressive stress can compensate externally applied tensile strain. Stress and mechanical properties of composite layers can be manipulated directly by embedding nanoparticles in an amorphous matrix film. Therefore nanoparticles and amorphous layers are investigated before they can be assembled in a composite layer. Growth rates as well as optical and mechanical properties are explored in this work. An inductively coupled plasma source was used for all amorphous layers and the silicon nanoparticles with diameter around 5 nm were produced in a capacitively coupled plasma reactor. This work is supported by DFG within SFB-TR87.

  12. Influence of creep and cyclic oxidation in thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Seiler, Philipp; Baeker, Martin; Roesler, Joachim [Technische Univ. Braunschweig (Germany). Inst. fuer Werkstoffe

    2012-01-15

    The lifetime of thermal barrier coating systems is limited by cracks close to the interfaces, causing delamination. To study the failure mechanisms, a simplified model system is analysed which consists of a bond-coat bulk material, a thermally grown oxide, and an yttria-stabilised zirconia topcoat. The stresses in the model system are calculated using a finite element model which covers the simulation of full thermal cycles, creep in all layers, and the anisotropic oxidation during dwelling. Creep in the oxide and the thermal barrier coating is varied with the use of different creep parameter sets. The influence of creep in the bondcoat is analysed by using two different bond-coat materials: fast creeping Fecralloy and slow creeping oxide dispersion strengthened MA956. It is shown that creep in the bondcoat influences the lifetime of the coatings. Furthermore, a fast creeping thermally grown oxide benefits the lifetime of the coating system. (orig.)

  13. Yttria-stabilized zirkonia / gadolinium zirconate double-layer plasma-sprayed thermal barrier coating systems (TBCs)

    Energy Technology Data Exchange (ETDEWEB)

    Bakan, Emine

    2015-07-01

    Thermal barrier coating (TBC) research and development is driven by the desirability of further increasing the maximum inlet temperature in a gas turbine engine. A number of new top coat ceramic materials have been proposed during the last decades due to limited temperature capability (1200 C) of the state-of-the-art yttria-stabilized zirconia (7 wt. % Y{sub 2}O{sub 3}-ZrO{sub 2}, YSZ) at long term operation. Zirconate pyrochlores of the large lanthanides((Gd → La){sub 2}Zr{sub 2}O{sub 7}) have been particularly attractive due to their higher temperature phase stability than that of the YSZ. Nonetheless, the issues related with the implementation of pyrochlores such as low fracture toughness and formation of deleterious interphases with thermally grown oxide (TGO, Al{sub 2}O{sub 3}) were reported. The implication was the requirement of an interlayer between the pyrochlores and TGO, which introduced double-layer systems to the TBC literature. Furthermore, processability issues of pyrochlores associated with the different evaporation rates of lanthanide oxides and zirconia resulting in unfavorable composition variations in the coatings were addressed in different studies. After all, although the material properties are available, there is a paucity of data in the literature concerning the properties of the coatings made of pyrochlores. From the processability point of view the most reported pyrochlore is La{sub 2}Zr{sub 2}O{sub 7}. Hence, the goal of this research was to investigate plasma-sprayed Gd{sub 2}Zr{sub 2}O{sub 7} (GZO) coatings and YSZ/GZO double-layer TBC systems. Three main topics were examined based on processing, performance and properties: (i) the plasma spray processing of the GZO and its impact on the microstructural and compositional properties of the GZO coatings; (ii) the cycling lifetime of the YSZ/GZO double-layer systems under thermal gradient at a surface temperature of 1400 C; (iii) the properties of the GZO and YSZ coatings such as

  14. Nanostructured zirconia layers as thermal barrier coatings

    Directory of Open Access Journals (Sweden)

    Radu Robert PITICESCU

    2011-09-01

    Full Text Available The coatings obtained by thermal spray are used both as antioxidant and connection materials (e.g. MCrAlY type alloys as well as thermal barrier coatings (e.g. partially stabilized zirconia oxide with yttria oxide. This paper studies the characteristics of the coatings obtained with nanostructured powders by thermal spraying and air plasma jet metallization. Testing of coatings is done against the most disturbing factor, thermal shock. Structural changes occurring after thermal shock tests are highlighted by investigations of optical and electronic microscopy. The results obtained after quick thermal shock show a good morphological and surface behavior of the developed coatings.

  15. Effect of Y2O3 stabilized ZrO2 coating with tri-model structure on bi-layered thermally grown oxide evolution in nano thermal barrier coating systems at elevated temperatures

    Institute of Scientific and Technical Information of China (English)

    Mohammadreza Daroonparvar; Muhamad Azizi Mat Yajid; Noordin Mohd Yusof; Hamid Reza Bakhsheshi-Rad; Z Valefi; Esah Hamzah

    2014-01-01

    Bi-layered thermally grown oxide (TGO) layer plays a major role in the spallation of Y2O3 stabilized ZrO2 (YSZ) layer form the bond coat in the thermal barrier coating (TBC) systems during oxidation. On the other hand, bi-layered TGO formation and growth in the TBC systems with nanostructured YSZ have not been deeply investigated during cyclic oxidation. Hence, Inconel 738/NiCrAlY/normal YSZ and Inconel 738/NiCrAlY/nano YSZ systems were pre-oxidized at 1000 °C and then subjected to cyclic oxidation at 1150 °C. According to microstructural observations, nanostructured YSZ layer over the bond coat should have less mi-cro-cracks and pinholes, due to the compactness of the nanostructure and the presence of nano zones that resulted in lower O infiltration into the nanothermal barrier coating system, formation of thinner and nearly continuous mono-layered thermally grown oxide on the bond coat during pre-oxidation, lower spinels formation at the Al2O3/YSZ interface and finally, reduction of bi-layered thermally grown oxide thickness during cyclic oxidation. It was found that pre-heat treatment and particularly coating microstructure could influence microstructural evolution (bi-layered TGO thickness) and durability of thermal barrier coating systems during cyclic oxidation.

  16. Improved metallic and thermal barrier coatings

    Science.gov (United States)

    Stecura, S.

    1981-01-01

    Low thermal conductivity two layer ceramic coatings are efficient thermal barriers between cooled matallic components and high temperature combustion gases. Potential components are combustors, blades, and vanes in aircraft engines of power-generating turbines. Presence of two layer coatings greatly reduces temperature and coolant requirements.

  17. Improving thermal barrier coatings by laser remelting.

    Science.gov (United States)

    Múnez, C J; Gómez-García, J; Sevillano, F; Poza, P; Utrilla, M V

    2011-10-01

    Thermal barrier coatings are extensively used to protect metallic components in applications where the operating conditions include aggressive environment at high temperatures. These coatings are usually processed by thermal spraying techniques and the resulting microstructure includes thin and large splats, associated with the deposition of individual droplets, with porosity between splats. This porosity reduces the oxidation and corrosion resistance favouring the entrance of aggressive species during service. To overcome this limitation, the top coat could be modified by laser glazing reducing surface roughness and sealing open porosity. ZrO2(Y2O3) top coat and NiCrAlY bond coating were air plasma sprayed onto an Inconel 600 Ni base alloy. The top coat was laser remelted and a densified ceramic layer was induced in the top surface of the ceramic coating. This layer inhibited the ingress of aggressive species and delayed bond coat oxidation.

  18. Thermal Barrier Coatings on Copper Substrates for Rocket Applications

    Science.gov (United States)

    Schloesser, Jana; Fedorova, Tatiana; Bäker, Martin; Rösler, Joachim

    Currently a new generation of relaunchable space transportation system using liquid hydrogen/ liquid oxygen rocket engines is under development. The inner combustion chamber is exposed to extreme thermal loads and environmental attack during starts. To prevent failure of the cooling channels, a thermal barrier coating to provide thermal and oxidation protection could be applied. Thermal barrier coatings are state of the art for gas turbines and this concept should be transferred to copper substrates in rocket engine applications. The thermomechanical loading conditions are quite different from the gas turbine applications as heat fluxes and temperature gradients are much higher while overall service time is much shorter. As a start for optimization of a suitable coating, a material system known for gas turbines is employed. In this work a thermal barrier coating system is applied by atmospheric plasma spraying to the copper-based high strength alloy Cu-1%Cr-0.3%Zr. The bond coat consists of a NiCrAlY alloy, while partially stabilized zirconia is used as a top coat. Spraying parameter optimization for the new substrate is described. The reached coating system is tested in thermal cycling experiments, where no failure of the coating could be detected. In oxidation experiments good environmental protection of the coating is shown.

  19. Advanced Environmental Barrier Coatings Development for Si-Based Ceramics

    Science.gov (United States)

    Zhu, Dong-Ming; Choi, R. Sung; Robinson, Raymond C.; Lee, Kang N.; Bhatt, Ramakrishna T.; Miller, Robert A.

    2005-01-01

    Advanced environmental barrier coating concepts based on multi-component HfO2 (ZrO2) and modified mullite systems are developed for monolithic Si3N4 and SiC/SiC ceramic matrix composite (CMC) applications. Comprehensive testing approaches were established using the water vapor cyclic furnace, high pressure burner rig and laser heat flux steam rig to evaluate the coating water vapor stability, cyclic durability, radiation and erosion resistance under simulated engine environments. Test results demonstrated the feasibility and durability of the environmental barrier coating systems for 2700 to 3000 F monolithic Si3N4 and SiC/SiC CMC component applications. The high-temperature-capable environmental barrier coating systems are being further developed and optimized in collaboration with engine companies for advanced turbine engine applications.

  20. Bond strength and stress measurements in thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Gell, M.; Jordan, E. [Univ. of Connecticut, Storrs, CT (United States)

    1995-10-01

    Thermal barrier coatings have been used extensively in aircraft gas turbines for more than 15 years to insulate combustors and turbine vanes from the hot gas stream. Plasma sprayed thermal barrier coatings (TBCs) provide metal temperature reductions as much as 300{degrees}F, with improvements in durability of two times or more being achieved. The introduction of TBCs deposited by electron beam physical vapor deposition (EB-PVD) processes in the last five years has provided a major improvement in durability and also enabled TBCs to be applied to turbine blades for improved engine performance. To meet the aggressive Advanced Turbine Systems goals for efficiency, durability and the environment, it will be necessary to employ thermal barrier coatings on turbine airfoils and other hot section components. For The successful application of TBCs to ATS engines with 2600{degrees}F turbine inlet temperatures and required component lives 10 times greater than those for aircraft gas turbine engines, it is necessary to develop quantitative assessment techniques for TBC coating integrity with time and cycles in ATS engines. Thermal barrier coatings in production today consist of a metallic bond coat, such as an MCrAlY overlay coating or a platinum aluminide (Pt-Al) diffusion coating. During heat treatment, both these coatings form a thin, tightly adherent alumina (Al{sub 2}O{sub 3}) film. Failure of TBC coatings in engine service occurs by spallation of the ceramic coating at or near the bond coat to alumina or the alumina to zirconia bonds. Thus, it is the initial strength of these bonds and the stresses at the bond plane, and their changes with engine exposure, that determines coating durability. The purpose of this program is to provide, for the first time, a quantitative assessment of TBC bond strength and bond plane stresses as a function of engine time and cycles.

  1. Opportunities for functional oxides in yttrium oxide-titanium oxide-zirconium oxide system: Applications for novel thermal barrier coatings

    Science.gov (United States)

    Francillon, Wesley

    This dissertation is an investigation of materials and processed under consideration for next generation thermal structural oxides with potential applications as thermal barrier coatings; wherein, high temperature stability and mechanical properties affect durability. Two notable next generation materials systems under investigation are pyrochlore and co-doped zirconia oxides. The motivation for this work is based on current limitations of the currently used thermal barrier material of yttria stabilized zirconia (YSZ) deposited by the plasma spray processes. The rapid quenching associated with the plasma spray process, results in a metastable structure that is a non-transformable tetragonal structure in the yttria partially stabilized zirconia system rather than the equilibrium anticipated two phase mixture of cubic and monoclinic phases. It has been shown that this metastable structure offers enhanced toughness and thus durability during thermomechanical cycling from the operating temperatures in excess of 1000C to ambient. However, the metastable oxides are susceptible to partitioning at temperatures greater than 1200C, thus resulting in a transformation of the tetragonal phase oxides. Transformations of the tetragonal prime phase into the parent cubic and tetragonal prime phase result in coating degradation. Several of the emerging oxides are based on rare earth additions to zirconia. However, there is limited information of the high temperature stability of these oxide coatings and more notably these compositions exhibit limited toughness for durable performance. A potential ternary composition based on the YSZ system that offers the ability to tailor the phase structure is based YO1.5-TiO2 -ZrO2. The ternary of YO1.5-TiO2-ZrO 2 has the current TBC composition of seven molar percent yttria stabilized zirconia, pyrochlore phase oxide and zirconia doped with yttria and titania additions (Ti-YSZ). The Ti-YSZ phase field is of interest because at equilibrium it is

  2. Thermal barrier coatings application in diesel engines

    Energy Technology Data Exchange (ETDEWEB)

    Fairbanks, J.W.

    1995-03-01

    Commercial use of thermal barrier coatings in diesel engines began in the mid 70`s by Dr. Ingard Kvernes at the Central Institute for Industrial Research in Oslo, Norway. Dr. Kvernes attributed attack on diesel engine valves and piston crowns encountered in marine diesel engines in Norwegian ships as hot-corrosion attributed to a reduced quality of residual fuel. His solution was to coat these components to reduce metal temperature below the threshold of aggressive hot-corrosion and also to provide protection. The Department of Energy has supported thermal barrier coating development for diesel engine applications. In the Clean Diesel - 50 Percent Efficient (CD-50) engine for the year 2000, thermal barrier coatings will be used on piston crowns and possibly other components. The primary purpose of the thermal barrier coatings will be to reduce thermal fatigue as the engine peak cylinder pressure will nearly be doubled. As the coatings result in higher available energy in the exhaust gas, efficiency gains are achieved through use of this energy by turbochargers, turbocompounding or thermoelectric generators.

  3. Thermal Residual Stress in Environmental Barrier Coated Silicon Nitride - Modeled

    Science.gov (United States)

    Ali, Abdul-Aziz; Bhatt, Ramakrishna T.

    2009-01-01

    When exposed to combustion environments containing moisture both un-reinforced and fiber reinforced silicon based ceramic materials tend to undergo surface recession. To avoid surface recession environmental barrier coating systems are required. However, due to differences in the elastic and thermal properties of the substrate and the environmental barrier coating, thermal residual stresses can be generated in the coated substrate. Depending on their magnitude and nature thermal residual stresses can have significant influence on the strength and fracture behavior of coated substrates. To determine the maximum residual stresses developed during deposition of the coatings, a finite element model (FEM) was developed. Using this model, the thermal residual stresses were predicted in silicon nitride substrates coated with three environmental coating systems namely barium strontium aluminum silicate (BSAS), rare earth mono silicate (REMS) and earth mono di-silicate (REDS). A parametric study was also conducted to determine the influence of coating layer thickness and material parameters on thermal residual stress. Results indicate that z-direction stresses in all three systems are small and negligible, but maximum in-plane stresses can be significant depending on the composition of the constituent layer and the distance from the substrate. The BSAS and REDS systems show much lower thermal residual stresses than REMS system. Parametric analysis indicates that in each system, the thermal residual stresses can be decreased with decreasing the modulus and thickness of the coating.

  4. Vibration Analysis of Commercial Thermal Barrier Coatings

    Science.gov (United States)

    2008-06-01

    different thermal barrier coatings, magnesium aluminate spinel and yttria stabilized zirconia; the confirmation that sweep rate does not cause data...coatings which have been extensively researched are discussed in this study: magnesium aluminate spinel (Blackwell, 2004; Ivancic, 2003; Reed, 2007...Reed, 2007). Objective In this study, the elastic modulus and loss factor will be evaluated for magnesium aluminate spinel with a NiCrAlY bond

  5. The Lattice and Thermal Radiation Conductivity of Thermal Barrier Coatings

    Science.gov (United States)

    Zhu, Dongming; Spuckler, Charles M.

    2008-01-01

    The lattice and radiation conductivity of thermal barrier coatings was evaluated using a laser heat flux approach. A diffusion model has been established to correlate the apparent thermal conductivity of the coating to the lattice and radiation conductivity. The radiation conductivity component can be expressed as a function of temperature and the scattering and absorption properties of the coating material. High temperature scattering and absorption of the coating systems can also be derived based on the testing results using the modeling approach. The model prediction is found to have good agreement with experimental observations.

  6. Barrier Coatings for Refractory Metals and Superalloys

    Energy Technology Data Exchange (ETDEWEB)

    SM Sabol; BT Randall; JD Edington; CJ Larkin; BJ Close

    2006-02-23

    In the closed working fluid loop of the proposed Prometheus space nuclear power plant (SNPP), there is the potential for reaction of core and plant structural materials with gas phase impurities and gas phase transport of interstitial elements between superalloy and refractory metal alloy components during service. Primary concerns are surface oxidation, interstitial embrittlement of refractory metals and decarburization of superalloys. In parallel with kinetic investigations, this letter evaluates the ability of potential coatings to prevent or impede communication between reactor and plant components. Key coating requirements are identified and current technology coating materials are reviewed relative to these requirements. Candidate coatings are identified for future evaluation based on current knowledge of design parameters and anticipated environment. Coatings were identified for superalloys and refractory metals to provide diffusion barriers to interstitial transport and act as reactive barriers to potential oxidation. Due to their high stability at low oxygen potential, alumina formers are most promising for oxidation protection given the anticipated coolant gas chemistry. A sublayer of iridium is recommended to provide inherent diffusion resistance to interstitials. Based on specific base metal selection, a thin film substrate--coating interdiffusion barrier layer may be necessary to meet mission life.

  7. Performance Evaluation and Modeling of Erosion Resistant Turbine Engine Thermal Barrier Coatings

    Science.gov (United States)

    Miller, Robert A.; Zhu, Dongming; Kuczmarski, Maria

    2008-01-01

    The erosion resistant turbine thermal barrier coating system is critical to the rotorcraft engine performance and durability. The objective of this work was to determine erosion resistance of advanced thermal barrier coating systems under simulated engine erosion and thermal gradient environments, thus validating a new thermal barrier coating turbine blade technology for future rotorcraft applications. A high velocity burner rig based erosion test approach was established and a new series of rare earth oxide- and TiO2/Ta2O5- alloyed, ZrO2-based low conductivity thermal barrier coatings were designed and processed. The low conductivity thermal barrier coating systems demonstrated significant improvements in the erosion resistance. A comprehensive model based on accumulated strain damage low cycle fatigue is formulated for blade erosion life prediction. The work is currently aiming at the simulated engine erosion testing of advanced thermal barrier coated turbine blades to establish and validate the coating life prediction models.

  8. Embedded Optical Sensors for Thermal Barrier Coatings

    Energy Technology Data Exchange (ETDEWEB)

    David R. Clarke

    2005-11-09

    In the second year of this program on developing embedded optical sensors for thermal barrier coatings, our research has focused three topics: (1) Eu{sup 3+} doping for temperature sensing, (2) the effect of long-term, high-temperature aging on the characteristics of the luminescence from the Eu{sup 3+} ions of 8YSZ materials, (3) construction of a fiber-optic based luminescence detector system. It has been demonstrated that the variation in luminescence lifetime with temperature is identical for electron-beam evaporated Eu-doped YSZ coatings as for bulk ceramics of the same composition. Experiments indicate that the luminescence lifetime method of measuring temperatures is sensitive up to 1150 C for both Eu-doped YSZ coatings and Eu-doped Gd{sub 2}Zr{sub 2}O{sub 7}. Furthermore, the technique is sensitive up to 1250 C for the composition Eu{sub 2}Zr{sub 2}O{sub 7}. The luminescence spectra Eu-doped YSZ are insensitive to long-term aging at high-temperatures, even to 195 hours at 1425 C, except for a small frequency shift that is probably too small in measure except with instruments of the highest spectral resolution. The temperature of 1425 C is much higher than present engines attain or even planned in the foreseeable future. Nevertheless, experiments are on-going to explore longer term exposures. A fiber-optic based luminescence system has been constructed in which the hottest section of fiber operates to at least 1250 C.

  9. Lifetime Modeling of Thermal Barrier Coatings

    NARCIS (Netherlands)

    Hille, T.S.

    2009-01-01

    Thermal barrier coatings (TBCs) are applied in gas turbines to enhance their thermal efficiency by isolating the metallic components from the aggressive hot gas. TBC lifetime is limited by damage processes originating at internal interfaces, which may ultimately lead to delamination and spallation.

  10. Superior Thermal Barrier Coatings Using Solution Precursor Plasma Spray

    Science.gov (United States)

    Jordan, E. H.; Xie, L.; Gell, M.; Padture, N. P.; Cetegen, B.; Ozturk, A.; Ma, X.; Roth, J.; Xiao, T. D.; Bryant, P. E. C.

    2004-03-01

    A novel process, solution precursor plasma spray (SPPS), is presented for depositing thermal barrier coatings (TBCs), in which aqueous chemical precursors are injected into a standard direct current plasma spray system. The resulting coatings microstructure has three unique features: (1) ultra fine splats (1 µm), (2) nanometer and micron-sized interconnected porosity, and (3) closely spaced, through-thickness cracks. Coatings over 3 mm thick can be readily deposited using the SPPS process. Coating durability is excellent, with SPPS coatings showing, in furnace cycling tests, 2.5 times the spallation life of air plasma coatings (APS) and 1.5 times the life of electron beam physical vapor deposited (EB-PVD) coatings. The conductivity of SPPS coatings is lower than EB-PVD coatings and higher than the best APS coatings. Manufacturing cost is expected to be similar to APS coatings and much lower than EB-PVD coatings. The SPPS deposition process includes droplet break-up and material arriving at the deposition surface in various physical states ranging from aqueous solution, gel phase, to fully-molten ceramic. The relation between the arrival state of the material and the microstructure is described.

  11. Delamination-Indicating Thermal Barrier Coatings

    Science.gov (United States)

    Eldridge, Jeffrey I.

    2007-01-01

    The risk of premature failure of thermal barrier coatings (TBCs), typically composed of yttria-stabilized zirconia (YSZ), compromises the reliability of TBCs used to provide thermal protection for turbine engine components. Unfortunately, TBC delamination proceeds well beneath the TBC surface and cannot be monitored by visible inspection. Nondestructive diagnostic tools that could reliably probe the subsurface damage state of TBCs would alleviate the risk of TBC premature failure by indicating when the TBC needs to be replaced before the level of TBC damage threatens engine performance or safety. To meet this need, a new coating design for thermal barrier coatings (TBCs) that are self-indicating for delamination has been successfully implemented by incorporating a europium-doped luminescent sublayer at the base of a TBC composed of YSZ. The luminescent sublayer has the same YSZ composition as the rest of the TBC except for the addition of low-level europium doping and therefore does not alter TBC performance.

  12. Effect of thermal barrier coatings on the performance of steam and water-cooled gas turbine/steam turbine combined cycle system

    Science.gov (United States)

    Nainiger, J. J.

    1978-01-01

    An analytical study was made of the performance of air, steam, and water-cooled gas-turbine/steam turbine combined-cycle systems with and without thermal-barrier coatings. For steam cooling, thermal barrier coatings permit an increase in the turbine inlet temperature from 1205 C (2200 F), resulting in an efficiency improvement of 1.9 percentage points. The maximum specific power improvement with thermal barriers is 32.4 percent, when the turbine inlet temperature is increased from 1425 C (2600 F) to 1675 C (3050 F) and the airfoil temperature is kept the same. For water cooling, the maximum efficiency improvement is 2.2 percentage points at a turbine inlet temperature of 1683 C (3062 F) and the maximum specific power improvement is 36.6 percent by increasing the turbine inlet temperature from 1425 C (2600 F) to 1730 C (3150 F) and keeping the airfoil temperatures the same. These improvements are greater than that obtained with combined cycles using air cooling at a turbine inlet temperature of 1205 C (2200 F). The large temperature differences across the thermal barriers at these high temperatures, however, indicate that thermal stresses may present obstacles to the use of coatings at high turbine inlet temperatures.

  13. TECHNOLOGICAL PECULIARITIES OF THERMAL BARRIER COATINGS BASED ON ZIRCONIUM DIOXIDE

    Directory of Open Access Journals (Sweden)

    V. V. Okovity

    2016-01-01

    Full Text Available A technology for formation of thermal barrier coatings (TBC based on zirconium dioxide has been developed in the paper. The paper investigates structures of phase composition and thermal stability of such developed coatings. Investigation results pertaining to formation of an oxide system ZrO2 – Y2O3, while using plasma spraying and subsequent high-energy processing, which allows to increase resistance of a thermal barrier coating to thermal cycling heat resistance of the coating at temperature of 1100 °C. This leads to longer protection of bottom layer against high-temperature exposure. The methodology is based on complex metallographic, X-ray diffraction and electron microscopy investigations of structural elements in composite plasma coatings of the ZrO2 – Y2O system. Resistance of plasma coatings (Мe – Cr – Al – Y/ZrO2 – Y2O3-type, used as TBC to protect gas turbine engine blades under conditions of frequent thermal cyclings is limited by cleavage of an outer ceramic layer. Structural and electron microprobe investigations have shown that as a result of thermal cycling an outer atmosphere due to porous structure of the ceramic coating layer, migrates to the surface of lower metal coating, causing its oxidation. As a result, the metal-ceramic Al2O3 layer is formed at a metal-ceramic interface and it changes a stress state of the coating that causes a reduction of protective properties. Thus, a high heat resistance of thermal barrier coatings depends on processes occurring at the interface between metal and ceramic coating layers. A laser impact on samples with TBC leads to changes in the structure of the oxide layer of ZrO2 – Y2O3. In this case its initial surface characterized by considerable relief is significantly flattened due to processing and the coating is fractured and it is separated in fragments. As the oxide coating has low thermal conductivity, and the time of laser exposure is about 10–3 sec, a heat flux

  14. A Theoretical Model for Predicting Residual Stress Generation in Fabrication Process of Double-Ceramic-Layer Thermal Barrier Coating System

    Science.gov (United States)

    Song, Yan; Wu, Weijie; Xie, Feng; Liu, Yilun; Wang, Tiejun

    2017-01-01

    Residual stress arisen in fabrication process of Double-Ceramic-Layer Thermal Barrier Coating System (DCL-TBCs) has a significant effect on its quality and reliability. In this work, based on the practical fabrication process of DCL-TBCs and the force and moment equilibrium, a theoretical model was proposed at first to predict residual stress generation in its fabrication process, in which the temperature dependent material properties of DCL-TBCs were incorporated. Then, a Finite Element method (FEM) has been carried out to verify our theoretical model. Afterwards, some important geometric parameters for DCL-TBCs, such as the thickness ratio of stabilized Zirconia (YSZ, ZrO2-8%Y2O3) layer to Lanthanum Zirconate (LZ, La2Zr2O7) layer, which is adjustable in a wide range in the fabrication process, have a remarkable effect on its performance, therefore, the effect of this thickness ratio on residual stress generation in the fabrication process of DCL-TBCs has been systematically studied. In addition, some thermal spray treatment, such as the pre-heating treatment, its effect on residual stress generation has also been studied in this work. It is found that, the final residual stress mainly comes from the cooling down process in the fabrication of DCL-TBCs. Increasing the pre-heating temperature can obviously decrease the magnitude of residual stresses in LZ layer, YSZ layer and substrate. With the increase of the thickness ratio of YSZ layer to LZ layer, magnitudes of residual stresses arisen in LZ layer and YSZ layer will increase while residual stress in substrate will decrease. PMID:28103275

  15. A Theoretical Model for Predicting Residual Stress Generation in Fabrication Process of Double-Ceramic-Layer Thermal Barrier Coating System.

    Science.gov (United States)

    Song, Yan; Wu, Weijie; Xie, Feng; Liu, Yilun; Wang, Tiejun

    2017-01-01

    Residual stress arisen in fabrication process of Double-Ceramic-Layer Thermal Barrier Coating System (DCL-TBCs) has a significant effect on its quality and reliability. In this work, based on the practical fabrication process of DCL-TBCs and the force and moment equilibrium, a theoretical model was proposed at first to predict residual stress generation in its fabrication process, in which the temperature dependent material properties of DCL-TBCs were incorporated. Then, a Finite Element method (FEM) has been carried out to verify our theoretical model. Afterwards, some important geometric parameters for DCL-TBCs, such as the thickness ratio of stabilized Zirconia (YSZ, ZrO2-8%Y2O3) layer to Lanthanum Zirconate (LZ, La2Zr2O7) layer, which is adjustable in a wide range in the fabrication process, have a remarkable effect on its performance, therefore, the effect of this thickness ratio on residual stress generation in the fabrication process of DCL-TBCs has been systematically studied. In addition, some thermal spray treatment, such as the pre-heating treatment, its effect on residual stress generation has also been studied in this work. It is found that, the final residual stress mainly comes from the cooling down process in the fabrication of DCL-TBCs. Increasing the pre-heating temperature can obviously decrease the magnitude of residual stresses in LZ layer, YSZ layer and substrate. With the increase of the thickness ratio of YSZ layer to LZ layer, magnitudes of residual stresses arisen in LZ layer and YSZ layer will increase while residual stress in substrate will decrease.

  16. Low VOC Barrier Coating for Industrial Maintenance

    Science.gov (United States)

    2012-09-01

    Technology Certification Program HAP Hazardous Air Pollutant HW hazardous waste LVBC low VOC barrier coating MEK methyl ethyl ketone MIL-DTL...peeling, blistering , tape adhesion, pull-off adhesion, film thickness, and LVBC/ZVT patch test adhesion testing in an acceptable or better manner...significant reductions in the amount of hazardous waste generated by the Navy. The ZVT technology contains less than 5 g/l of VOC and the resulting

  17. The Development of Erosion and Impact Resistant Turbine Airfoil Thermal Barrier Coatings

    Science.gov (United States)

    Zhu, Dongming; Miller, Robert A.

    2007-01-01

    Thermal barrier coatings are used in gas turbine engines to protect engine hot-section components in the harsh combustion environments and extend component lifetimes. For thermal barrier coatings designed for turbine airfoil applications, further improved erosion and impact resistance are crucial for engine performance and durability. Advanced erosion resistant thermal barrier coatings are being developed, with a current emphasis on the toughness improvements using a combined rare earth- and transition metal-oxide doping approach. The performance of the doped thermal barrier coatings has been evaluated in burner rig and laser heat-flux rig simulated engine erosion and thermal gradient environments. The results have shown that the coating composition optimizations can effectively improve the erosion and impact resistance of the coating systems, while maintaining low thermal conductivity and cyclic durability. The erosion and impact damage mechanisms of the thermal barrier coatings will also be discussed.

  18. Therma1 Conductivity and Durability of Advanced Thermal Barrier Coatings

    Science.gov (United States)

    Zhu, Dong-Ming; Miller, Robert A.

    2003-01-01

    Thermal barrier coatings (TBCs) will play a crucial role in advanced gas turbine engines because of their ability to further increase engine operating temperature and reduce cooling, thus helping to achieve engine emission and efficiency goals. Future TBCs must be designed with increased phase stability, lower thermal conductivity, and improved sintering and thermal stress resistance in order to effectively protect engine hot-section components. Advanced low conductivity TBCs are being developed at NASA by incorporating multi-component oxide dopants into zirconia-yttria or hafnia-yttria to promote the formation of thermodynamically stable defect clusters within the coating structures. This presentation will primarily focus on thermal conductivity and durability of the novel defect cluster thermal barrier coatings for turbine airfoil and combustor applications, determined by a unique CO2 laser heat-flux approach. The laser heat-flux testing approach emphasizes the real-time monitoring and assessment of the coating thermal conductivity under simulated engine temperature and thermal gradient conditions. The conductivity increase due to coating sintering (and/or phase change) and the conductivity decrease due to coating delamination have been determined under steady-state, cyclic, uniform or non-uniform heat-flux conditions. The coating radiation flux resistance has been evaluated by varying coating thermal gradients, and also by using a laser-heated radiative-flux source. Advanced multi-component TBC systems have been shown to have significantly reduced thermal conductivity and improved high temperature stability due to the nano-sized, low mobility defect clusters associated with the paired rare earth dopant additions. The effect of oxide defect cluster dopants on coating thermal conductivity, thermal stability and furnace cyclic durability will also be discussed. The current low conductivity TBC systems have demonstrated long-term cyclic durability at very high

  19. Creep, Fatigue and Fracture Behavior of Environmental Barrier Coating and SiC-SiC Ceramic Matrix Composite Systems: The Role of Environment Effects

    Science.gov (United States)

    Zhu, Dongming; Ghosn, Louis J.

    2015-01-01

    Advanced environmental barrier coating (EBC) systems for low emission SiCSiC CMC combustors and turbine airfoils have been developed to meet next generation engine emission and performance goals. This presentation will highlight the developments of NASAs current EBC system technologies for SiC-SiC ceramic matrix composite combustors and turbine airfoils, their performance evaluation and modeling progress towards improving the engine SiCSiC component temperature capability and long-term durability. Our emphasis has also been placed on the fundamental aspects of the EBC-CMC creep and fatigue behaviors, and their interactions with turbine engine oxidizing and moisture environments. The EBC-CMC environmental degradation and failure modes, under various simulated engine testing environments, in particular involving high heat flux, high pressure, high velocity combustion conditions, will be discussed aiming at quantifying the protective coating functions, performance and durability, and in conjunction with damage mechanics and fracture mechanics approaches.

  20. EMBEDDED OPTICAL SENSORS FOR THERMAL BARRIER COATINGS

    Energy Technology Data Exchange (ETDEWEB)

    David R. Clarke

    2004-12-16

    In this first year of the program we have focused on the selection of rare-earth dopants for luminescent sensing in thermal barrier coating materials, the effect of dopant concentration on several of the luminescence characteristics and initial fabrication of one type of embedded sensor, the ''red-line'' sensor. We have initially focused on erbium as the lanthanide dopant for luminescence doping of yttria-stabilized zirconia and europium as the lanthanide for luminescence doping of gadolinium zirconate. The latter exhibits a temperature-dependent luminescence lifetime up to at least 1100 C. A buried layer, ''red-line'' sensor in an electron-beam deposited yttria-stabilized zirconia coating with erbium has been demonstrated and exhibits a temperature-dependent luminescence lifetime up to at least 400 C.

  1. Development and Life Prediction of Erosion Resistant Turbine Low Conductivity Thermal Barrier Coatings

    Science.gov (United States)

    Zhu, Dongming; Miller, Robert A.; Kuczmarski, Maria A.

    2010-01-01

    Future rotorcraft propulsion systems are required to operate under highly-loaded conditions and in harsh sand erosion environments, thereby imposing significant material design and durability issues. The incorporation of advanced thermal barrier coatings (TBC) in high pressure turbine systems enables engine designs with higher inlet temperatures, thus improving the engine efficiency, power density and reliability. The impact and erosion resistance of turbine thermal barrier coating systems are crucial to the turbine coating technology application, because a robust turbine blade TBC system is a prerequisite for fully utilizing the potential coating technology benefit in the rotorcraft propulsion. This paper describes the turbine blade TBC development in addressing the coating impact and erosion resistance. Advanced thermal barrier coating systems with improved performance have also been validated in laboratory simulated engine erosion and/or thermal gradient environments. A preliminary life prediction modeling approach to emphasize the turbine blade coating erosion is also presented.

  2. Advanced Low Conductivity Thermal Barrier Coatings: Performance and Future Directions (Invited paper)

    Science.gov (United States)

    Zhu, Dongming; Miller, Robert A.

    2008-01-01

    Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. In this presentation, thermal barrier coating development considerations and performance will be emphasized. Advanced thermal barrier coatings have been developed using a multi-component defect clustering approach, and shown to have improved thermal stability and lower conductivity. The coating systems have been demonstrated for high temperature combustor applications. For thermal barrier coatings designed for turbine airfoil applications, further improved erosion and impact resistance are crucial for engine performance and durability. Erosion resistant thermal barrier coatings are being developed, with a current emphasis on the toughness improvements using a combined rare earth- and transition metal-oxide doping approach. The performance of the toughened thermal barrier coatings has been evaluated in burner rig and laser heat-flux rig simulated engine erosion and thermal gradient environments. The results have shown that the coating composition optimizations can effectively improve the erosion and impact resistance of the coating systems, while maintaining low thermal conductivity and cyclic durability. The erosion, impact and high heat-flux damage mechanisms of the thermal barrier coatings will also be described.

  3. Effect of an Opaque Reflecting Layer on the Thermal Behavior of a Thermal Barrier Coating

    Science.gov (United States)

    Spuckler, Charles M.

    2007-01-01

    A parametric study using a two-flux approximation of the radiative transfer equation was performed to examine the effects of an opaque reflective layer on the thermal behavior of a typical semitransparent thermal barrier coating on an opaque substrate. Some ceramic materials are semitransparent in the wavelength ranges where thermal radiation is important. Even with an opaque layer on each side of the semitransparent thermal barrier coating, scattering and absorption can have an effect on the heat transfer. In this work, a thermal barrier coating that is semitransparent up to a wavelength of 5 micrometers is considered. Above 5 micrometers wavelength, the thermal barrier coating is opaque. The absorption and scattering coefficient of the thermal barrier was varied. The thermal behavior of the thermal barrier coating with an opaque reflective layer is compared to a thermal barrier coating without the reflective layer. For a thicker thermal barrier coating with lower convective loading, which would be typical of a combustor liner, a reflective layer can significantly decrease the temperature in the thermal barrier coating and substrate if the scattering is weak or moderate and for strong scattering if the absorption is large. The layer without the reflective coating can be about as effective as the layer with the reflective coating if the absorption is small and the scattering strong. For low absorption, some temperatures in the thermal barrier coating system can be slightly higher with the reflective layer. For a thin thermal barrier coating with high convective loading, which would be typical of a blade or vane that sees the hot sections of the combustor, the reflective layer is not as effective. The reflective layer reduces the surface temperature of the reflective layer for all conditions considered. For weak and moderate scattering, the temperature of the TBC-substrate interface is reduced but for strong scattering, the temperature of the substrate is increased

  4. Wavelet analysis of acoustic emission signals from thermal barrier coatings

    Institute of Scientific and Technical Information of China (English)

    YANG Li; ZHOU Yi-chun

    2006-01-01

    The wavelet transform is applied to the analysis of acoustic emission signals collected during tensile test of the ZrO2-8% Y2O3 (YSZ) thermal barrier coatings (TBCs). The acoustic emission signals are de-noised using the Daubechies discrete wavelets,and then decomposed into different wavelet levels using the programs developed by the authors. Each level is examined for its specific frequency range. The ratio of energy in different levels to the total energy gives information on the failure modes (coating micro-failures and substrate micro-failures) associated with TBCs system.

  5. Thermochemistry of CaO-MgO-Al2O3-SiO2 (CMAS) and Advanced Thermal and Environmental Barrier Coating Systems

    Science.gov (United States)

    Costa, Gustavo C. C.; Zhu, Dongming

    2016-01-01

    CaO-MgO-Al2O3-SiO2 (CMAS) oxides are constituents in a broad number of materials and minerals which have recently inferred to discussions in materials science, planetary science, geochemistry and cosmochemistry communities. In materials science, there is increasing interest in the degradation studies of thermal (TBC) and environmental (EBC) barrier coatings of gas turbines by molten CMAS. These coatings have been explored to be applied on silicon-based ceramics and composites which are lighter and more temperature capable hot-section materials of gas turbines than the current Ni-based superalloys. The degradation of the coatings occurs when CMAS minerals carried by the intake air into gas turbines, e.g. in aircraft engines, reacts at high temperatures (1000C) with the coating materials. This causes premature failure of the static and rotating components of the turbine engines. We discuss some preliminary results of the reactions between CMAS and Rare-Earth (RE Y, Yb and Gd) oxide stabilized ZrO2 systems, and stability of the resulting oxides and silicates.

  6. Novel hybrid polymeric materials for barrier coatings

    Science.gov (United States)

    Pavlacky, Erin Christine

    Polymer-clay nanocomposites, described as the inclusion of nanometer-sized layered silicates into polymeric materials, have been widely researched due to significant enhancements in material properties with the incorporation of small levels of filler (1--5 wt.%) compared to conventional micro- and macro-composites (20--30 wt.%). One of the most promising applications for polymer-clay nanocomposites is in the field of barrier coatings. The development of UV-curable polymer-clay nanocomposite barrier coatings was explored by employing a novel in situ preparation technique. Unsaturated polyesters were synthesized in the presence of organomodified clays by in situ intercalative polymerization to create highly dispersed clays in a precursor resin. The resulting clay-containing polyesters were crosslinked via UV-irradiation using donor-acceptor chemistry to create polymer-clay nanocomposites which exhibited significantly enhanced barrier properties compared to alternative clay dispersion techniques. The impact of the quaternary alkylammonium organic modifiers, used to increase compatibility between the inorganic clay and organic polymer, was studied to explore influence of the organic modifier structure on the nanocomposite material properties. By incorporating just the organic modifiers, no layered silicates, into the polyester resins, reductions in film mechanical and thermal properties were observed, a strong indicator of film plasticization. An alternative in situ preparation method was explored to further increase the dispersion of organomodified clay within the precursor polyester resins. In stark contrast to traditional in situ polymerization methods, a novel "reverse" in situ preparation method was developed, where unmodified montmorillonite clay was added during polyesterification to a reaction mixture containing the alkylammonium organic modifier. The resulting nanocomposite films exhibited reduced water vapor permeability and increased mechanical properties

  7. Healing particles in self-healing thermal barrier coatings

    NARCIS (Netherlands)

    Derelioglu, Z.; Anusuya Ponnusami, S.; Turteltaub, S.; Van der Zwaag, S.; Sloof, W.G.

    2013-01-01

    Crack healing in ceramic thermal barrier coatings (TBCs) may be realized by embedding Mo-Si based particles in the thermal barrier coating. Upon cracking, these particles are exposed to oxygen that permeates through the top layer and the crack gap is filled with SiO2 which is produced from oxidation

  8. Enhancing thermal barrier coatings performance through reinforcement of ceramic topcoat

    Science.gov (United States)

    Bogdanovich, V. I.; Giorbelidze, M. G.

    2016-11-01

    This paper studies structure of thermal barrier coatings applied to hot gas path components in gas turbine engines and produced in a number of ways, and its impact on performance. Methods of structural reinforcement for ceramic topcoat in thermal barrier coatings are considered.

  9. Effect of Sintering on Thermal Conductivity and Thermal Barrier Effects of Thermal Barrier Coatings

    Institute of Scientific and Technical Information of China (English)

    WANG Kai; PENG Hui; GUO Hongbo; GONG Shengkai

    2012-01-01

    Thermal barrier coatings (TBCs) are mostly applied to hot components of advanced turbine engines to insulate the components from hot gas.The effect of sintering on thermal conductivity and thermal barrier effects of conventional plasma sprayed and nanostructured yttria stabilized zirconia (YSZ) thermal barrier coatings (TBCs) are investigated.Remarkable increase in thermal conductivity occurs to both typical coatings after heat treatment.The change of porosity is just the opposite.The grain size of the nanostructured zirconia coating increases more drastically with annealing time compared to that of the conventional plasma sprayed coating,which indicates that coating sintering makes more contributions to the thermal conductivity of the nanostructured coating than that of the conventional coating.Thermal barrier effect tests using temperature difference technique are performed on both coatings.The thermal barrier effects decrease with the increase of thermal conductivity after heat treatment and the decline seems more drastic in low thermal conductivity range.The decline in thermal barrier effects is about 80 ℃for nanostructured coating after 100 h heat treatment,while the conventional coating reduces by less than 60 ℃ compared to the as-sprayed coating.

  10. Thermal and Environmental Barrier Coatings for Advanced Turbine Engine Applications

    Science.gov (United States)

    Zhu, Dong-Ming; Miller, Robert A.

    2005-01-01

    Ceramic thermal and environmental barrier coatings (T/EBCs) will play a crucial role in advanced gas turbine engine systems because of their ability to significantly increase engine operating temperatures and reduce cooling requirements, thus help achieve engine low emission and high efficiency goals. Advanced T/EBCs are being developed for the low emission SiC/SiC ceramic matrix composite (CMC) combustor applications by extending the CMC liner and vane temperature capability to 1650 C (3000 F) in oxidizing and water vapor containing combustion environments. Low conductivity thermal barrier coatings (TBCs) are also being developed for metallic turbine airfoil and combustor applications, providing the component temperature capability up to 1650 C (3000 F). In this paper, ceramic coating development considerations and requirements for both the ceramic and metallic components will be described for engine high temperature and high-heat-flux applications. The underlying coating failure mechanisms and life prediction approaches will be discussed based on the simulated engine tests and fracture mechanics modeling results.

  11. Thermal Conductivity and Sintering Behavior of Advanced Thermal Barrier Coatings

    Science.gov (United States)

    Zhu, Dongming; Miller, Robert A.

    2002-01-01

    Advanced thermal barrier coatings, having significantly reduced long-term thermal conductivities, are being developed using an approach that emphasizes real-time monitoring of thermal conductivity under conditions that are engine-like in terms of temperatures and heat fluxes. This is in contrast to the traditional approach where coatings are initially optimized in terms of furnace and burner rig durability with subsequent measurement in the as-processed or furnace-sintered condition. The present work establishes a laser high-heat-flux test as the basis for evaluating advanced plasma-sprayed and physical vapor-deposited thermal barrier coatings under the NASA Ultra Efficient Engine Technology (UEET) Program. The candidate coating materials for this program are novel thermal barrier coatings that are found to have significantly reduced thermal conductivities due to an oxide-defect-cluster design. Critical issues for designing advanced low conductivity coatings with improved coating durability are also discussed.

  12. Development and Performance Evaluations of HfO2-Si and Rare Earth-Si Based Environmental Barrier Bond Coat Systems for SiC/SiC Ceramic Matrix Composites

    Science.gov (United States)

    Zhu, Dongming

    2014-01-01

    Ceramic environmental barrier coatings (EBC) and SiCSiC ceramic matrix composites (CMCs) will play a crucial role in future aircraft propulsion systems because of their ability to significantly increase engine operating temperatures, improve component durability, reduce engine weight and cooling requirements. Advanced EBC systems for SiCSiC CMC turbine and combustor hot section components are currently being developed to meet future turbine engine emission and performance goals. One of the significant material development challenges for the high temperature CMC components is to develop prime-reliant, high strength and high temperature capable environmental barrier coating bond coat systems, since the current silicon bond coat cannot meet the advanced EBC-CMC temperature and stability requirements. In this paper, advanced NASA HfO2-Si based EBC bond coat systems for SiCSiC CMC combustor and turbine airfoil applications are investigated. The coating design approach and stability requirements are specifically emphasized, with the development and implementation focusing on Plasma Sprayed (PS) and Electron Beam-Physic Vapor Deposited (EB-PVD) coating systems and the composition optimizations. High temperature properties of the HfO2-Si based bond coat systems, including the strength, fracture toughness, creep resistance, and oxidation resistance were evaluated in the temperature range of 1200 to 1500 C. Thermal gradient heat flux low cycle fatigue and furnace cyclic oxidation durability tests were also performed at temperatures up to 1500 C. The coating strength improvements, degradation and failure modes of the environmental barrier coating bond coat systems on SiCSiC CMCs tested in simulated stress-environment interactions are briefly discussed and supported by modeling. The performance enhancements of the HfO2-Si bond coat systems with rare earth element dopants and rare earth-silicon based bond coats are also highlighted. The advanced bond coat systems, when

  13. Effects of yttrium, aluminum and chromium concentrations in bond coatings on the performance of zirconia-yttria thermal barriers

    Science.gov (United States)

    Stecura, S.

    1980-01-01

    A cyclic furnace study was conducted on thermal barrier systems to evaluate the effects of yttrium, chromium and aluminum in nickel-base alloy bond coatings and the effect of bond coating thickness on yttria-stabilized zirconia thermal barrier coating life. Without yttrium in the bond coatings, the zirconia coatings failed very rapidly. Increasing chromium and aluminum in the Ni-Cr-Al-Y bond coatings increased total coating life. This effect was not as great as that due to yttrium. Increased bond coat thickness was also found to increase life.

  14. Laser drilling of thermal barrier coated jet-engine components

    Science.gov (United States)

    Sezer, H. K.

    Aero engine hot end components are often covered with ceramic Thermal Barrier Coatings (TBCs). Laser drilling in the TBC coated components can be a source of service life TBC degradation and spallation. The present study aims to understand the mechanisms of TBC delamination and develop techniques to drill holes without damaging the TBC, Nimonic 263 workpieces coated with TBC are used in the experiments. Microwave non-destructive testing (NDT) is employed to monitor the integrity of the coating /substrate interfaces of the post-laser drilled materials. A numerical modelling technique is used to investigate the role of melt ejection on TBC delamination. The model accounts for the vapour and the assist gas flow effects in the process. Broadly, melt ejection induced mechanical stresses for the TBC coating / bond coating and thermal effects for the bond coating / substrate interfaces are found the key delamination mechanisms. Experiments are carried out to validate the findings from the model. Various techniques that enable laser drilling without damaging the TBC are demonstrated. Twin jet assisted acute angle laser drilling is one successful technique that has been analysed using the melt ejection simulation. Optimisation of the twin jet assisted acute angle laser drilling process parameters is carried out using Design of Experiments (DoE) and statistical modelling approaches. Finally, an industrial case study to develop a high speed, high quality laser drilling system for combustor cans is described. Holes are drilled by percussion and trepan drilling in TBC coated and uncoated Haynes 230 workpieces. The production rate of percussion drilling is significantly higher than the trepan drilling, however metallurgical hole quality and reproducibility is poor. A number of process parameters are investigated to improve these characteristics. Gas type and gas pressure effects on various characteristics of the inclined laser drilled holes are investigated through theoretical

  15. Diffusion Barriers to Increase the Oxidative Life of Overlay Coatings

    Science.gov (United States)

    Nesbitt, James A.; Lei, Jih-Fen

    1999-01-01

    Currently, most blades and vanes in the hottest section of aero gas turbine engines require some type of coating for oxidation protection. Newly developed single crystal superalloys have the mechanical potential to operate at increasingly higher component temperatures. However, at these elevated temperatures, coating/substrate interdiffusion can shorten the protective life of the coating. Diffusion barriers between overlay coatings and substrates are being examined to extend the protective life of the coating. A previously- developed finite-difference diffusion model has been modified to predict the oxidative life enhancement due to use of a diffusion barrier. The original diffusion model, designated COSIM, simulates Al diffusion in the coating to the growing oxide scale as well as Al diffusion into the substrate. The COSIM model incorporates an oxide growth and spalling model to provide the rate of Al consumption during cyclic oxidation. Coating failure is predicted when the Al concentration at the coating surface drops to a defined critical level. The modified COSIM model predicts the oxidative life of an overlay coating when a diffusion barrier is present eliminating diffusion of Al from the coating into the substrate. Both the original and the modified diffusion models have been used to predict the effectiveness of a diffusion barrier in extending the protective life of a NiCrAl overlay coating undergoing cyclic oxidation at 1100 C.

  16. Analytical investigation of thermal barrier coatings for advanced power generation combustion turbines

    Science.gov (United States)

    Amos, D. J.

    1977-01-01

    An analytical evaluation was conducted to determine quantitatively the improvement potential in cycle efficiency and cost of electricity made possible by the introduction of thermal barrier coatings to power generation combustion turbine systems. The thermal barrier system, a metallic bond coat and yttria stabilized zirconia outer layer applied by plasma spray techniques, acts as a heat insulator to provide substantial metal temperature reductions below that of the exposed thermal barrier surface. The study results show the thermal barrier to be a potentially attractive means for improving performance and reducing cost of electricity for the simple, recuperated, and combined cycles evaluated.

  17. Phase transformations and residual stresses in environmental barrier coatings

    Science.gov (United States)

    Harder, Bryan J.

    Silicon-based ceramics (SiC, Si3N4) are promising materials for high-temperature structural applications in turbine engines. However, the silica layer that forms on these materials is susceptible to attack from water vapor present in combustion environments. To protect against this degradation, environmental barrier coatings (EBCs) were developed to protect the underlying substrate. In the case of silicon carbide (SiC), multilayer coating systems consist of a Ba1-xSrxAl2Si 2O8 (BSAS) topcoat, a mullite or mullite + SrAl2Si 2O8 (SAS) interlayer, and a silicon bond coat. In this work, biaxial strains were measured on as-sprayed and heat-treated samples to analyze the stress and phase evolution in the coating system as a function of depth and temperature. Models were used to compare the results with an ideal coating system. In the assprayed state, tensile stresses as high as 175 MPa were measured, and cracking was observed. After thermally cycling the samples, stresses were significantly reduced and cracks in the topcoat had closed. The addition of SAS to the interlayer increased the compressive stress in the BSAS topcoat in thermally-cycled samples, which was desirable for EBC applications. The BSAS topcoat transformed from the as-deposited hexacelsian state to the stable celsian above 1200°C. This phase transformation is accompanied by a CTE reduction. The kinetics of the hexacelsian-to-celsian transformation were quantified for freestanding plasma-sprayed BSAS. Activation energies for bulk bars and crushed powder were determined to be ˜340 kJ/mol and ˜500 kJ/mol, respectively. X-ray diffraction and electron backscatter diffraction were used to establish how microstructural constraints reduce the transformation energy. Barrier coating lifetime and stability are also influenced by exposure to reactive, low-melting point calcium-magnesium-aluminosilicate (CMAS) deposits formed from dust and sand. Multilayer doped aluminosilicate coatings and bulk BSAS material were

  18. Residual stress analysis of multilayer environmental barrier coatings.

    Energy Technology Data Exchange (ETDEWEB)

    Harder, B.; Almer, J.; Weyant, C.; Lee, K.; Faber, K.; Northwestern Univ.; Rolls-Royce Corp.

    2009-02-01

    Silicon-based ceramics (SiC, Si{sub 3}N{sub 4}) are promising materials systems for high-temperature structural applications in gas turbine engines. However, the silica layer that forms on these materials is susceptible to attack from water vapor present in combustion environments. To protect against this degradation, environmental barrier coatings (EBCs) have been developed to shield the underlying substrate and prevent degradation. Here we report on elastic and thermal properties, as well as internal stresses of candidate multilayer coatings, as measured in situ using microfocused high-energy X-rays in a transmission diffraction geometry. Doped aluminosilicate coatings were investigated for their stability on a SiC/SiC melt-infiltrated substrate. The coatings consisted of a Ba{sub 1-x}Sr{sub x}Al{sub 2}Si{sub 2}O{sub 8} topcoat with a mullite or mullite+SrAl{sub 2}Si{sub 2}O{sub 8} interlayer, and a silicon bond coat. A numerical model was used to compare the stress results with an ideal coating system. Experiments were carried out on as-sprayed and heat-treated samples in order to analyze the strain and phase evolution as a function of multilayer depth and temperature. The phase transformation of the topcoat promoted healing of cracks in the EBC and reduced stresses in the underlying layers and the addition of SAS to the interlayer reduced stresses in thermally cycled coatings, but did not stop cracks from forming.

  19. Plasma sprayed and electrospark deposited zirconium metal diffusion barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Hollis, Kendall J [Los Alamos National Laboratory; Pena, Maria I [Los Alamos National Laboratory

    2010-01-01

    Zirconium metal coatings applied by plasma spraying and electrospark deposition (ESD) have been investigated for use as diffusion barrier coatings on low enrichment uranium fuel for research nuclear reactors. The coatings have been applied to both stainless steel as a surrogate and to simulated nuclear fuel uranium-molybdenum alloy substrates. Deposition parameter development accompanied by coating characterization has been performed. The structure of the plasma sprayed coating was shown to vary with transferred arc current during deposition. The structure of ESD coatings was shown to vary with the capacitance of the deposition equipment.

  20. Thermal conductivity of thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Klemens, P.G.; Gell, M. [Connecticut Univ., Storrs, CT (United States). Inst. of Materials Science

    1998-05-01

    In thermal barrier coatings and other ceramic oxides, heat is conducted by lattice waves, and also by a radiative component which becomes significant at high temperatures. The theory of heat conduction by lattice waves is reviewed in the equipartition limit (above room temperature). The conductivity is composed of contributions from a spectrum of waves, determined by the frequency dependent attenuation length. Interaction between lattice waves (intrinsic processes), scattering by atomic scale point defects and scattering by extended imperfections such as grain boundaries, each limit the attenuation length in different parts of the spectrum. Intrinsic processes yield a spectral conductivity which is independent of frequency. Point defects reduce the contribution of the high frequency spectrum, grain boundaries and other extended defects that of the low frequencies. These reductions are usually independent of each other. Estimates will be given for zirconia containing 7wt% Y{sub 2}O{sub 3}, and for yttrium aluminum garnet. They will be compared to measurements. The effects of grain size, cracks and porosity will be discussed both for the lattice and the radiative components. While the lattice component of the thermal conductivity is reduced substantially by decreasing the grain size to nanometers, the radiative component requires pores or other inclusions of micrometer scale. (orig.) 9 refs.

  1. Advanced Environmental Barrier Coating Development for SiC-SiC Ceramic Matrix Composite Components

    Science.gov (United States)

    Zhu, Dongming; Harder, Bryan; Bhatt, Ramakrishna; Kiser, Doug; Wiesner, Valerie L.

    2016-01-01

    This presentation reviews the NASA advanced environmental barrier coating (EBC) system development for SiCSiC Ceramic Matrix Composite (CMC) components for next generation turbine engines. The emphasis has been placed on the current design challenges of the 2700F environmental barrier coatings; coating processing and integration with SiCSiC CMCs and component systems; and performance evaluation and demonstration of EBC-CMC systems. This presentation also highlights the EBC-CMC system temperature capability and durability improvements through advanced compositions and architecture designs, as shown in recent simulated engine high heat flux, combustion environment, in conjunction with mechanical creep and fatigue loading testing conditions.

  2. Measurement of residual stress in thermally grown oxide layers in thermal barrier coating systems - development of non-destructive test methods.

    Energy Technology Data Exchange (ETDEWEB)

    Saunders, S.R.J.; Banks, J.P.; Chen, G.; Chunnilall, C.J. [National Physical Lab., Teddington, Middlesex (United Kingdom)

    2004-07-01

    It is established that the adhesion of thermal barrier coatings (TBCs) is dependent upon the characteristics of the thermally grown oxide (TGO) that forms between the TBC (zirconia) and the corrosion resistant bond coat. Work has been carried using laser induced fluorescence out to investigate the properties of the TGO (normally alumina) as a function of ageing treatments. The zirconia layer is transparent to the laser light used and thus the laser light can cause fluorescence in the TGO layer present on the bondcoat, so that the method is non-destructive. Fluorescence in the TGO is caused by trace impurities of Cr in the alumina layer. The position of the spectral peaks generated is stress dependent so that residual stress in the TGO can be determined; the method is also known as piezospectroscopy. Residual stress maps were generated for an electron beam physical vapour deposited (EB-PVD) TBC that showed a large variation in residual stress over the surface of a coated sample. The two peaks generally associated with {alpha} alumina (R1 and R2) frequently appear as doublets with a high and low stress component. In addition, the presence of a metastable {theta}-alumina was detected in aged samples. It is believed that these observations can be related to incipient spallation of the TBC. The development of residual stress and the metastable oxide have been studied and correlated with the spallation behaviour of the TBC. Additionally, the intensity of the spectra has been shown to yield information about the Cr content of the TGO, and this in turn could also be used as an indication of the remaining life of the TBC system. (orig.)

  3. Thermal barrier coating on high temperature industrial gas turbine engines

    Science.gov (United States)

    Carlson, N.; Stoner, B. L.

    1977-01-01

    The thermal barrier coating used was a yttria stabilized zirconia material with a NiCrAlY undercoat, and the base engine used to establish improvements was the P&WA FT50A-4 industrial gas turbine engine. The design benefits of thermal barrier coatings include simplified cooling schemes and the use of conventional alloys in the engine hot section. Cooling flow reductions and improved heating rates achieved with thermal barrier coating result in improved performance. Economic benefits include reduced power production costs and reduced fuel consumption. Over the 30,000 hour life of the thermal barrier coated parts, fuel savings equivalent to $5 million are projected and specific power (megawatts/mass of engine airflow) improvements on the order of 13% are estimated.

  4. Elastic behaviour of plasma sprayed thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Steinbrech, R.W.; Frahm, J.; Herzog, R.; Schubert, F. [Inst. for Materials and Processes in Energy Systems, Forschungszentrum Juelich GmbH, Juelich (Germany)

    2002-07-01

    The elastic behaviour of air plasma sprayed (APS) thermal barrier coatings (TBCs) of 8 wt.% yttria stabilised zirconia was studied using various mechanical tests with global and local resolution. Results are presented, which reveal the complex relationship between lamellar APS-microstructure and stiffness and illustrate scaling aspects. Also the influence of residual stresses is addressed. The obtained stiffness values for as-sprayed TBCs show a systematic variation between 10 and 100 GPa. Typically results from bending tests of free-standing TBCs are at the low end, whereas results from depth sensitive indentation tests with TBCs bonded to a substrate are found at the high end. When heat treated above 950 C the TBCs exhibit a rapid increase in stiffness which can be attributed to defect healing within the spraying lamellae. Discussion of the results focuses on the implications of a non-uniform stiffness modulus for the mechanical characterisation of thermal barrier systems. (orig.)

  5. Aspects of fatigue life in thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Brodin, H.

    2001-08-01

    Thermal barrier coatings (TBC) are applied on hot components in airborne and land based gas turbines when higher turbine inlet temperature, meaning better thermal efficiency, is desired. The TBC is mainly applied to protect underlying material from high temperatures, but also serves as a protection from the aggressive corrosive environment. Plasma sprayed coatings are often duplex TBC's with an outer ceramic top coat (TC) made from partially stabilised zirconia - ZrO{sub 2} + 6-8% Y{sub 2}O{sub 3}. Below the top coat there is a metallic bond coat (BC). The BC is normally a MCrAlX coating (M=Ni, Co, Fe... and X=Y, Hf, Si ... ). In gas turbine components exposed to elevated temperatures nickel-based superalloys are commonly adopted as load carrying components. In the investigations performed here a commercial wrought Ni-base alloy Haynes 230 has been used as substrate for the TBC. As BC a NiCoCrAlY serves as a reference material and in all cases 7% Yttria PS zirconia has been used. Phase development and failure mechanisms in APS TBC during service-like conditions, have been evaluated in the present study. This is done by combinations of thermal cycling and low cycle fatigue tests. The aim is to achieve better knowledge regarding how, when and why thermal barrier coatings fail. As a final outcome of the project a model capable of predicting fatigue life of a given component will help engineers and designers of land based gas turbines for power generation to better optimise TBC's. In the investigations it is seen that TBC life is strongly influenced by oxidation of the BC and interdiffusion between BC and the substrate. The bond coat is known to oxidise with time at high temperature. The initial oxide found during testing is alumina. With increased time at high temperature Al is depleted from the bond coat due to inter-diffusion and oxidation. Oxides others than alumina start to form when the Al content is reduced below a critical limit. It is here believed

  6. Advanced Multi-Component Defect Cluster Oxide Doped Zirconia-Yttria Thermal Barrier Coatings

    Science.gov (United States)

    Zhu, Dongming; Miller, Robert A.

    2003-01-01

    The advantages of using ceramic thermal barrier coatings in gas turbine engine hot sections include increased fuel efficiency and improved engine reliability. However, current thermal barrier coatings will not have the low thermal conductivity and necessary sintering resistance under higher operating temperatures and thermal gradients required by future advanced ultra efficient and low emission aircraft engines. In this paper, a novel oxide defect cluster design approach is described for achieving low thermal conductivity and excellent thermal stability of the thermal barrier coating systems. This approach utilizes multi-component rare earth and other metal cluster oxide dopants that are incorporated in the zirconia-yttna based systems, thus significantly reducing coating thermal conductivity and sintering resistance by effectively promoting the formation of thermodynamically stable, essentially immobile defect clusters and/or nanoscale phases. The performance of selected plasma-sprayed cluster oxide thermal barrier coating systems has been evaluated. The advanced multi-component thermal barrier coating systems were found to have significantly lower initial and long-term thermal conductivities, and better high temperature stability. The effect of oxide cluster dopants on coating thermal conductivity, sintering resistance, oxide grain growth behavior and durability will be discussed.

  7. Advanced Environmental Barrier Coating Development for SiC/SiC Ceramic Matrix Composites: NASA's Perspectives

    Science.gov (United States)

    Zhu, Dongming

    2016-01-01

    This presentation reviews NASA environmental barrier coating (EBC) system development programs and the coating materials evolutions for protecting the SiC/SiC Ceramic Matrix Composites in order to meet the next generation engine performance requirements. The presentation focuses on several generations of NASA EBC systems, EBC-CMC component system technologies for SiC/SiC ceramic matrix composite combustors and turbine airfoils, highlighting the temperature capability and durability improvements in simulated engine high heat flux, high pressure, high velocity, and with mechanical creep and fatigue loading conditions. The current EBC development emphasis is placed on advanced NASA 2700F candidate environmental barrier coating systems for SiC/SiC CMCs, their performance benefits and design limitations in long-term operation and combustion environments. Major technical barriers in developing environmental barrier coating systems, the coating integrations with next generation CMCs having the improved environmental stability, erosion-impact resistance, and long-term fatigue-environment system durability performance are described. The research and development opportunities for advanced turbine airfoil environmental barrier coating systems by utilizing improved compositions, state-of-the-art processing methods, and simulated environment testing and durability modeling are discussed.

  8. Oxidation and thermal fatigue of EB-PVD thermal barrier coatings on tube superalloy substrate

    Institute of Scientific and Technical Information of China (English)

    GAO Yu; ZHANG Chun-xia; ZHOU Chun-gen; GONG Sheng-kai; XU Hui-bin

    2006-01-01

    Two-layer structure thermal barrier coatings (TBCs) (NiCoCrAlY (bond coat)+(6%-8%, mass fraction) Y2O3-stabilized ZrO2(YSZ top coat)) were deposited by electron beam physical vapor deposition (EB-PVD) on tube superalloy substrates. The samples were investigated by isothermal oxidation and thermal shock tests. It is found that the mass gains of the substrate with and without TBCs are 0.165 and 7.34 mg/cm2, respectively. So the TBCs system is a suitable protection for the substrate. In thermal shock tests the vertical cracks initiate at the top coat and grow into the bond coat, causing the oxidation of the bond coat along the cracks. Failure of the TBCs system occurs by the spallation of the YSZ from the bond coat, and some micro-cracks are found at the location where the fragment of the YSZ top coat spalled from.

  9. Thermomechanical behavior of plasma-sprayed zirconia thermal barrier coatings.

    Energy Technology Data Exchange (ETDEWEB)

    Singh, J. P.

    1998-04-01

    The effect of coating porosity and thickness on the resistance to damage of yttria stabilized zirconia thermal barrier coatings in an oxidizing environment by thermal cycling was evaluated. Hardness and elastic modulus of an as-processed porous coating were lower than those of a dense coating and the porous coating failed after fewer thermal cycles. Similarly, specimen with a thicker coating failed after fewer thermal cycles than specimen with a thinner coating. The earlier failure of the porous coating is due to lower fracture toughness and enhanced oxidation of the coating/substrate interface, whereas, the earlier failure of the thick coating is due to higher thermal transient stresses that developed in the coating during thermal cycling. Generally, an increase in coating density led to initial increase in both hardness and elastic modulus with increasing thermal cycles. However, hardness and density gradually decreased as the number of thermal cycles increase because of microcracks formation and growth. Microscopic observations indicated that the formation of multiple microcracks and their subsequent growth and coalescence led to final coating failure.

  10. The Lattice and Thermal Radiation Conductivity of Thermal Barrier Coatings: Models and Experiments

    Science.gov (United States)

    Zhu, Dongming; Spuckler, Charles M.

    2010-01-01

    The lattice and radiation conductivity of ZrO2-Y2O3 thermal barrier coatings was evaluated using a laser heat flux approach. A diffusion model has been established to correlate the coating apparent thermal conductivity to the lattice and radiation conductivity. The radiation conductivity component can be expressed as a function of temperature, coating material scattering, and absorption properties. High temperature scattering and absorption of the coating systems can be also derived based on the testing results using the modeling approach. A comparison has been made for the gray and nongray coating models in the plasma-sprayed thermal barrier coatings. The model prediction is found to have a good agreement with experimental observations.

  11. High Pressure Burner Rig Testing of Advanced Environmental Barrier Coatings for Si3N4 Turbine Components

    Science.gov (United States)

    Zhu, Dongming; Fox, Dennis S.; Pastel, Robert T.

    2007-01-01

    Advanced thermal and environmental barrier coatings are being developed for Si3N4 components for turbine engine propulsion applications. High pressure burner rig testing was used to evaluate the coating system performance and durability. Test results demonstrated the feasibility and durability of the coating component systems under the simulated engine environments.

  12. Ceramic thermal barrier coatings for gas turbine engines

    Science.gov (United States)

    Bratton, R. J.; Lau, S. K.; Andersson, C. A.; Lee, S. Y.

    1982-01-01

    The results of studies concerning the high temperature corrosion resistance of ZrO2-Y2O3, ZrO2-MgO, and Ca2SiO4 plasma-sprayed coatings, which may be used as gas turbine engine thermal barriers, are reported. The coatings were evaluated in atmospheric burner rig and pressurized passage tests, using GT No. 2 fuel in pure form and with sodium, sulfur and vanadium corrosive impurities doping. It is found that, while the coatings performed well in both pressurized passage and burner rig tests with pure fuel chemical reactions between the ceramic coatings and combustion gases/condensates resulted in coating degradation with impure fuels. Chemical reactions between the ceramic coatings and vanadium compounds played a critical role in coating degradation.

  13. Mechanical properties testing and results for thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Cruse, T.A.; Johnsen, B.P.; Nagy, A.

    1995-10-01

    The paper reports on several years of mechanical testing of thermal barrier coatings. The test results were generated to support the development of durability models for the coatings in heat engine applications. The test data that are reviewed include modulus, static strength, and fatigue strength data. The test methods and results are discussed, along with the significant difficulties inherent in mechanical testing of thermal barrier coating materials. The materials include 7 percent wt. and 8 percent wt. yttria, partially stabilized zirconia as well as a cermet material. Both low pressure plasma spray and electron-beam physical vapor deposited coatings were tested. The data indicate the basic trends in the mechanical properties of the coatings over a wide range of isothermal conditions. Some of the trends are correlated with material density.

  14. Mechanical properties testing and results for thermal barrier coatings

    Science.gov (United States)

    Cruse, Thomas A.; Johnsen, B. P.; Nagy, Andrew

    1995-01-01

    The paper reports on several years of mechanical testing of thermal barrier coatings. The test results were generated to support the development of durability models for the coatings in heat engine applications. The test data that are reviewed include modulus, static strength, and fatigue strength data. The test methods and results are discussed, along with the significant difficulties inherent in mechanical testing of thermal barrier coating materials. The materials include 7 percent wt. and 8 percent wt. yttria, partially stabilized zirconia as well as a cermet material. Both low pressure plasma spray and electron-beam physical vapor deposited coatings were tested. The data indicate the basic trends in the mechanical properties of the coatings over a wide range of isothermal conditions. Some of the trends are correlated with material density.

  15. Development of a CuNiCrAl Bond Coat for Thermal Barrier Coatings in Rocket Combustion Chambers

    Science.gov (United States)

    Fiedler, Torben; Rösler, Joachim; Bäker, Martin

    2015-12-01

    The lifetime of rocket combustion chambers can be increased by applying thermal barrier coatings. The standard coating systems usually used in gas turbines or aero engines will fail at the bond coat/substrate interface due to the chemical difference as well as the different thermal expansion between the copper liner and the applied NiCrAlY bond coat. A new bond coat alloy for rocket engine applications was designed previously with a chemical composition and coefficient of thermal expansion more similar to the copper substrate. Since a comparable material has not been applied by thermal spraying before, coating tests have to be carried out. In this work, the new Ni-30%Cu-6%Al-5%Cr bond coat alloy is applied via high velocity oxygen fuel spraying. In a first step, the influence of different coating parameters on, e.g., porosity, amount of unmolten particles, and coating roughness is investigated and a suitable parameter set for further studies is chosen. In a second step, copper substrates are coated with the chosen parameters to test the feasibility of the process. The high-temperature behavior and adhesion is tested with laser cycling experiments. The new coatings showed good adhesion even at temperatures beyond the maximum test temperatures of the NiCrAlY bond coat in previous studies.

  16. Chemical Vapor Deposition of Turbine Thermal Barrier Coatings

    Science.gov (United States)

    Haven, Victor E.

    1999-01-01

    Ceramic thermal barrier coatings extend the operating temperature range of actively cooled gas turbine components, therefore increasing thermal efficiency. Performance and lifetime of existing ceram ic coatings are limited by spallation during heating and cooling cycles. Spallation of the ceramic is a function of its microstructure, which is determined by the deposition method. This research is investigating metalorganic chemical vapor deposition (MOCVD) of yttria stabilized zirconia to improve performance and reduce costs relative to electron beam physical vapor deposition. Coatings are deposited in an induction-heated, low-pressure reactor at 10 microns per hour. The coating's composition, structure, and response to the turbine environment will be characterized.

  17. Mechanical Properties and Durability of Advanced Environmental Barrier Coatings in Calcium-Magnesium-Alumino-Silicate Environments

    Science.gov (United States)

    Miladinovich, Daniel S.; Zhu, Dongming

    2011-01-01

    Environmental barrier coatings are being developed and tested for use with SiC/SiC ceramic matrix composite (CMC) gas turbine engine components. Several oxide and silicate based compositons are being studied for use as top-coat and intermediate layers in a three or more layer environmental barrier coating system. Specifically, the room temperature Vickers-indentation-fracture-toughness testing and high-temperature stability reaction studies with Calcium Magnesium Alumino-Silicate (CMAS or "sand") are being conducted using advanced testing techniques such as high pressure burner rig tests as well as high heat flux laser tests.

  18. Method of Producing Controlled Thermal Expansion Coat for Thermal Barrier Coatings

    Science.gov (United States)

    Brindley, William J. (Inventor); Miller, Robert A. (Inventor); Aikin, Beverly J. M. (Inventor)

    2000-01-01

    An improved thermal barrier coating and method for producing and applying such is disclosed herein. The thermal barrier coatings includes a high temperature substrate, a first bond coat layer applied to the substrate of MCrAlX and a second bond coat layer of MCrAlX with particles of a particulate dispersed throughout the MCrAlX and the preferred particulate is Al2O3. The particles of the particulate dispersed throughout the second bond coat layer preferably have a diameter of less then the height of the peaks of the second bond coat layer or a diameter of less than 5 micron. The method of producing the second bond coat layer may either include the steps of mechanical alloying of particles throughout the second bond coat layer, attrition milling the particles of the particulate throughout the second bond coat layer, or using electrophoresis to disperse the particles throughout the second bond coat layer. In the preferred embodiment of the invention the first bond coat layer is applied to the substrate. and then the second bond coat layer is thermally sprayed onto the first bond coat layer. Further, in a preferred embodiment of the invention a ceramic insulating layer covers the second bond coat layer.

  19. Roll-to-roll vacuum deposition of barrier coatings

    CERN Document Server

    Bishop, Charles A

    2015-01-01

    It is intended that the book will be a practical guide to provide any reader with the basic information to help them understand what is necessary in order to produce a good barrier coated web or to improve the quality of any existing barrier product. After providing an introduction, where the terminology is outlined and some of the science is given (keeping the mathematics to a minimum), including barrier testing methods, the vacuum deposition process will be described. In theory a thin layer of metal or glass-like material should be enough to convert any polymer film into a perfect barrier material. The reality is that all barrier coatings have their performance limited by the defects in the coating. This book looks at the whole process from the source materials through to the post deposition handling of the coated material. This holistic view of the vacuum coating process provides a description of the common sources of defects and includes the possible methods of limiting the defects. This enables readers...

  20. Thermal barrier coatings (TBC's) for high heat flux thrust chambers

    Science.gov (United States)

    Bradley, Christopher M.

    The last 30 years materials engineers have been under continual pressure to develop materials with a greater temperature potential or to produce configurations that can be effectively cooled or otherwise protected at elevated temperature conditions. Turbines and thrust chambers produce some of the harshest service conditions for materials which lead to the challenges engineers face in order to increase the efficiencies of current technologies due to the energy crisis that the world is facing. The key tasks for the future of gas turbines are to increase overall efficiencies to meet energy demands of a growing world population and reduce the harmful emissions to protect the environment. Airfoils or blades tend to be the limiting factor when it comes to the performance of the turbine because of their complex design making them difficult to cool as well as limitations of their thermal properties. Key tasks for space transportation it to lower costs while increasing operational efficiency and reliability of our space launchers. The important factor to take into consideration is the rocket nozzle design. The design of the rocket nozzle or thrust chamber has to take into account many constraints including external loads, heat transfer, transients, and the fluid dynamics of expanded hot gases. Turbine engines can have increased efficiencies if the inlet temperature for combustion is higher, increased compressor capacity and lighter weight materials. In order to push for higher temperatures, engineers need to come up with a way to compensate for increased temperatures because material systems that are being used are either at or near their useful properties limit. Before thermal barrier coatings were applied to hot-section components, material alloy systems were able to withstand the service conditions necessary. But, with the increased demand for performance, higher temperatures and pressures have become too much for those alloy systems. Controlled chemistry of hot

  1. Silicon oxide permeation barrier coating of PET bottles and foils

    Science.gov (United States)

    Steves, Simon; Deilmann, Michael; Awakowicz, Peter

    2009-10-01

    Modern packaging materials such as polyethylene terephthalate (PET) have displaced established materials in many areas of food and beverage packaging. Plastic packing materials offer are various advantages concerning production and handling. PET bottles for instance are non-breakable and lightweight compared to glass and metal containers. However, PET offers poor barrier properties against gas permeation. Therefore, the shelf live of packaged food is reduced. Permeation of gases can be reduced by depositing transparent plasma polymerized silicon oxide (SiOx) barrier coatings. A microwave (2.45 GHz) driven low pressure plasma reactor is developed based on a modified Plasmaline antenna to treat PET foils or bottles. To increase the barrier properties of the coatings furthermore a RF substrate bias (13.56 MHz) is applied. The composition of the coatings is analyzed by means of Fourier transform infrared (FTIR) spectroscopy regarding carbon and hydrogen content. Influence of gas phase composition and substrate bias on chemical composition of the coatings is discussed. A strong relation between barrier properties and film composition is found: good oxygen barriers are observed as carbon content is reduced and films become quartz-like. Regarding oxygen permeation a barrier improvement factor (BIF) of 70 is achieved.

  2. Development of Advanced Low Conductivity Thermal Barrier Coatings

    Science.gov (United States)

    Zhu, Dong-Ming; Miller, Robert A.

    2004-01-01

    Advanced multi-component, low conductivity oxide thermal barrier coatings have been developed using an approach that emphasizes real-time monitoring of thermal conductivity under conditions that are engine-like in terms of temperatures and heat fluxes. This is in contrast to the traditional approach where coatings are initially optimized in terms of furnace and burner rig durability with subsequent measurement in the as-processed or furnace-sintered condition. The present work establishes a laser high-heat-flux test as the basis for evaluating advanced plasma-sprayed and electron beam-physical vapor deposited (EB-PVD) thermal barrier coatings under the NASA Ultra-Efficient Engine Technology (UEET) Program. The candidate coating materials for this program are novel thermal barrier coatings that are found to have significantly reduced thermal conductivities and improved thermal stability due to an oxide-defect-cluster design. Critical issues for designing advanced low conductivity coatings with improved coating durability are also discussed.

  3. Thermoelastic Characteristics in Thermal Barrier Coatings with a Graded Layer between the Top and Bond Coats

    Directory of Open Access Journals (Sweden)

    Seokchan Kim

    2013-01-01

    Full Text Available A graded layer was introduced at the interface between the top and bond coats to reduce the risk of failure in a thermal barrier coating (TBC system, and the thermoelastic behavior was investigated through mathematical approaches. Two types of TBC model with and without the graded layer, subject to a symmetric temperature distribution in the longitudinal direction, were taken into consideration to evaluate thermoelastic behaviors such as temperature distribution, displacement, and thermal stress. Thermoelastic theory was applied to derive two governing partial differential equations, and a finite volume method was developed to obtain approximations because of the complexity. The TBC with the graded layer shows improved durability in thermoelastic characteristics through mathematical approaches, in agreement with the experimental results. The results will be useful in discovering technologies for enhancing the thermomechanical properties of TBCs.

  4. Performance Testing of Suspension Plasma Sprayed Thermal Barrier Coatings Produced with Varied Suspension Parameters

    Directory of Open Access Journals (Sweden)

    Nicholas Curry

    2015-07-01

    Full Text Available Suspension plasma spraying has become an emerging technology for the production of thermal barrier coatings for the gas turbine industry. Presently, though commercial systems for coating production are available, coatings remain in the development stage. Suitable suspension parameters for coating production remain an outstanding question and the influence of suspension properties on the final coatings is not well known. For this study, a number of suspensions were produced with varied solid loadings, powder size distributions and solvents. Suspensions were sprayed onto superalloy substrates coated with high velocity air fuel (HVAF -sprayed bond coats. Plasma spray parameters were selected to generate columnar structures based on previous experiments and were maintained at constant to discover the influence of the suspension behavior on coating microstructures. Testing of the produced thermal barrier coating (TBC systems has included thermal cyclic fatigue testing and thermal conductivity analysis. Pore size distribution has been characterized by mercury infiltration porosimetry. Results show a strong influence of suspension viscosity and surface tension on the microstructure of the produced coatings.

  5. Bond strength and stress measurements in thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Gell, M.; Jordan, E.

    1995-12-31

    Thermal barrier coatings have been used extensively in aircraft gas turbines for more than 15 years to insulate combustors and turbine vanes from the hot gas stream. Plasma sprayed thermal barrier coatings (TBCs) provide metal temperature reductions as much as 300{degrees}F, with improvements in durability of two times or more being achieved. The introduction of TBCs deposited by electron beam physical vapor deposition (EB-PVD) processes in the last five years has provided a major improvement in durability and also enabled TBCs to be applied to turbine blades for improved engine performance. This program evaluates the bond strength of yttria stabilized zirconia coatings with MCrAlY and Pt-Al bond coats utilizing diffraction and fluorescence methods.

  6. FAILURE MECHANISMS OF THERMAL BARRIER COATINGS INTERNAL COMBUSTION ENGINES AND llMPROVEMENTS

    Directory of Open Access Journals (Sweden)

    ADNAN PARLAK

    2003-04-01

    Full Text Available MechanicaJ properties of high performance ceramics have been improved to the point where their use in heat engines is possible. The high temperature strength and low thermal expansion properties of bigh performance ceramics offer an advantage over metals in the development of non-water cooling engine. However, because bard environment in diesel engine combustion chamber, solving the problem of durabiUty of TBC is important. DurabiUty of thermal barrier coatings(TBC is liınited by two main failure mechanisms: Therınal expansion nlİsmatch betwcen bond coat and top coat and bond coat oxidation. Both of these can cause failure of the ceramic top coat. Developments of recent years sholv that bond coats \\Vith higher oxidation resistance tend to have better coating system cyclic lives

  7. Heat-barrier coatings for combustion chambers

    Science.gov (United States)

    Carpenter, H. W.

    1970-01-01

    Arc-plasma-sprayed layered coating of graded Inconel and zirconia protects film-coolant ring below injector plate of rocket engine combustion chamber. Interfacial temperature is designed for minimum buildup of stress and to avoid melting of the metal phase in the graded layers.

  8. SELECTION OF OXIDES FOR STABILIZATION OF ZIRCONIUM DIOXIDE WHILE OBTAINING THERMAL BARRIER COATINGS

    Directory of Open Access Journals (Sweden)

    V. V. Okovity

    2015-01-01

    Full Text Available The paper analyzes selection of oxides and describes in details a majority of oxide systems which are applicable for stabilization of zirconium dioxide while obtaining thermal barrier coatings with maximum amount of tetragonal phase. Methodology of investigation is based on a review of analytical information on the current state of thermal barrier coatings on the basis of zirconium dioxide stabilized by oxides of rare-earth metals. The method used for application of  zirconium dioxide thermal barrier coatings is plasma spraying. Positive results have been also obtained while applying e-beam sputtering, ion-plasma deposition and magnetron sputtering. Nevertheless preferred plasma spraying application for thermal barrier coatings still continues due to its high productivity and versatility that permits to deposit metallic and ceramic materials of the ordered chemical and phase composition.Ytterbium and cerium oxides have been selected as oxides for stabilization of zirconium dioxide in order to obtain thermal barrier coatings. The paper also considers аn oxide system of zirconium dioxide: “hafnium oxide – yttrium oxide”, representing in itself the structure which is similar to zirconium dioxide.

  9. The Development of Environmental Barrier Coatings for SiCSiC Ceramic Matrix Composites: Challenges and Opportunities

    Science.gov (United States)

    Zhu, Dongming

    2014-01-01

    Environmental barrier coatings (EBCs) and SiC/SiC ceramic matrix composites (CMCs) systems will play a crucial role in future turbine engines for hot-section component applications because of their ability to significantly increase engine operating temperatures, reduce engine weight and cooling requirements. The development of prime-reliant environmental barrier coatings is a key to enable the applications of the envisioned CMC components to help achieve next generation engine performance and durability goals. This paper will primarily address the performance requirements and design considerations of environmental barrier coatings for turbine engine applications. The emphasis is placed on current candidate environmental barrier coating systems for SiCSiC CMCs, their performance benefits and design limitations in long-term operation and combustion environments. Major technical barriers in developing advanced environmental barrier coating systems, the coating integrations with next generation CMC turbine components having improved environmental stability, cyclic durability and system performance will be described. The development trends for turbine environmental barrier coating systems by utilizing improved compositions, state-of-the-art processing methods, and simulated environment testing and durability modeling will be discussed.

  10. High Temperature Damping Behavior of Plasma-Sprayed Thermal Barrier and Protective Coatings

    Science.gov (United States)

    Zhu, Dongming; Miller, Robert A.; Duffy, Kirsten P.; Ghosn, Louis J.

    2010-01-01

    A high temperature damping test apparatus has been developed using a high heat flux CO 2 laser rig in conjunction with a TIRA S540 25 kHz Shaker and Polytec OFV 5000 Vibrometer system. The test rig has been successfully used to determine the damping performance of metallic and ceramic protective coating systems at high temperature for turbine engine applications. The initial work has been primarily focused on the microstructure and processing effects on the coating temperature-dependence damping behavior. Advanced ceramic coatings, including multicomponent tetragonal and cubic phase thermal barrier coatings, along with composite bond coats, have also been investigated. The coating high temperature damping mechanisms will also be discussed.

  11. Development of new thermal barrier coating materials for gas turbines

    Energy Technology Data Exchange (ETDEWEB)

    Cao, X.

    2004-04-01

    New thermal barrier coating (TBC) materials for gas turbines were studied in this work. Two of the most important properties of the material for TBCs, thermal expansion coefficient and phase stability, and the powder preparation by spray-drying are investigated.

  12. Phase Stability and Thermal Conductivity of Composite Environmental Barrier Coatings on SiC/SiC Ceramic Matrix Composites

    Science.gov (United States)

    Benkel, Samantha; Zhu, Dongming

    2011-01-01

    Advanced environmental barrier coatings are being developed to protect SiC/SiC ceramic matrix composites in harsh combustion environments. The current coating development emphasis has been placed on the significantly improved cyclic durability and combustion environment stability in high-heat-flux and high velocity gas turbine engine environments. Environmental barrier coating systems based on hafnia (HfO2) and ytterbium silicate, HfO2-Si nano-composite bond coat systems have been processed and their stability and thermal conductivity behavior have been evaluated in simulated turbine environments. The incorporation of Silicon Carbide Nanotubes (SiCNT) into high stability (HfO2) and/or HfO2-silicon composite bond coats, along with ZrO2, HfO2 and rare earth silicate composite top coat systems, showed promise as excellent environmental barriers to protect the SiC/SiC ceramic matrix composites.

  13. Self-healing thermal barrier coatings; with application to gas turbine engines

    NARCIS (Netherlands)

    Ponnusami, S.A.

    2013-01-01

    Thermal Barrier Coating (TBC) systems have been applied in turbine engines for aerospace and power plants since the beginning of the 1980s to increase the energy efficiency of the engine, by allowing for higher operation temperatures. TBC systems on average need to be replaced about four times durin

  14. Some effects of metallic substrate composition on degradation of thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Wright, I.G.; Pint, B.A.; Lee, W.Y.; Alexander, K.B.; Pruessner, K.

    1997-12-31

    Comparisons have been made in laboratory isothermal and cyclic oxidation tests of the degradation of oxide scales grown on single crystal superalloy substrates and bond coating alloys intended for use in thermal barrier coatings systems. The influence of desulfurization of the superalloy and bond coating, of reactive element addition to the bond coating alloy, and of oxidation temperature on the spallation behavior of the alumina scales formed was assessed from oxidation kinetics and from SEM observations of the microstructure and composition of the oxide scales. Desulfurization of nickel-base superalloy (in the absence of a Y addition) resulted in an increase in the lifetime of a state-of-the-art thermal barrier coating applied to it compared to a Y-free, non-desulfurized version of the alloy. The lifetime of the same ceramic coating applied without a bond coating to a non-desulfurized model alloy that formed an ideal alumina scale was also found to be at least four times longer than on the Y-doped superalloy plus state-of-the-art bond coating combination. Some explanations are offered of the factors controlling the degradation of such coatings.

  15. Environmental Barrier Coatings for the Energy Efficient Heat Engines Program

    Energy Technology Data Exchange (ETDEWEB)

    Katherine Faber

    2004-10-31

    This program aimed to develop a fundamental understanding of the microstructural, mechanical, and chemical properties of Ta{sub 2}O{sub 5}-based coatings for Si{sub 3}N{sub 4} (AS800) substrates and optimize such coatings for environmental barriers. The program consisted of three tasks: processing of Ta{sub 2}O{sub 5} coatings, phase and microstructural development, and life-limiting phenomena. Northwestern University formed a cross-functional team with Lehigh University, Honeywell Inc., and Oak Ridge National Laboratory. The major accomplishments are: (1) Conditions for the plasma spray of Ta{sub 2}O{sub 5} and its alloys were optimized to provide maximum density and thickness. (2) Adherent small particle plasma spray coatings of Ta{sub 2}O{sub 5} can be routinely prepared. (3) Ta{sub 2}O{sub 5} can be stabilized against its disruptive phase transformation to 1400 C by the addition of one or more oxides of Al, La, and/or Nb. (4) Residual stresses in the Ta{sub 2}O{sub 5} coatings were measured using X-rays and changed with thermal exposure. (5) Properly doped coatings are more resistant against thermal cycling than undoped coatings, and can be cycled many thousand times without spallation. (6) Water vapor testing in the ORNL Keiser Rig of adherent coatings showed that undoped Ta{sub 2}O{sub 5} is not an effective barrier at preventing chemical changes to the AS800. (7) Limited water vapor testing of doped and adherent coatings, which had successfully survived many thermal cycles, showed that in the water vapor environment, de-cohesion may occur.

  16. Lower-Conductivity Ceramic Materials for Thermal-Barrier Coatings

    Science.gov (United States)

    Bansal, Narottam P.; Zhu, Dongming

    2006-01-01

    Doped pyrochlore oxides of a type described below are under consideration as alternative materials for high-temperature thermal-barrier coatings (TBCs). In comparison with partially-yttria-stabilized zirconia (YSZ), which is the state-of-the-art TBC material now in commercial use, these doped pyrochlore oxides exhibit lower thermal conductivities, which could be exploited to obtain the following advantages: For a given difference in temperature between an outer coating surface and the coating/substrate interface, the coating could be thinner. Reductions in coating thicknesses could translate to reductions in weight of hot-section components of turbine engines (e.g., combustor liners, blades, and vanes) to which TBCs are typically applied. For a given coating thickness, the difference in temperature between the outer coating surface and the coating/substrate interface could be greater. For turbine engines, this could translate to higher operating temperatures, with consequent increases in efficiency and reductions in polluting emissions. TBCs are needed because the temperatures in some turbine-engine hot sections exceed the maximum temperatures that the substrate materials (superalloys, Si-based ceramics, and others) can withstand. YSZ TBCs are applied to engine components as thin layers by plasma spraying or electron-beam physical vapor deposition. During operation at higher temperatures, YSZ layers undergo sintering, which increases their thermal conductivities and thereby renders them less effective as TBCs. Moreover, the sintered YSZ TBCs are less tolerant of stress and strain and, hence, are less durable.

  17. Thermal Properties, Thermal Shock, and Thermal Cycling Behavior of Lanthanum Zirconate-Based Thermal Barrier Coatings

    Science.gov (United States)

    Guo, Xingye; Lu, Zhe; Jung, Yeon-Gil; Li, Li; Knapp, James; Zhang, Jing

    2016-06-01

    Lanthanum zirconate (La2Zr2O7) coatings are newly proposed thermal barrier coating (TBC) systems which exhibit lower thermal conductivity and potentially higher thermal stability compared to other traditional thermal barrier systems. In this work, La2Zr2O7 and 8 wt pct yttria stabilized zirconia (8YSZ) single-layer and double-layer TBC systems were deposited using the air plasma spray technique. Thermal properties of the coatings were measured. Furnace heat treatment and jet engine thermal shock tests were implemented to evaluate coating performance during thermal cycling. The measured average thermal conductivity of porous La2Zr2O7 coating ranged from 0.59 to 0.68 W/m/K in the temperature range of 297 K to 1172 K (24 °C to 899 °C), which was approximately 25 pct lower than that of porous 8YSZ (0.84 to 0.87 W/m/K) in the same temperature range. The coefficients of thermal expansion values of La2Zr2O7 were approximately 9 to 10 × 10-6/K from 400 K to 1600 K (127 °C to 1327 °C), which were about 10 pct lower than those of porous 8YSZ. The double-layer coating system consisting of the porous 8YSZ and La2Zr2O7 layers had better thermal shock resistance and thermal cycling performance than those of single-layer La2Zr2O7 coating and double-layer coating with dense 8YSZ and La2Zr2O7 coatings. This study suggests that porous 8YSZ coating can be employed as a buffer layer in La2Zr2O7-based TBC systems to improve the overall coating durability during service.

  18. Plasma-sprayed thermal barrier coatings: numerical study on damage localization and evolution

    Directory of Open Access Journals (Sweden)

    K. Slámečka

    2016-01-01

    Full Text Available Thermal barrier coatings (TBCs are advanced material systems used to enhance performance and in-service life of components operated at high temperatures in gas turbines and other power-generation devices. Because of complexity, numerical methods became important tools both for design of these coatings and for in-service life estimations and optimization. In this contribution, two main features that affect the TBCs’ performance, namely the roughness of the bond coat and the microstructure of the ceramic top coat, are discussed based on Finite Element Method (FEM and Finite Element Microstructure MEshfree (FEMME simulations that were used to calculate stresses and assess damage within the coating. Roughness data obtained from plasma-sprayed CoNiCrAlY + YSZ coated samples are supplemented to discuss assumptions and results of employed numerical models.

  19. AN INVESTIGATION OF THE THERMAL SHOCK BEHAVIOR OF THERMAL BARRIER COATINGS

    Directory of Open Access Journals (Sweden)

    ANDERSON.A

    2011-11-01

    Full Text Available High temperature thermal cycling fatigue causes the breakdown of Thermal Barrier Coating (TBCsystems. This paper presents the development of thick TBCs, focusing attention on the microstructure of the Yttria Partially Stabilized Zirconia (YPSZ coating and Zirconia ceria powder (Ce+YPSZ, in relation to its resistance to thermal cycling fatigue. Thick TBCs, were produced by means of a CoNiCrAlY bond coat and Yttria Partially Stabilised Zirconia top coat or Zirconia ceria powder (Ce+YPSZ, both sprayed by AtmosphericPlasma Spray process. The thermal fatigue resistance of new TBC systems and the evolution of the coatings before and after thermal cycling were evaluated. The limit of thermal fatigue resistance increases in the Zirconia ceria powder (Ce+YPSZ top coat.

  20. Development of Advanced Thermal and Environmental Barrier Coatings Using a High-Heat-Flux Testing Approach

    Science.gov (United States)

    Zhu, Dongming; Miller, Robert A.

    2003-01-01

    The development of low conductivity, robust thermal and environmental barrier coatings requires advanced testing techniques that can accurately and effectively evaluate coating thermal conductivity and cyclic resistance at very high surface temperatures (up to 1700 C) under large thermal gradients. In this study, a laser high-heat-flux test approach is established for evaluating advanced low conductivity, high temperature capability thermal and environmental barrier coatings under the NASA Ultra Efficient Engine Technology (UEET) program. The test approach emphasizes the real-time monitoring and assessment of the coating thermal conductivity, which initially rises under the steady-state high temperature thermal gradient test due to coating sintering, and later drops under the cyclic thermal gradient test due to coating cracking/delamination. The coating system is then evaluated based on damage accumulation and failure after the combined steady-state and cyclic thermal gradient tests. The lattice and radiation thermal conductivity of advanced ceramic coatings can also be evaluated using laser heat-flux techniques. The external radiation resistance of the coating is assessed based on the measured specimen temperature response under a laser- heated intense radiation-flux source. The coating internal radiation contribution is investigated based on the measured apparent coating conductivity increases with the coating surface test temperature under large thermal gradient test conditions. Since an increased radiation contribution is observed at these very high surface test temperatures, by varying the laser heat-flux and coating average test temperature, the complex relation between the lattice and radiation conductivity as a function of surface and interface test temperature may be derived.

  1. The oxidation behavior of classical thermal barrier coatings exposed to extreme temperature

    Directory of Open Access Journals (Sweden)

    Alina DRAGOMIRESCU

    2017-03-01

    Full Text Available Thermal barrier coatings (TBC are designed to protect metal surfaces from extreme temperatures and improve their resistance to oxidation during service. Currently, the most commonly used systems are those that have the TBC structure bond coat (BC / top coat (TC layers. The top coat layer is a ceramic layer. Oxidation tests are designed to identify the dynamics of the thermally oxide layer (TGO growth at the interface of bond coat / top coat layers, delamination mechanism and the TBC structural changes induced by thermal conditions. This paper is a short study on the evolution of aluminum oxide protective layer along with prolonged exposure to the testing temperature. There have been tested rectangular specimens of metal super alloy with four surfaces coated with a duplex thermal barrier coating system. The specimens were microscopically and EDAX analyzed before and after the tests. In order to determine the oxide type, the samples were analyzed using X-ray diffraction. The results of the investigation are encouraging for future studies. The results show a direct relationship between the development of the oxide layer and long exposure to the test temperature. Future research will focus on changing the testing temperature to compare the results.

  2. Biodegradation and recycling potential of barrier coated paperboards

    Directory of Open Access Journals (Sweden)

    Nazhad, M.

    2007-05-01

    Full Text Available Four commercial barrier coated boards (i.e., internally-sized uncoated board, one-side polyethylene coated board, double-side polyethylene coated board, and multilayer laminated board were examined for biodegradation using a soil burial approach on a laboratory scale. It was observed that the base-boards were fully biodegradable in a matter of weeks or months, and the degradation process could be accelerated either by sample size modification or enrichment of the soil microbial population. Freezing pretreatment of boards or the fiber directionality of boards had no influence on the rate of degradation. The boards were also found to be recyclable following a simple procedure of re-slushing and screening. The base-boards became almost fully separated from the polyethylene coated material without any special pretreatment.

  3. Plasma spray for forming nanostructured thermal barrier coatings

    Institute of Scientific and Technical Information of China (English)

    LIN; Feng; JIANG; Xian-liang; YU; Yue-guang; ZENG; Ke-li; REN; Xian-jing

    2005-01-01

    Nanocrystalline powders of yttrium partially stabilized zirconia (YPSZ) are reprocessed into agglomerated feedstocks for plasma spraying thermal barrier coatings (TBCs), using the methods of ball milling, slurry dispersion, spray drying, and heat treatment. Atmospheric plasma is used to spray the agglomerated nanocrystalline particle feedstocks and coatings were deposited on the substrate of Ni-based superalloy. Scanning electron microscopy (SEM) is used to examine the morphology and cross-section of the agglomerated feedstocks and the free-section and cross-section of the nanostructured TBCs. Experimental results show that the agglomerated nanocrystalline particles are spherical and dense. Unlike conventional plasma-sprayed coatings, the micron/nano/micron sandwich structure can be found in the nanostructured YPSZ coatings deposited by atmospheric plasma spraying.

  4. Calcium-Magnesium-Aluminosilicate (CMAS) Infiltration and Cyclic Degradations of Thermal and Environmental Barrier Coatings in Thermal Gradients

    Science.gov (United States)

    Zhu, Dongming; Harder, Bryan; Smialek, Jim; Miller, Robert A.

    2014-01-01

    In a continuing effort to develop higher temperature capable turbine thermal barrier and environmental barrier coating systems, Calcium-Magnesium-Aluminosilicate (CMAS) resistance of the advanced coating systems needs to be evaluated and improved. This paper highlights some of NASA past high heat flux testing approaches for turbine thermal and environmental barrier coatings assessments in CMAS environments. One of our current emphases has been focused on the thermal barrier - environmental barrier coating composition and testing developments. The effort has included the CMAS infiltrations in high temperature and high heat flux turbine engine like conditions using advanced laser high heat flux rigs, and subsequently degradation studies in laser heat flux thermal gradient cyclic and isothermal furnace cyclic testing conditions. These heat flux CMAS infiltration and related coating durability testing are essential where appropriate CMAS melting, infiltration and coating-substrate temperature exposure temperature controls can be achieved, thus helping quantify the CMAS-coating interaction and degradation mechanisms. The CMAS work is also playing a critical role in advanced coating developments, by developing laboratory coating durability assessment methodologies in simulated turbine engine conditions and helping establish CMAS test standards in laboratory environments.

  5. Computational design and experimental validation of new thermal barrier systems

    Energy Technology Data Exchange (ETDEWEB)

    Guo, Shengmin [Louisiana State Univ., Baton Rouge, LA (United States)

    2015-03-31

    The focus of this project is on the development of a reliable and efficient ab initio based computational high temperature material design method which can be used to assist the Thermal Barrier Coating (TBC) bond-coat and top-coat design. Experimental evaluations on the new TBCs are conducted to confirm the new TBCs’ properties. Southern University is the subcontractor on this project with a focus on the computational simulation method development. We have performed ab initio density functional theory (DFT) method and molecular dynamics simulation on screening the top coats and bond coats for gas turbine thermal barrier coating design and validation applications. For experimental validations, our focus is on the hot corrosion performance of different TBC systems. For example, for one of the top coatings studied, we examined the thermal stability of TaZr2.75O8 and confirmed it’s hot corrosion performance.

  6. The deformation and fracture of thick thermal barrier coatings

    Science.gov (United States)

    Gao, Husheng

    Plasma-sprayed thick thermal barrier coatings (TTBCs) are being developed for thermal protection of diesel engine components in high temperature service. Comparing to thin thermal barrier coatings used in gas turbine industry, increased thickness causes some TTBCs failure to occur within the bulk of the coating materials and away from the interface. This necessitated the study of mechanical properties of the coating materials independent of the substrate. In order to enhance the performance and to predict the life of TTBCs, we have to understand the materials response under multiaxial stress states, the deformation mechanisms, failure criteria, and the constitutive relations. In this study, the deformation behavior, the deformation mechanisms, and the failure criteria were investigated. The results shows that under combined axial and shear loading, thin walled tubular specimens of ceramic coatings failed in one of two modes, a tensile failure perpendicular to the maximum principal stress when s1≥sTf or a shear failure through the thickness when s3≤sCf . Two apparatuses for in situ SEM torsion and compression testing were developed for deformation mechanisms investigation. The deformation mechanisms were identified as tensile microcracking, crack closing, and crack sliding. A model has been developed for the constitution relation of functionally graded TTBCs. It is shown that with a few simple experiments, this model can be used to predict the cyclic deformation behavior of the functionally graded TTBCs.

  7. Thermal shock behavior of platinum aluminide bond coat/electron beam-physical vapor deposited thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Xu, Zhenhua, E-mail: zhxuciac@163.com [Beijing Institute of Aeronautical Materials, Department 5, P.O. Box 81-5, Beijing 100095 (China); Dai, Jianwei [Beijing Institute of Aeronautical Materials, Department 5, P.O. Box 81-5, Beijing 100095 (China); Niu, Jing [Shenyang Liming Aero-engine (Group) Corporation Ltd., Institute of Metallurgical Technology, Technical Center, Shengyang 110043 (China); Li, Na; Huang, Guanghong; He, Limin [Beijing Institute of Aeronautical Materials, Department 5, P.O. Box 81-5, Beijing 100095 (China)

    2014-12-25

    Highlights: • TBCs of (Ni, Pt)Al bond coat with grit blasting process and YSZ ceramic coating. • Grain boundary ridges are the sites for spallation damage initiation in TBCs. • Ridges removed, cavities formation appeared and the damage initiation deteriorated. • Damage initiation and progression at interface lead to a buckling failure. - Abstract: Thermal barrier coating systems (TBCs) including of chemical vapor deposited (Ni, Pt)Al bond coat with grit blasting process and electron beam physical vapor deposited Y{sub 2}O{sub 3}-stabilized-ZrO{sub 2} (YSZ) ceramic coating were investigated. The phase structures, surface and cross-sectional morphologies, thermal shock behaviors and residual stresses of the coatings were studied in detail. Grain boundary ridges still remain on the surface of bond coat prior to the deposition of the ceramic coating, which are shown to be the major sites for spallation damage initiation in TBCs. When these ridges are mostly removed, they appear some of cavities formation and then the damage initiation mode is deteriorated. Damage initiation and progression occurs at the bond coat to thermally grown oxide (TGO) interface leading to a buckling failure behavior. A buckle failure once started may be arrested when it runs into a region of high bond coat to TGO interface toughness. Thus, complete failure requires further loss in toughness of the bond coat to TGO interface during cooling. The suppressed cavities formation, the removed ridges at the grain boundaries, the relative high TGO to bond coat interface toughness, the uniform growth behavior of TGO thickening and the lower of the residual stress are the primary factors for prolonging the lifetime of TBCs.

  8. Thermal barrier coatings for diesel engine exhaust applications

    OpenAIRE

    2014-01-01

    The strive to increase the engine efficiency in terms of fuel consumption and lower emissions have lead to higher demands on materials. In this thesis five different thermal barrier coatings applied using air plasma spraying to three materials commonly used for exhaust application are evaluated. This thesis work was done at Scania CV in Södertälje with main focus on evaluation during thermal cycling. The goal of this thesis is to evaluate the coatings and correlate their behaviour to their ch...

  9. Very Tough, Erosion-Resistant Turbine Airfoil Thermal Barrier Coatings Developed

    Science.gov (United States)

    Zhu, Dong-Ming; Miller, Robert A.

    2005-01-01

    Ceramic thermal barrier coatings (TBCs) are receiving increased attention for advanced gas turbine engine applications. These coatings are considered to be technologically important because of their ability to further increase engine operating temperatures and reduce cooling requirements, thus achieving higher engine efficiency, lower emissions, and increased performance goals. To take full advantage of the capabilities of these coatings, researchers need to use an aggressive design approach whenever possible--one that allows greater temperature reductions through the coating systems and less cooling air to the components. Advanced TBCs that have significantly lower thermal conductivity and better thermal stability than current coatings have been developed for future ultra-efficient, low-emission engine systems. Multicomponent-doped, defect-clustered TBCs have been shown to offer the low conductivity and high stability required for future high-temperature engine applications.

  10. Thermal Fatigue Testing of ZrO2-Y2O3 Thermal Barrier Coating Systems using a High Power CO2 Laser

    Science.gov (United States)

    Zhu, Dongming; Miller, Robert A.

    1997-01-01

    In the present study, the mechanisms of fatigue crack initiation and propagation, and of coating failure, under thermal loads that simulate diesel engine conditions, are investigated. The surface cracks initiate early and grow continuously under thermal Low Cycle Fatigue (LCF) and High Cycle Fatigue (HCF) stresses. It is found that, in the absence of interfacial oxidation, the failure associated with LCF is closely related to coating sintering and creep at high temperatures. Significant LCF and HCF interactions have been observed in the thermal fatigue tests. The fatigue crack growth rate in the ceramic coating strongly depends on the characteristic HCF cycle number, N*(sub NCF), which is defined as the number of HCF cycles per LCF cycle. The crack growth rate is increased from 0.36 microns/LCF cycle for a pure LCF test to 2.8 microns/LCF cycle for a combined LCF and HCF test at N*(sub NCF) about 20,000. A surface wedging model has been proposed to account for the HCF crack growth in the coating systems. This mechanism predicts that HCF damage effect increases with increasing surface temperature swing, the thermal expansion coefficient and the elastic modulus of the ceramic coating, as well as with the HCF interacting depth. A good agreement has been found between the analysis and experimental evidence.

  11. Low conductivity and sintering-resistant thermal barrier coatings

    Science.gov (United States)

    Zhu, Dongming (Inventor); Miller, Robert A. (Inventor)

    2007-01-01

    A thermal barrier coating composition is provided. The composition has a base oxide, a primary stabilizer, and at least two additional cationic oxide dopants. Preferably, a pair of group A and group B defect cluster-promoting oxides is used in conjunction with the base and primary stabilizer oxides. The new thermal barrier coating is found to have significantly lower thermal conductivity and better sintering resistance. In preferred embodiments, the base oxide is selected from zirconia and hafnia. The group A and group B cluster-promoting oxide dopants preferably are selected such that the group A dopant has a smaller cationic radius than the primary stabilizer oxide, and so that the primary stabilizer oxide has a small cationic radius than that of the group B dopant.

  12. Effect of Plasma Pretreatment on Thermal Durability of Thermal Barrier Coatings in Cyclic Thermal Exposure

    Directory of Open Access Journals (Sweden)

    Sang-Won Myoung

    2014-01-01

    Full Text Available Plasma pretreatment on the top and bond coats was performed and its influence on the thermal durability of thermal barrier coating (TBC system was investigated through cyclic thermal exposure. Two types of bond coat were prepared by different methods, namely, air plasma spray (APS and high-velocity oxy-fuel (HVOF, and two kinds of feedstock powder were employed for preparing the top coat in APS process. The better thermal durability was achieved in the vertically cracked TBC with the surface modified bond coat or with the bond coat prepared by APS process. The hardness and fracture toughness values of TBCs increased because of densification of the top coat during cyclic thermal exposure, and the bond coat prepared by HVOF process showed higher values than that by APS process. The TBCs with the surface modified bond coat were more efficient in improving adhesive strength than those without plasma pretreatment on the bond coat. The relationship between microstructure evolution and thermomechanical characteristics of TBCs with plasma pretreatment was discussed in cyclic thermal exposure.

  13. Multicomponent, Rare-Earth-Doped Thermal-Barrier Coatings

    Science.gov (United States)

    Miller, Robert A.; Zhu, Dongming

    2005-01-01

    Multicomponent, rare-earth-doped, perovskite-type thermal-barrier coating materials have been developed in an effort to obtain lower thermal conductivity, greater phase stability, and greater high-temperature capability, relative to those of the prior thermal-barrier coating material of choice, which is yttria-partially stabilized zirconia. As used here, "thermal-barrier coatings" (TBCs) denotes thin ceramic layers used to insulate air-cooled metallic components of heat engines (e.g., gas turbines) from hot gases. These layers are generally fabricated by plasma spraying or physical vapor deposition of the TBC materials onto the metal components. A TBC as deposited has some porosity, which is desirable in that it reduces the thermal conductivity below the intrinsic thermal conductivity of the fully dense form of the material. Undesirably, the thermal conductivity gradually increases because the porosity gradually decreases as a consequence of sintering during high-temperature service. Because of these and other considerations such as phase transformations, the maximum allowable service temperature for yttria-partially stabilized zirconia TBCs lies in the range of about 1,200 to 1,300 C. In contrast, the present multicomponent, rare-earth-doped, perovskite-type TBCs can withstand higher temperatures.

  14. Surface Coatings as Xenon Diffusion Barriers for Improved Detection of Clandestine Nuclear Explosions

    OpenAIRE

    Bläckberg, Lisa

    2014-01-01

    This thesis investigates surface coatings as xenon diffusion barriers on plastic scintillators. The motivation for the work is improved radioxenon detection systems, used within the verification regime of the Comprehensive Nuclear-Test-Ban Treaty (CTBT). One type of radioxenon detection systems used in this context is the Swedish SAUNA system. This system uses a cylindrical plastic scintillator cell to measure the beta decay from radioxenon isotopes. The detector cell also acts as a container...

  15. Thermal Conductivity Analysis and Lifetime Testing of Suspension Plasma-Sprayed Thermal Barrier Coatings

    Directory of Open Access Journals (Sweden)

    Nicholas Curry

    2014-08-01

    Full Text Available Suspension plasma spraying (SPS has become an interesting method for the production of thermal barrier coatings for gas turbine components. The development of the SPS process has led to structures with segmented vertical cracks or column-like structures that can imitate strain-tolerant air plasma spraying (APS or electron beam physical vapor deposition (EB-PVD coatings. Additionally, SPS coatings can have lower thermal conductivity than EB-PVD coatings, while also being easier to produce. The combination of similar or improved properties with a potential for lower production costs makes SPS of great interest to the gas turbine industry. This study compares a number of SPS thermal barrier coatings (TBCs with vertical cracks or column-like structures with the reference of segmented APS coatings. The primary focus has been on lifetime testing of these new coating systems. Samples were tested in thermo-cyclic fatigue at temperatures of 1100 °C for 1 h cycles. Additional testing was performed to assess thermal shock performance and erosion resistance. Thermal conductivity was also assessed for samples in their as-sprayed state, and the microstructures were investigated using SEM.

  16. Inelastic constitutive equation of plasma-sprayed ceramic thermal barrier coatings

    Institute of Scientific and Technical Information of China (English)

    Masayuki ARAI

    2011-01-01

    Ceramic thermal barrier coatings (TBCs) are a very important technology for protecting the hot parts of gas turbines (GTs) from a high-temperature environment. The coating stress generated in the operation of GTs brings cracking and peeling damage to the TBCs. Thus, it is necessary to evaluate precisely such coating stress in a TBC system. We have obtained a stress-strain curve for a freestanding ceramic coat specimen peeled from a TBC coated substrate by conducting the bending test. The test results have revealed that the ceramic coating deforms nonlinearly with the applied loading. In this study, an inelastic constitutive equation for the ceramic thermal barrier coatings deposited by APS is developed. The obtained results are as follows: (1) the micromechanics-based constitutive equation was formulated with micro crack density formed at splat boundary, and (2) it was shown that the numerical results for a nonlinearly deformed beam simulated by the developed constitutive equation agreed with the experimental results obtained by cantilever bending tests.

  17. Investigation of Amorphous/Nanocrystalline Iron-Based Thermal Barrier Coatings

    Science.gov (United States)

    Bobzin, K.; Öte, M.; Königstein, T.

    2017-02-01

    Because of their favorable thermophysical properties, good machinability and low material costs, iron-based coatings which exhibit a highly amorphous/nanocrystalline microstructure are currently in the focus of research. Considering the crystallization temperature of the material, iron-based coatings might be the next generation of thermal barrier coatings (TBCs) for low-temperature systems, reducing thermal losses. The objective of this research project is the development of highly amorphous, iron-based coatings. For this purpose, amorphous feedstock materials with different chromium contents have been developed and characterized regarding their microstructures, phase compositions, crystallization temperatures and amorphous content. The results show that the amorphous content is reduced with increasing particle size and chromium content. The coatings were deposited by air plasma spraying (APS) and high-velocity oxygen fuel spraying (HVOF). It is shown that all coatings exhibit amorphous structures. HVOF coatings show a smaller amount of amorphous content compared to the feedstock materials, indicating crystallization occurring in not fully melted particles or insufficient rapid cooling. The APS process can increase the amount of amorphous content compared to the feedstock material, as shown for x Cr = 15%. All coatings proof good thermal shock behavior. Lowest thermal diffusivity values were determined for APS coatings, which confirms the potential of iron-based TBCs.

  18. Investigation of Amorphous/Nanocrystalline Iron-Based Thermal Barrier Coatings

    Science.gov (United States)

    Bobzin, K.; Öte, M.; Königstein, T.

    2017-01-01

    Because of their favorable thermophysical properties, good machinability and low material costs, iron-based coatings which exhibit a highly amorphous/nanocrystalline microstructure are currently in the focus of research. Considering the crystallization temperature of the material, iron-based coatings might be the next generation of thermal barrier coatings (TBCs) for low-temperature systems, reducing thermal losses. The objective of this research project is the development of highly amorphous, iron-based coatings. For this purpose, amorphous feedstock materials with different chromium contents have been developed and characterized regarding their microstructures, phase compositions, crystallization temperatures and amorphous content. The results show that the amorphous content is reduced with increasing particle size and chromium content. The coatings were deposited by air plasma spraying (APS) and high-velocity oxygen fuel spraying (HVOF). It is shown that all coatings exhibit amorphous structures. HVOF coatings show a smaller amount of amorphous content compared to the feedstock materials, indicating crystallization occurring in not fully melted particles or insufficient rapid cooling. The APS process can increase the amount of amorphous content compared to the feedstock material, as shown for x Cr = 15%. All coatings proof good thermal shock behavior. Lowest thermal diffusivity values were determined for APS coatings, which confirms the potential of iron-based TBCs.

  19. Analysis of Heat-insulating Performance of Air Plasma Sprayed Thermal Barrier Coating Systems%等离子喷涂热障涂层隔热性能分析方法

    Institute of Scientific and Technical Information of China (English)

    王千文; 毛卫国; 喻明

    2011-01-01

    Thermal barrier coating material has become a kind of key materials applied in modern high perfor-mance aircraft engines, and the evaluation of thermal insulation performance of thermal barrier coatings has been an important indicator of good or bad performance. One-dimensional temperature field analytical solution was derived based on Fourier s law. The effects of ceramic thickness, the surface temperature of ceramic layer and the bottom temperature of metal substrate on thermal insulation performance of thermal barrier coating system were discussed in detail. A new experimental method was designed and introduced to real-time test temperature data in the different cross-sectional locations along the system thickness direction. The results indicated that the experimental data collect-ed from these special locations consisted well with the corresponding theoretical results. The measurement method proposed can provide an important experimental basis for the prediction of thermal insulation performance of other thermal barrier coating systems.%热障涂层材料已成为现代高性能航空发动机的关键材料,而隔热性能一直是评价热障涂层性能的一个重要指标.首先基于傅里叶导热定律,推导出一维稳态温度场的解析表达式,并讨论了陶瓷层厚度、陶瓷层上表面工作温度和金属基底下表面工作温度对热障涂层系统隔热性能的影响.设计了一种比较新颖的实验测试方法,成功实现了对热障涂层系统内部不同位置的温度进行实时测试和保存实验数据.结果表明,各个温度采集点的实验测试结果与理论预测结果吻合很好,说明提出的实验测试方法可以有效评估不同类型的热障涂层材料体系的隔热性能.

  20. Evaluation of interface reactions in thermal barrier ceramic coatings

    Energy Technology Data Exchange (ETDEWEB)

    Celik, E.; Avci, E.; Yilmaz, F. [Sakarya Univ. (Turkey). Eng. Fac.

    1997-12-01

    In this study, the interface reactions in thermal barrier ceramic coatings (TBCs) on AISI 304L stainless steel substrates were investigated. The plasma-spray technique was employed to deposit metallic and ceramic powders such as MgZrO{sub 3}, NiAl+MgZrO{sub 3} and NiCrAl+MgZrO{sub 3} on the substrate. The porosity of these coatings, measured by an optical method, was found to be between 6 and 9%. Oxidation tests were carried out to evaluate the interface reactions in TBCs at temperatures of 800, 900 and 1000 C. The microstructures of the powders, coatings and oxidized coatings were examined by means of an optical microscope and X-ray diffractometry. The results show that the oxidation kinetics depend strongly on oxide layer thickness, temperature, duration of oxidation and composition of the bond coat. It was also observed that the oxidation rate changed with temperature was initially linear and then exponential. (orig.) 14 refs.

  1. Evaluation of the degradation of plasma sprayed thermal barrier coatings using nano-indentation.

    Science.gov (United States)

    Kim, Dae-Jin; Cho, Sung-Keun; Choi, Jung-Hun; Koo, Jae-Mean; Seok, Chang-Sung; Kim, Moon-Young

    2009-12-01

    In this study, the disk type of a thermal barrier coating (TBC) system for a gas turbine blade was isothermally aged at 1100 degrees C for various times up to 400 hours. For each aging condition, the thickness of the thermally grown oxide (TGO) was measured by optical microscope and mechanical properties such as the elastic modulus and hardness were measured by micro-indentation and nano-indentation on the cross-section of a coating specimen. In the case of micro-indentation, the mechanical properties of a Ni-base superalloy substrate and MCrAlY bond coat material did not significantly change with an increase in exposure time. In the case of nano-indentation, the gamma-Ni phase and beta-NiAl phase in the bond coat and top coat material show no significant change in their properties. However, the elastic modulus and the hardness of TGO show a remarkable decrease from 100 h to 200 h then remain nearly constant after 200 h due to the internal delamination of TBC. It has been confirmed that the nano-indentation technique is a very effective way to evaluate the degradation of a thermal barrier coating system.

  2. Oscillatory shear response of moisture barrier coatings containing clay of different shape factor.

    Science.gov (United States)

    Kugge, C; Vanderhoek, N; Bousfield, D W

    2011-06-01

    Oscillatory shear rheology of barrier coatings based on dispersed styrene-butadiene latex and clay of various shape factors or aspect ratio has been explored. Barrier performance of these coatings when applied to paperboard has been assessed in terms of water vapour transmission rates and the results related to shape factor, dewatering and critical strain. It has been shown that a system based on clay with high shape factor gives a lower critical strain, dewatering and water vapour transmission rate compared with clays of lower shape factor. The dissipated energy, as calculated from an amplitude sweep, indicated no attractive interaction between clay and latex implying a critical strain that appears to be solely dependent on the shape factor at a constant volume fraction. Particle size distribution was shown to have no effect on the critical strain while coatings of high elasticity exhibited high yield strains as expected. The loss modulus demonstrated strain hardening before the elastic to viscous transition. The loss modulus peak was identified by a maximum strain which was significantly lower for a coating based on clay with a high shape factor. The characteristic elastic time was found to vary between 0.6 and 1.3s. The zero shear viscosity of barrier dispersion coatings were estimated from the characteristic elastic time and the characteristic modulus to be of the order of 25-100 Pa s.

  3. Crack propagation studies and bond coat properties in thermal barrier coatings under bending

    Indian Academy of Sciences (India)

    A K Ray; N Roy; K M Godiwalla

    2001-04-01

    Ceramic based thermal barrier coatings (TBC) are currently considered as a candidate material for advanced stationary gas turbine components. Crack propagation studies under bending are described that were performed on plasma sprayed ZrO2, bonded by MCrAlY layer to Ni base superalloy. The crack propagation behaviour of the coatings at room temperature in as received and oxidized conditions revealed a linear growth of the cracks on the coating till the yield point of the super alloy was reached. High threshold load at the interface between the ceramic layer and the bond coat was required to propagate the crack further into the bond coat. Once the threshold load was surpassed the crack propagated into the brittle bond coat without an appreciable increase in the load. At temperatures of 800°C the crack propagated only in the TBC (ceramic layer), as the ductile bond coat offered an attractive sink for the stress relaxation. Effects of bond coat oxidation on crack propagation in the interface region have been examined and are discussed.

  4. Optical Diagnostics for High-Temperature Thermal Barrier Coatings

    Science.gov (United States)

    Eldridge, Jeffrey I.

    2009-01-01

    Thermal barrier coatings (TBCs) are typically composed of translucent ceramic oxides that provide thermal protection for metallic components exposed to high-temperature environments, such as in jet turbine engines. Taking advantage of the translucent nature of TBCs, optical diagnostics have been developed that can provide an informed assessment of TBC health that will allow mitigating action to be taken before TBC degradation threatens performance or safety. In particular, rare-earth-doped luminescent sublayers have been integrated into the TBC structure to produce luminescence that monitors TBC erosion, delamination, and temperature gradients. Erosion monitoring of TBC-coated specimens is demonstrated by utilizing visible luminescence that is excited from a sublayer that is exposed by erosion. TBC delamination monitoring is achieved in TBCs with a base rare-earth-doped luminescent sublayer by the reflectance-enhanced increase in luminescence produced in regions containing buried delamination cracks. TBC temperature monitoring is demonstrated using the temperature-dependent decay time for luminescence originating from the specific coating depth associated with a rare-earth-doped luminescent sublayer. The design and implementation of these TBCs with integrated luminescent sublayers is discussed, including co-doping strategies to produce more penetrating near-infrared luminescence. It is demonstrated that integration of the rare-earth-doped sublayers is achieved with no reduction in TBC life. In addition, results for multilayer TBCs designed to also perform as radiation barriers are also presented.

  5. Graphene Oxide Bionanocomposite Coatings with High Oxygen Barrier Properties

    Directory of Open Access Journals (Sweden)

    Ilke Uysal Unalan

    2016-12-01

    Full Text Available In this work, we present the development of bionanocomposite coatings on poly(ethylene terephthalate (PET with outstanding oxygen barrier properties. Pullulan and graphene oxide (GO were used as main polymer phase and nanobuilding block (NBB, respectively. The oxygen barrier performance was investigated at different filler volume fractions (ϕ and as a function of different relative humidity (RH values. Noticeably, the impermeable nature of GO was reflected under dry conditions, in which an oxygen transmission rate (OTR, mL·m−2·24 h−1 value below the detection limit of the instrument (0.01 mL·m−2·24 h−1 was recorded, even for ϕ as low as 0.0004. A dramatic increase of the OTR values occurred in humid conditions, such that the barrier performance was totally lost at 90% RH (the OTR of coated PET films was equal to the OTR of bare PET films. Modelling of the experimental OTR data by Cussler’s model suggested that the spatial ordering of GO sheets within the main pullulan phase was perturbed because of RH fluctuations. In spite of the presence of the filler, all the formulations allowed the obtainment of final materials with haze values below 3%, the only exception being the formulation with the highest loading of GO (ϕ ≈ 0.03. The mechanisms underlying the experimental observations are discussed.

  6. The Development of 2700-3000 F Environmental Barrier Coatings for SiC/SiC Ceramic Matrix Composites: Challenges and Opportunities

    Science.gov (United States)

    Zhu, Dongming

    2015-01-01

    Environmental barrier coatings (EBCs) and SiCSiC ceramic matrix composites (CMCs) systems will play a crucial role in future turbine engines for hot-section component applications because of their ability to significantly increase engine operating temperatures, reduce engine weight and cooling requirements. The development of prime-reliant environmental barrier coatings is a key to enable the applications of the envisioned 2700-3000F EBC - CMC systems to help achieve next generation engine performance and durability goals. This paper will primarily address the performance requirements and design considerations of environmental barrier coatings for turbine engine applications. The emphasis is placed on current NASA candidate environmental barrier coating systems for SiCSiC CMCs, their performance benefits and design limitations in long-term operation and combustion environments. The efforts have been also directed to developing prime-reliant, self-healing 2700F EBC bond coat; and high stability, lower thermal conductivity, and durable EBC top coats. Major technical barriers in developing environmental barrier coating systems, the coating integrations with next generation CMCs having the improved environmental stability, cyclic durability, erosion-impact resistance, and long-term system performance will be described. The research and development opportunities for turbine engine environmental barrier coating systems by utilizing improved compositions, state-of-the-art processing methods, and simulated environment testing and durability modeling will be discussed.

  7. Environmental Barrier Coating Development for SiC/SiC Ceramic Matrix Composites: Recent Advances and Future Directions

    Science.gov (United States)

    Zhu, Dongming

    2016-01-01

    This presentation briefly reviews the SiC/SiC major environmental and environment-fatigue degradations encountered in simulated turbine combustion environments, and thus NASA environmental barrier coating system evolution for protecting the SiC/SiC Ceramic Matrix Composites for meeting the engine performance requirements. The presentation will review several generations of NASA EBC materials systems, EBC-CMC component system technologies for SiC/SiC ceramic matrix composite combustors and turbine airfoils, highlighting the temperature capability and durability improvements in simulated engine high heat flux, high pressure, high velocity, and with mechanical creep and fatigue loading conditions. This paper will also focus on the performance requirements and design considerations of environmental barrier coatings for next generation turbine engine applications. The current development emphasis is placed on advanced NASA candidate environmental barrier coating systems for SiC/SiC CMCs, their performance benefits and design limitations in long-term operation and combustion environments. The efforts have been also directed to developing prime-reliant, self-healing 2700F EBC bond coat; and high stability, lower thermal conductivity, and durable EBC top coats. Major technical barriers in developing environmental barrier coating systems, the coating integrations with next generation CMCs having the improved environmental stability, erosion-impact resistance, and long-term fatigue-environment system durability performance will be described. The research and development opportunities for turbine engine environmental barrier coating systems by utilizing improved compositions, state-of-the-art processing methods, and simulated environment testing and durability modeling will be briefly discussed.

  8. Environmental/Thermal Barrier Coatings for Ceramic Matrix Composites: Thermal Tradeoff Studies

    Science.gov (United States)

    Murthy, Pappu L. M.; Brewer, David; Shah, Ashwin R.

    2007-01-01

    Recent interest in environmental/thermal barrier coatings (EBC/TBCs) has prompted research to develop life-prediction methodologies for the coating systems of advanced high-temperature ceramic matrix composites (CMCs). Heat-transfer analysis of EBC/TBCs for CMCs is an essential part of the effort. It helps establish the resulting thermal profile through the thickness of the CMC that is protected by the EBC/TBC system. This report documents the results of a one-dimensional analysis of an advanced high-temperature CMC system protected with an EBC/TBC system. The one-dimensional analysis was used for tradeoff studies involving parametric variation of the conductivity; the thickness of the EBC/TBCs, bond coat, and CMC substrate; and the cooling requirements. The insight gained from the results will be used to configure a viable EBC/TBC system for CMC liners that meet the desired hot surface, cold surface, and substrate temperature requirements.

  9. Applications of barrier bucket RF systems at Fermilab

    Energy Technology Data Exchange (ETDEWEB)

    Bhat, C.M.; /Fermilab

    2006-03-01

    In recent years, the barrier rf systems have become important tools in a variety of beam manipulation applications at synchrotrons. Four out of six proton synchrotrons at Fermilab are equipped with broad-band barrier rf systems. All of the beam manipulations pertaining to the longitudinal phase space in the Fermilab Recycler (synchrotron used for antiproton storage) are carried out using a barrier system. Recently, a number of new applications of barrier rf systems have been developed- the longitudinal momentum mining, longitudinal phase-space coating, antiproton stacking, fast bunch compression and more. Some of these techniques have been critical for the recent spectacular success of the collider performance at the Fermilab Tevatron. Barrier bunch coalescing to produce bright proton bunches has a high potential to increase proton antiproton luminosity significantly. In this paper, I will describe some of these techniques in detail. Finally, I make a few general remarks on issues related to barrier systems.

  10. Processing, characterization, and properties of some novel thermal barrier coatings

    Science.gov (United States)

    Jadhav, Amol D.

    The efficacy of ceramic thermal barrier coatings (TBCs) used to protect and to insulate metal components in engines increases with the thickness of the TBCs. However, the durabilities of thick TBCs deposited using conventional ceramic-coating deposition methods have not been adequate. Here the feasibility of depositing highly durable thick TBCs (1.5 to 4 mm thickness) of ZrO 2-7 wt.% Y2O3 (7YSZ) on bond-coated superalloy substrates using the solution-precursor plasma spray (SPPS) method has been demonstrated. Thermal cyclic durabilities of the thick SPPS TBCs have been shown to be much superior compared to TBCs deposited using the conventional air-plasma-spray (APS) process. To evaluate the performance of thick APS and SPPS TBCs, mechanical properties of free-standing coatings and coating/substrate interfaces have been determined experimentally. Additional evaluation of TBC performance has been obtained from studies of damage and development of thermally grown oxide (TGO) at the interface as a result of thermal cycling. The later results are used to suggest mechanisms of chemical failure of TGO in thick plasma-sprayed TBCs. Based on the experimental results and numerical analysis of the TBC residual stresses, the dramatic improvement in the thermal cycling life in the SPPS TBCs is attributed to superior mechanical properties of SPPS coatings. The presence of the strain tolerant vertical cracks in SPPS TBCs reduces the driving force for TBC spallation under mode-II loading. Additionally, high in-plane fracture toughness in the SPPS TBCs under mode-I loading delays the TBC spallation significantly. Finally, thermal conductivity of the SPPS TBCs has been reduced by microstructural tailoring. Analytical and object-oriented finite element (OOF) models have been used to analyze the experimental thermal conductivity data, and to predict thermal conductivities of engineered TBCs.

  11. Thermal barrier coatings for gas-turbine engine applications.

    Science.gov (United States)

    Padture, Nitin P; Gell, Maurice; Jordan, Eric H

    2002-04-12

    Hundreds of different types of coatings are used to protect a variety of structural engineering materials from corrosion, wear, and erosion, and to provide lubrication and thermal insulation. Of all these, thermal barrier coatings (TBCs) have the most complex structure and must operate in the most demanding high-temperature environment of aircraft and industrial gas-turbine engines. TBCs, which comprise metal and ceramic multilayers, insulate turbine and combustor engine components from the hot gas stream, and improve the durability and energy efficiency of these engines. Improvements in TBCs will require a better understanding of the complex changes in their structure and properties that occur under operating conditions that lead to their failure. The structure, properties, and failure mechanisms of TBCs are herein reviewed, together with a discussion of current limitations and future opportunities.

  12. Overview on the Development of Nanostructured Thermal Barrier Coatings

    Institute of Scientific and Technical Information of China (English)

    2007-01-01

    Thermal barrier coatings (TBCs) have successfully been used in gas turbine engines for increasing operation temperature and improving engine efficiency. Over the past thirty years, a variety of TBC materials and TBC deposition techniques have been developed. Recently, nanostructured TBCs emerge with the potential of commercial applications in various industries. In this paper, TBC materials and TBC deposition techniques such as air plasma spray (APS), electron beam physical vapor deposition (EB-PVD), laser assisted chemical vapor deposition (LACVD) are briefly reviewed. Nanostructured 7-8 wt pct yttria stabilized zirconia (7-8YSZ)TBC by air plasma spraying of powder and new TBC with novel structure deposited by solution precursor plasma spray (SPPS) are compared. Plasma spray conditions, coating forming mechanisms, microstructures,phase compositions, thermal conductivities, and thermal cycling lives of the APS nanostructured TBC and the SPPS nanostructured TBC are discussed. Research opportunities and challenges of nanostructured TBCs deposited by air plasma spray are prospected.

  13. Laser Remelting of Plasma Sprayed Thermal Barrier Coatings

    Institute of Scientific and Technical Information of China (English)

    Gang ZHANG; Yong LIANG; Yingna WU; Zhongchao FENG; Bingchun ZHANG; Fangjun LIU

    2001-01-01

    A CO2 continuous wave laser with defocused beam was used for remelting the surface of plasma sprayed ZrO2-8 wt pct Y2O3 (8YSZ)/Ni22Cr10AlY thermal barrier coatings (TBCs) on GH536 superalloy substrate. Two main laser processing parameters, power and travel speed, were adopted to produce a completely remelted layer, and their effects on remelted appearance,remelting depth, density and diameter of depression, space of segment crack and remelted microstructure were evaluated. With energy of 4.0 to 8.0 J.mm-2, an appropriate laser processing for applicable remelted layer was suggested.

  14. Preparation of thermal barrier coatings by ultrasonic plasma spraying

    Institute of Scientific and Technical Information of China (English)

    WEN Xiong-wei; LI Lu-ming; ZHANG Hua-tang; HAO Hong-wei; LU Zhi-qing

    2004-01-01

    Modulated plasma arc not only can heat the powder, but also can excite ultrasonic of different frequencies and different powers. The principles and characters of the plasma arc-excited ultrasonic were described, and the ultrasonic plasma spraying was compared with normal plasma spraying. Zirconia thermal barrier coatings (TBCs) were fabricated with two kinds of method. The TBCs were studied by the optical microscope observation, SEM observation and bonding strength experiment. The results show that suitable ultrasonic changes the performance and microstructure of TBCs in evidence. And the mechanism of ultrasonic influencing the TBCs was also discussed.

  15. TBCs for better engine efficiency. [thermal barrier coatings

    Science.gov (United States)

    Brindley, William J.; Miller, Robert A.

    1989-01-01

    State-of-the-art thermal barrier coatings (TBCs) developed for aircraft engines can achieve both hot-section component operating temperature reductions and superior oxidation resistance. Such TBCs typically consist of two layers: a metallic, often NiCrAlY 'bond' inner layer in contact with the superalloy structural component, and an outer, insulating ceramic layer. A ceramic frequently used in this role due to its high durability is plasma-sprayed ZrO2, partially stabilized with 6-8 wt pct Y2O3. TBCs can also be useful in nonaircraft gas turbines, which frequently use highly contaminated fuels.

  16. Design and Performance Optimizations of Advanced Erosion-Resistant Low Conductivity Thermal Barrier Coatings for Rotorcraft Engines

    Science.gov (United States)

    Zhu, Dongming; Miller, Robert A.; Kuczmarski, Maria A.

    2012-01-01

    Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future rotorcraft engine higher fuel efficiency and lower emission goals. For thermal barrier coatings designed for rotorcraft turbine airfoil applications, further improved erosion and impact resistance are crucial for engine performance and durability, because the rotorcraft are often operated in the most severe sand erosive environments. Advanced low thermal conductivity and erosion-resistant thermal barrier coatings are being developed, with the current emphasis being placed on thermal barrier coating toughness improvements using multicomponent alloying and processing optimization approaches. The performance of the advanced thermal barrier coatings has been evaluated in a high temperature erosion burner rig and a laser heat-flux rig to simulate engine erosion and thermal gradient environments. The results have shown that the coating composition and architecture optimizations can effectively improve the erosion and impact resistance of the coating systems, while maintaining low thermal conductivity and cyclic oxidation durability

  17. Life Prediction Issues in Thermal/Environmental Barrier Coatings in Ceramic Matrix Composites

    Science.gov (United States)

    Shah, Ashwin R.; Brewer, David N.; Murthy, Pappu L. N.

    2001-01-01

    Issues and design requirements for the environmental barrier coating (EBC)/thermal barrier coating (TBC) life that are general and those specific to the NASA Ultra-Efficient Engine Technology (UEET) development program have been described. The current state and trend of the research, methods in vogue related to the failure analysis, and long-term behavior and life prediction of EBCITBC systems are reported. Also, the perceived failure mechanisms, variables, and related uncertainties governing the EBCITBC system life are summarized. A combined heat transfer and structural analysis approach based on the oxidation kinetics using the Arrhenius theory is proposed to develop a life prediction model for the EBC/TBC systems. Stochastic process-based reliability approach that includes the physical variables such as gas pressure, temperature, velocity, moisture content, crack density, oxygen content, etc., is suggested. Benefits of the reliability-based approach are also discussed in the report.

  18. Failure of EB-PVD Thermal Barrier Coatings Subjected to Thermo-Mechanical Loading

    Institute of Scientific and Technical Information of China (English)

    CHEN Chen; ZHANG Chun-xia; GUO Hong-bo; GONG Sheng-kai; ZHANG Yue

    2006-01-01

    Thermal barrier coatings (TBCs) were developed to protect metallic blades and vanes working in turbo-engines. The two-layered structure TBCs, consisting of NiCoCrAlY bond coat and yttria stabilized zirconia (YSZ), were deposited on a cylinder of superalloy substrate by the electron beam-physical vapor deposition (EB-PVD). The failure mechanism of the TBCs was investigated with a thermo-mechanical fatigue testing system under the service condition similar to that for turbine blades. Non-destructive evaluation of the coated specimens was conducted through the impedance spectroscopy. It is found that the crack initiation mainly takes place on the top coat at the edge of the heated zones.

  19. Nanocomposite Lanthanum Zirconate Thermal Barrier Coating Deposited by Suspension Plasma Spray Process

    Science.gov (United States)

    Wang, Chaohui; Wang, You; Wang, Liang; Hao, Guangzhao; Sun, Xiaoguang; Shan, Fan; Zou, Zhiwei

    2014-10-01

    This work seeks to develop an innovative nanocomposite thermal barrier coating (TBC) exhibiting low thermal conductivity and high durability compared with that of current TBCs. To achieve this objective, nanosized lanthanum zirconate particles were selected for the topcoat of the TBC system, and a new process—suspension plasma spray—was employed to produce desirable microstructural features: the nanocomposite lanthanum zirconate TBC contains ultrafine splats and high volume porosity, for lower thermal conductivity, and better durability. The parameters of plasma spray experiment included two main variables: (i) spray distance varying from 40 to 80 mm and (ii) the concentration of suspension 20, 25, and 30 wt.%, respectively. The microstructure of obtained coatings was characterized with scanning electron microscope and x-ray diffraction. The porosity of coatings is in the range of 6-10%, and the single phase in the as-sprayed coatings was pyrochlore lanthanum zirconate.

  20. Initial Assessment of Environmental Barrier Coatings for the Prometheus Project

    Energy Technology Data Exchange (ETDEWEB)

    M. Frederick

    2005-12-15

    Depending upon final design and materials selections, a variety of engineering solutions may need to be considered to avoid chemical degradation of components in a notional space nuclear power plant (SNPP). Coatings are one engineered approach that was considered. A comprehensive review of protective coating technology for various space-reactor structural materials is presented, including refractory metal alloys [molybdenum (Mo), tungsten (W), rhenium (Re), tantalum (Ta), and niobium (Nb)], nickel (Ni)-base superalloys, and silicon carbide (Sic). A summary description of some common deposition techniques is included. A literature survey identified coatings based on silicides or iridium/rhenium as the primary methods for environmental protection of refractory metal alloys. Modified aluminide coatings have been identified for superalloys and multilayer ceramic coatings for protection of Sic. All reviewed research focused on protecting structural materials from extreme temperatures in highly oxidizing conditions. Thermodynamic analyses indicate that some of these coatings may not be protective in the high-temperature, impure-He environment expected in a Prometheus reactor system. Further research is proposed to determine extensibility of these coating materials to less-oxidizing or neutral environments.

  1. Synchrotron X-ray measurement techniques for thermal barrier coated cylindrical samples under thermal gradients.

    Science.gov (United States)

    Siddiqui, Sanna F; Knipe, Kevin; Manero, Albert; Meid, Carla; Wischek, Janine; Okasinski, John; Almer, Jonathan; Karlsson, Anette M; Bartsch, Marion; Raghavan, Seetha

    2013-08-01

    Measurement techniques to obtain accurate in situ synchrotron strain measurements of thermal barrier coating systems (TBCs) applied to hollow cylindrical specimens are presented in this work. The Electron Beam Physical Vapor Deposition coated specimens with internal cooling were designed to achieve realistic temperature gradients over the TBC coated material such as that occurring in the turbine blades of aeroengines. Effects of the circular cross section on the x-ray diffraction (XRD) measurements in the various layers, including the thermally grown oxide, are investigated using high-energy synchrotron x-rays. Multiple approaches for beam penetration including collection, tangential, and normal to the layers, along with variations in collection parameters are compared for their ability to attain high-resolution XRD data from the internal layers. This study displays the ability to monitor in situ, the response of the internal layers within the TBC, while implementing a thermal gradient across the thickness of the coated sample. The thermal setup maintained coating surface temperatures in the range of operating conditions, while monitoring the substrate cooling, for a controlled thermal gradient. Through variation in measurement location and beam parameters, sufficient intensities are obtained from the internal layers which can be used for depth resolved strain measurements. Results are used to establish the various techniques for obtaining XRD measurements through multi-layered coating systems and their outcomes will pave the way towards goals in achieving realistic in situ testing of these coatings.

  2. Synchrotron X-ray measurement techniques for thermal barrier coated cylindrical samples under thermal gradients

    Energy Technology Data Exchange (ETDEWEB)

    Siddiqui, Sanna F.; Knipe, Kevin; Manero, Albert; Raghavan, Seetha [Department of Mechanical and Aerospace Engineering, University of Central Florida, Orlando, Florida 32816 (United States); Meid, Carla; Wischek, Janine; Bartsch, Marion [German Aerospace Center (DLR), Institute of Materials Research, 51147 Cologne (Germany); Okasinski, John; Almer, Jonathan [X-Ray Science Division, Advanced Photon Source, Argonne National Laboratory, Argonne, Illinois 60439 (United States); Karlsson, Anette M. [Cleveland State University, 2121 Euclid Avenue, Cleveland, Ohio 44115 (United States)

    2013-08-15

    Measurement techniques to obtain accurate in situ synchrotron strain measurements of thermal barrier coating systems (TBCs) applied to hollow cylindrical specimens are presented in this work. The Electron Beam Physical Vapor Deposition coated specimens with internal cooling were designed to achieve realistic temperature gradients over the TBC coated material such as that occurring in the turbine blades of aeroengines. Effects of the circular cross section on the x-ray diffraction (XRD) measurements in the various layers, including the thermally grown oxide, are investigated using high-energy synchrotron x-rays. Multiple approaches for beam penetration including collection, tangential, and normal to the layers, along with variations in collection parameters are compared for their ability to attain high-resolution XRD data from the internal layers. This study displays the ability to monitor in situ, the response of the internal layers within the TBC, while implementing a thermal gradient across the thickness of the coated sample. The thermal setup maintained coating surface temperatures in the range of operating conditions, while monitoring the substrate cooling, for a controlled thermal gradient. Through variation in measurement location and beam parameters, sufficient intensities are obtained from the internal layers which can be used for depth resolved strain measurements. Results are used to establish the various techniques for obtaining XRD measurements through multi-layered coating systems and their outcomes will pave the way towards goals in achieving realistic in situ testing of these coatings.

  3. Thermal Shock Property of Al/Ni-ZrO2 Gradient Thermal Barrier Coatings

    Institute of Scientific and Technical Information of China (English)

    FAN Jin-juan; WANG Quan-sheng; ZHANG Wei-fang

    2004-01-01

    Al/Ni-ZrO2 gradient thermal barrier coatings are made on aluminum substrate using plasma spraying method and one direction thermal shock properties of the coatings are studied in this paper. The results show that pores in coatings link to form cracks vertical to coating surface. They go through the whole ZrO2 coating once vertical cracks form. When thermal shock cycles increase, horizontal cracks that result in coatings failure forms in the coatings and interface. And vertical cracks delay appearance of horizontal cracks and enhance thermal shock property of coatings. Failure mechanisms of coating thermal shock are discussed using experiments and finite element method.

  4. Thermal Shock Property of Al/Ni-ZrO2 Gradient Thermal Barrier Coatings

    Institute of Scientific and Technical Information of China (English)

    FANJin-juan; WANGQuan-sheng; ZHANGWei-fang

    2004-01-01

    Al/Ni-ZrO2 gradient thermal barrier coatings are made on aluminum substrate using plasma spraying method and one direction thermal shock properties of the coatings are studied in this paper. The results show that pores in coatings link to form cracks vertical to coating surface. They go through the whole ZrO2 coating once vertical cracks form. When thermal shock cycles increase, horizontal cracks that result in coatings failure forms in the coatings and interface. And vertical cracks delay appearance of horizontal cracks and enhance thermal shock property of coatings. Failure mechanisms of coating thermal shock are discussed using experiments and finite element method.

  5. Tunable Staged Release of Therapeutics from Layer-by-Layer Coatings with Clay Interlayer Barrier

    Science.gov (United States)

    Min, Jouha; Braatz, Richard D.; Hammond, Paula T.

    2014-01-01

    In developing new generations of coatings for medical devices and tissue engineering scaffolds, there is a need for thin coatings that provide controlled sequential release of multiple therapeutics while providing a tunable approach to time dependence and the potential for sequential or staged release. Herein, we demonstrate the ability to develop a self-assembled, polymer-based conformal coating, built by using a water-based layer-by-layer (LbL) approach, as a dual-purpose biomimetic implant surface that provides staggered and/or sustained release of an antibiotic followed by active growth factor for orthopedic implant applications. This multilayered coating consists of two parts: a base osteoinductive component containing bone morphogenetic protein-2 (rhBMP-2) beneath an antibacterial component containing gentamicin (GS). For the fabrication of truly stratified composite films with the customized release behavior, we present a new strategy—implementation of laponite clay barriers—that allows for a physical separation of the two components by controlling interlayer diffusion. The clay barriers in a single-component GS system effectively block diffusion-based release, leading to approximately 50% reduction in bolus doses and 10-fold increase in the release timescale. In a dual-therapeutic composite coating, the top GS component itself was found to be an effective physical barrier for the underlying rhBMP-2, leading to an order of magnitude increase in the release timescale compared to the single-component rhBMP-2 system. The introduction of a laponite interlayer barrier further enhanced the temporal separation between release of the two drugs, resulting in a more physiologically appropriate dosing of rhBMP-2. Both therapeutics released from the composite coating retained their efficacy over their established release timeframes. This new platform for multi-drug localized delivery can be easily fabricated, tuned, and translated to a variety of implant

  6. Property Evaluation and Damage Evolution of Environmental Barrier Coatings and Environmental Barrier Coated SiC/SiC Ceramic Matrix Composite Sub-Elements

    Science.gov (United States)

    Zhu, Dongming; Halbig, Michael; Jaskowiak, Martha; Hurst, Janet; Bhatt, Ram; Fox, Dennis S.

    2014-01-01

    This paper describes recent development of environmental barrier coatings on SiC/SiC ceramic matrix composites. The creep and fatigue behavior at aggressive long-term high temperature conditions have been evaluated and highlighted. Thermal conductivity and high thermal gradient cyclic durability of environmental barrier coatings have been evaluated. The damage accumulation and complex stress-strain behavior environmental barrier coatings on SiCSiC ceramic matrix composite turbine airfoil subelements during the thermal cyclic and fatigue testing of have been also reported.

  7. Mid-Infrared Reflectance Imaging of Thermal-Barrier Coatings

    Science.gov (United States)

    Edlridge, Jeffrey I.; Martin, Richard E.

    2009-01-01

    An apparatus for mid-infrared reflectance imaging has been developed as means of inspecting for subsurface damage in thermal-barrier coatings (TBCs). The apparatus is designed, more specifically, for imaging the progression of buried delamination cracks in plasma-sprayed yttria-stabilized zirconia coatings on turbine-engine components. Progression of TBC delamination occurs by the formation of buried cracks that grow and then link together to produce eventual TBC spallation. The mid-infrared reflectance imaging system described here makes it possible to see delamination progression that is invisible to the unaided eye, and therefore give sufficiently advanced warning before delamination progression adversely affects engine performance and safety. The apparatus (see figure) includes a commercial mid-infrared camera that contains a liquid-nitrogen-cooled focal plane indium antimonide photodetector array, and imaging is restricted by a narrow bandpass centered at wavelength of 4 microns. This narrow wavelength range centered at 4 microns was chosen because (1) it enables avoidance of interfering absorptions by atmospheric OH and CO2 at 3 and 4.25 microns, respectively; and (2) the coating material exhibits maximum transparency in this wavelength range. Delamination contrast is produced in the midinfrared reflectance images because the introduction of cracks into the TBC creates an internal TBC/air-gap interface with a high diffuse reflectivity of 0.81, resulting in substantially higher reflectance of mid-infrared radiation in regions that contain buried delamination cracks. The camera is positioned a short distance (.12 cm) from the specimen. The mid-infrared illumination is generated by a 50-watt silicon carbide source positioned to the side of the mid-infrared camera, and the illumination is collimated and reflected onto the specimen by a 6.35-cm-diameter off-axis paraboloidal mirror. Because the collected images are of a steady-state reflected intensity (in

  8. Vibration damping of superalloys and thermal barrier coatings at high-temperatures

    Energy Technology Data Exchange (ETDEWEB)

    Gregori, Giuliano [California NanoSystems Institute, University of California, Santa Barbara, CA 93160-5050 (United States)], E-mail: g.gregori@fkf.mpg.de; Li Li [Materials Department, University of California, Santa Barbara, CA 93160-5050 (United States); Nychka, John A. [Department of Chemical and Materials Engineering, University of Kentucky, Lexington, KY 40506-0046 (United States); Clarke, David R. [Materials Department, University of California, Santa Barbara, CA 93160-5050 (United States)

    2007-09-25

    A high-temperature mechanical spectroscopy system, based on non-contact laser vibrometry, has been developed to investigate the temperature dependence of the flexural damping properties of materials and coatings up to 900 deg. C. Results for the damping coefficient and Young's modulus have been obtained for several high temperature alloys (FeCrAlY and a single crystal, Ni-based superalloy PWA 1484), ceramics (polycrystalline alumina and yttria-stabilized zirconia) and an electron-beam deposited thermal barrier coating. The results indicate that the thermally grown oxide, formed by high-temperature oxidation does not confer significant damping, whereas, coatings of the yttria-stabilized zirconia produce measurable damping over the entire temperature range with a peak centered at {approx}200 deg. C. The damping peak appears to be an intrinsic property of the YSZ material whether in the form of a bulk material or a metastable coating. Data on the temperature dependent in-plane Young's modulus of the 7 wt.% yttria-stabilized zirconia thermal barrier coating between room temperature (22 GPa) and 900 deg. C (18 GPa) is also reported for the first time.

  9. Microstructural characterization of thermal barrier coating on Inconel 617 after high temperature oxidation

    Directory of Open Access Journals (Sweden)

    Mohammadreza Daroonparvar

    2013-06-01

    Full Text Available A turbine blade was protected against high temperature corrosion and oxidation by thermal barrier coatings (TBCsusing atmospheric plasma spraying technique (APS on a Ni-based superalloy (Inconel 617. The coatings (NiCr6AlY/ YSZ and NiCr10AlY/YSZ consist of laminar structure with substantial interconnected porosity transferred oxygen from Yittria stabilized Zirconia (YSZ layer toward the bond coat (NiCrAlY. Hence, a thermally grown oxide layer (TGO was formed on the metallic bond coat and internal oxidation of the bond coat occurred during oxidation. The TBC systems were oxidized in a normal electrically heated furnace at 1150 °C for 18, 22, 26, 32 and 40h.Microstructural characterization of coatings demonstrated that the growth of the TGO layer on the nickel alloy with 6wt. % Al is more rapid than TGO with 10wt. % Al. In addition, many micro-cracks were observed at the interface of NiCr6AlY/YSZ. X-ray diffraction analysis (XRD showed the existence of detrimental oxides such as NiCr2O4, NiCrO3 and NiCrO4 in the bond coat containing 6wt. % Al, accompanied by rapid volume expansion causing the destruction of TBC. In contrast, in the bond coat with 10wt. % Al, NiO, Al2O3and Cr2O3 oxides were formed while very low volume expansion occurred. The oxygen could not penetrate into the TGO layer of bond coat with 10 wt. % Al during high temperature oxidation and the detrimental oxides were not extensively formed within the bond coat as more oxygen was needed. The YSZ with higher Al content showed higher oxidation resistance.

  10. Numerical Parametric Analysis of Bond Coat Thickness Effect on Residual Stresses in Zirconia-Based Thermal Barrier Coatings

    Science.gov (United States)

    Abbas, Musharaf; Hasham, Hasan Junaid; Baig, Yasir

    2016-02-01

    Numerical-based finite element investigation has been conducted to explain the effect of bond coat thickness on stress distribution in traditional and nanostructured yttria-stabilized zirconia (YSZ)-based thermal barrier coatings (TBC). Stress components have been determined to quantitatively analyze the mechanical response of both kinds of coatings under the thermal shock effect. It has been found that maximum radial tensile and compressive stresses that exist at thermally grown oxide (TGO)/bond coat interface and within TGO respectively decrease with an increase in bond coat thickness. Effect of bond coat thickness on axial tensile stresses is not significant. However, axial compressive stresses that exist at the edge of the specimen near bond coat/substrate interface decrease appreciably with the increase in bond coat thickness. Residual stress profile as a function of bond coat thickness is further explained for comparative analysis of both coatings to draw some useful conclusions helpful in failure studies of TBCs.

  11. Microstructural features and properties of plasma sprayed YPSZ/NiCrAlY thermal barrier coating (TBC)

    Institute of Scientific and Technical Information of China (English)

    孙大谦; 王文权; 宣兆志; 宫文彪

    2004-01-01

    The plasma sprayed thermal barrier coating (TBC) consists of NiCrAlY bond coating and yttria partially stabilized zirconia (YPSZ) top coating. NiCrAlY coating mainly contains Ni solid solution with face centered cubic lattice, Al2O3 oxides and pores. The most obvious feature of YPSZ coating with tetragonal zirconia is a lot of vertical microcracks in this coating. The thermal insulation capability of the TBC increased with an increase in YPSZ coating thickness, the temperature drop across the TBC increasing from 60℃ to 92℃ with increasing YPSZ coating thickness with increasing YPSZ coating thickness and cracks initiated mainly in original vertical microcrack tips of the YPSZ coating and propagated not only along YPSZ coating / NiCrAlY coating interface but also through into two stages: transient oxidation stage with rapid oxidation rate and steady oxidation stage with slow oxidation. Their transition time was favorable to increase YPSZ coating toughness and to decrease the pores and oxides of the TBC system for improving thermal shock resistance and oxidation resistance of the TBC.

  12. High-temperature stability of yttria-stabilized zirconia thermal barrier coating on niobium alloy—C-103

    Indian Academy of Sciences (India)

    S S Panwar; T Umasankar Patro; K Balasubramanian; B Venkataraman

    2016-02-01

    Thermal barrier coatings (TBCs) of yttria-stabilized zirconia (YSZ) of different thicknesses with an intermediate bond coat were deposited on C-103 Nb alloy using the air plasma spraying technique. The coatings were subjected to rapid infra-red (IR) heating ($\\sim$25°C s$^{−1}$) up to $\\sim$1250°C and exposed up to 100 s at this temperature with heat flux varying from 55 to 61 Wcm$^{−2}$. The TBCs were found to be stable and intact after the heat treatment. In contrast, at the same conditions, the uncoated C-103 alloy specimen showed extensive oxidation followed by weight loss due to spallation. A maximum temperature drop of $\\sim$200°C was observed on the opposite side of the coated alloy with 600 $\\mu$m YSZ coat; as against negligible temperature drop in case of bare alloy specimen. The temperature drop was found to increase with the coating thickness of YSZ. The coatings before and after IR heating were investigated by scanning electron microscopy, X-ray diffraction, electron probe microanalysis, microhardness and residual stress measurements in order to understand the effect of thermal shock on the properties of the TBC. On account of these high-temperature properties, YSZ coating along with the bond coat is expected to find potential thermal barrier coating system on niobium alloys for supersonic vehicles.

  13. Thermal shock behavior of toughened gadolinium zirconate/YSZ double-ceramic-layered thermal barrier coating

    Energy Technology Data Exchange (ETDEWEB)

    Zhong, Xinghua, E-mail: xhzhong@mail.sic.ac.cn; Zhao, Huayu; Zhou, Xiaming; Liu, Chenguang; Wang, Liang; Shao, Fang; Yang, Kai; Tao, Shunyan; Ding, Chuanxian

    2014-04-01

    Highlights: • Gd{sub 2}Zr{sub 2}O{sub 7}/YSZ DCL thermal barrier coating was designed and fabricated. • The Gd{sub 2}Zr{sub 2}O{sub 7} top ceramic layer was toughened by addition of nanostructured 3YSZ. • Remarkable improvement in thermal shock resistance of the DCL coating was achieved. - Abstract: Double-ceramic-layered (DCL) thermal barrier coating system comprising of toughened Gadolinium zirconate (Gd{sub 2}Zr{sub 2}O{sub 7}, GZ) as the top ceramic layer and 4.5 mol% Y{sub 2}O{sub 3} partially-stabilized ZrO{sub 2} (4.5YSZ) as the bottom ceramic layer was fabricated by plasma spraying and thermal shock behavior of the DCL coating was investigated. The GZ top ceramic layer was toughened by addition of nanostructured 3 mol% Y{sub 2}O{sub 3} partially-stabilized ZrO{sub 2} (3YSZ) to improve fracture toughness of the matrix. The thermal shock resistance of the DCL coating was enhanced significantly compared to that of single-ceramic-layered (SCL) GZ-3YSZ composite coating, which is believed to be primarily attributed to the two factors: (i) the increase in fracture toughness of the top ceramic layer by incorporating nanostructured YSZ particles and (ii) the improvement in strain tolerance through the utilization of 4.5YSZ as the bottom ceramic layer. In addition, the failure mechanisms are mainly attributed to the still low fracture toughness of the top ceramic layer and oxidation of the bond-coat.

  14. Mechanisms and Mitigation of CMAS Attack on Thermal Barrier Coatings

    Science.gov (United States)

    Zaleski, Elisa Marie

    As gas turbine engines are driven to operate at higher temperatures to maximize efficiency, components become susceptible to attack by deposits of calcium magnesium alumino-silicate (CMAS) ingested with the intake air. Of particular interest to this work is the degradation of thermal barrier coatings (TBCs) by CMAS. Molten CMAS is known to interact with TBCs both thermochemically, by dissolving the ceramic and reprecipitating it as a new or modified phase, and thermomechanically, by infiltrating the porosity and degrading the strain tolerance. The thermochemical degradation of TBCs was investigated using primarily differential scanning calorimetry (DSC) by comparing the endotherms and exotherms recorded for pure, model silicates to those observed for silicates mixed with various TBC materials including YSZ and GZO. The five ternary silicates studied (CaO-AlO1.5-SiO2) began melting over a relatively narrow range (˜1125-1145°C). Introducing magnesium to the ternary results in higher melting temperatures and only minor changes to the crystallization behavior. Iron decreases the melting temperature, and markedly improves the crystallization kinetics of pure silicate systems, especially absent magnesium. Modification of the crystallization behavior of pure silicates has been proposed in the literature as a mitigation strategy for CMAS. This work utilizes DSC to look for characteristic changes as described above to probe potentially effective TBCs. The addition of YSZ to a quaternary CMAS results in little change to the melting or crystallization in the DSC, despite the dissolution of YSZ into the silicate. In stark contrast, GZO with CMAS generates a significant crystallization exotherm that appears in the DSC immediately after the silicate melts. As the fraction of GZO is increased, the melting endotherm begins to shrink due to the thermal overlap of the melting and crystallization processes. This signifies a rapid reaction, and a potentially useful TBC material for

  15. Fatigue testing of plasma-sprayed thermal barrier coatings, volume 2

    Science.gov (United States)

    Cruse, T. A.; Nagy, A.; Popelar, C. F.

    1990-01-01

    A plasma sprayed thermal barrier coating for diesel engines were fatigue tested. Candidate thermal barrier coating materials were fatigue screened and a data base was generated for the selected candidate material. Specimen configurations are given for the bend fatigue tests, along with test setup, specimen preparation, test matrix and procedure, and data analysis.

  16. Fatigue testing of plasma-sprayed thermal barrier coatings, Volume 2. Final report

    Energy Technology Data Exchange (ETDEWEB)

    Cruse, T.A.; Nagy, A.; Popelar, C.F.

    1990-07-01

    A plasma sprayed thermal barrier coating for diesel engines were fatigue tested. Candidate thermal barrier coating materials were fatigue screened and a data base was generated for the selected candidate material. Specimen configurations are given for the bend fatigue tests, along with test setup, specimen preparation, test matrix and procedure, and data analysis.

  17. Thermal Conductivity of Advanced Ceramic Thermal Barrier Coatings Determined by a Steady-state Laser Heat-flux Approach

    Science.gov (United States)

    Zhu, Dong-Ming; Miller, Robert A.

    2004-01-01

    The development of low conductivity and high temperature capable thermal barrier coatings requires advanced testing techniques that can accurately and effectively evaluate coating thermal conductivity under future high-performance and low-emission engine heat-flux conditions. In this paper, a unique steady-state CO2 laser (wavelength 10.6 microns) heat-flux approach is described for determining the thermal conductivity and conductivity deduced cyclic durability of ceramic thermal and environmental barrier coating systems at very high temperatures (up to 1700 C) under large thermal gradients. The thermal conductivity behavior of advanced thermal and environmental barrier coatings for metallic and Si-based ceramic matrix composite (CMC) component applications has also been investigated using the laser conductivity approach. The relationships between the lattice and radiation conductivities as a function of heat flux and thermal gradient at high temperatures have been examined for the ceramic coating systems. The steady-state laser heat-flux conductivity approach has been demonstrated as a viable means for the development and life prediction of advanced thermal barrier coatings for future turbine engine applications.

  18. Reliability assessment on interfacial failure of thermal barrier coatings

    Science.gov (United States)

    Guo, Jin-Wei; Yang, Li; Zhou, Yi-Chun; He, Li-Min; Zhu, Wang; Cai, Can-Ying; Lu, Chun-Sheng

    2016-10-01

    Thermal barrier coatings (TBCs) usually exhibit an uncertain lifetime owing to their scattering mechanical properties and severe service conditions. To consider these uncertainties, a reliability assessment method is proposed based on failure probability analysis. First, a limit state equation is established to demarcate the boundary between failure and safe regions, and then the failure probability is calculated by the integration of a probability density function in the failure area according to the first- or second-order moment. It is shown that the parameters related to interfacial failure follow a Weibull distribution in two types of TBC. The interfacial failure of TBCs is significantly affected by the thermal mismatch of material properties and the temperature drop in service.

  19. Acoustic emission assessment of interface cracking in thermal barrier coatings

    Science.gov (United States)

    Yang, Li; Zhong, Zhi-Chun; Zhou, Yi-Chun; Zhu, Wang; Zhang, Zhi-Biao; Cai, Can-Ying; Lu, Chun-Sheng

    2016-04-01

    In this paper, acoustic emission (AE) and digital image correlation methods were applied to monitor interface cracking in thermal barrier coatings under compression. The interface failure process can be identified via its AE features, including buckling, delamination incubation and spallation. According to the Fourier transformation of AE signals, there are four different failure modes: surface vertical cracks, opening and sliding interface cracks, and substrate deformation. The characteristic frequency of AE signals from surface vertical cracks is 0.21 MHz, whilst that of the two types of interface cracks are 0.43 and 0.29 MHz, respectively. The energy released of the two types of interface cracks are 0.43 and 0.29 MHz, respectively. Based on the energy released from cracking and the AE signals, a relationship is established between the interface crack length and AE parameters, which is in good agreement with experimental results.

  20. Reliability assessment on interfacial failure of thermal barrier coatings

    Institute of Scientific and Technical Information of China (English)

    Jin-Wei Guo; Li Yang; Yi-Chun Zhou; Li-Min He; Wang Zhu; Can-Ying Cai; Chun-Sheng Lu

    2016-01-01

    Thermal barrier coatings (TBCs) usually exhibit an uncertain lifetime owing to their scattering mechanical properties and severe service conditions. To consider these uncertainties, a reliability assessment method is proposed based on failure probability analysis. First, a limit state equa-tion is established to demarcate the boundary between failure and safe regions, and then the failure probability is calculated by the integration of a probability density function in the failure area according to the first-or second-order moment. It is shown that the parameters related to interfacial failure follow a Weibull distribution in two types of TBC. The inter-facial failure of TBCs is significantly affected by the thermal mismatch of material properties and the temperature drop in service.

  1. Some recent trends in research and technology of advanced thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Schulz, U.; Leyens, Ch.; Fritscher, K.; Peters, M.; Saruhan-Brings, B. [Deutsches Zentrum fur Luft- und Raumfahrt, DLR, Institute of Mateirals Research, Koln (Germany); Lavigne, O.; Dorvaux, J.M.; Poulain, M.; Mevrel, R.; Caliez, M. [Office National d' Etudes et de Recherches Aerospatiales (ONERA), Dept. of Metallic Materials and Processing, 92 - Chatillon (France)

    2003-01-01

    Ceramic thermal barrier coatings (TBCs) offer the potential to significantly improve efficiencies of aero engines as well as stationary gas turbines for power generation. On internally cooled turbine parts temperature gradients of the order of 100 to 150 deg. C can be achieved. Today, state-of-the-art TBCs, typically consisting of an yttria-stabilised zirconia top coat and a metallic bond coat deposited onto a superalloy substrate, are mainly used to extend lifetime. Further efficiency improvements require TBCs being an integral part of the component which, in turn, requires reliable and predictable TBC performance. Presently, TBCs produced by electron beam physical vapour deposition are favoured for high performance applications. The paper highlights critical R and D needs for advanced TBC systems with a special focus on reduced thermal conductivity and life prediction needs. (authors)

  2. Hafnia-Based Nanostructured Thermal Barrier Coatings for Advanced Hydrogen Turbine Technology

    Energy Technology Data Exchange (ETDEWEB)

    Ramana, Chintalapalle; Choudhuri, Ahsan

    2013-01-31

    Thermal barrier coatings (TBCs) are critical technologies for future gas turbine engines of advanced coal based power generation systems. TBCs protect engine components and allow further increase in engine temperatures for higher efficiency. In this work, nanostructured HfO{sub 2}-based coatings, namely Y{sub 2}O{sub 3}-stabilized HfO{sub 2} (YSH), Gd{sub 2}O{sub 3}-stabilized HfO{sub 2} (GSH) and Y{sub 2}O{sub 3}-stabilized ZrO{sub 2}-HfO{sub 2} (YSZH) were investigated for potential TBC applications in hydrogen turbines. Experimental efforts are aimed at creating a fundamental understanding of these TBC materials. Nanostructured ceramic coatings of YSH, GSH and YSZH were grown by physical vapor deposition methods. The effects of processing parameters and ceramic composition on the microstructural evolution of YSH, GSH and YSZH nanostructured coatings was studied using combined X-ray diffraction (XRD) and Electron microscopy analyses. Efforts were directed to derive a detailed understanding of crystal-structure, morphology, and stability of the coatings. In addition, thermal conductivity as a function of composition in YSH, YSZH and GSH coatings was determined. Laboratory experiments using accelerated test environments were used to investigate the relative importance of various thermo-mechanical and thermo-chemical failure modes of TBCs. Effects of thermal cycling, oxidation and their complex interactions were evaluated using a syngas combustor rig.

  3. Application of Rare Earths in Thermal Barrier Coating Materials

    Institute of Scientific and Technical Information of China (English)

    Xueqiang CAO

    2007-01-01

    Rare earths are a series of minerals with special properties that make them essential for applications including miniaturized electronics, computer hard disks, display panels, missile guidance, pollution controlling catalysts,H2-storage and other advanced materials. The use of thermal barrier coatings (TBCs) has the potential to extend the working temperature and the life of a gas turbine by providing a layer of thermal insulation between the metallic substrate and the hot gas. Yttria (Y2O3), as one of the most important rare earth oxides, has already been used in the typical TBC material YSZ (yttria stabilized zirconia). In the development of the TBC materials, especially in the latest ten years, rare earths have been found to be more and more important. All the new candidates of TBC materials contain a large quantity of rare earths, such as R2Zr2O7 (R=La, Ce, Nd,Gd), CeO2-YSZ, RMeAI11O19 (R=La, Nd; Me=Mg, Ca, Sr) and LaPO4. The concept of double-ceramiclayer coatings based on the rare earth materials and YSZ is effective for the improvement of the thermal shock life of TBCs at high temperature.

  4. Coupled Effects of Temperature Gradient and Oxidation on the Thermal Barrier Coating Failure

    Institute of Scientific and Technical Information of China (English)

    Y.C.Zhou; T.Hashida

    2000-01-01

    The present article reviews the investigation about the coupled effects of temperature gradient and oxidation on the failure of thermal barrier ceramic coatings in the past ten years in our laboratory. The investigations include the experimental and theoretical study. On the experimental investigation, the heating method, non-destructive evaluation and interface properties are mainly reviewed. An attempt is done for developing four different heating methods, which are furnace heating, burner heating, plasma heating and laser beam heating. The non-destructive evaluation such as temperature test, acoustic emission (AE) signals detected and impedance spectroscopy (IS) method are successfully used in the study of TBCs system degradation. The interface properties such as oxidation and fracture toughness are studied by test and observation. On the theoretical investigation, the temperature fields and the related thermal stresses fields are analytical solved where the coupling effect of temperature gradient, oxidation, thermal fatigue, creep, morphology of the TBC system as well as the cooling rate are considered. The delamination cracking in thermal barrier coating system with ceramic coating deposited on a substrate is analytical studied. Due to the complication of TBCs degradation, a real physical map of TBCs system failure is not obtained up to now. The investigation on the further is proposed.

  5. Barrier properties and storage stability of edible coatings prepared with electrospraying

    NARCIS (Netherlands)

    Khan, M.K.I.; Schutyser, M.A.I.; Schroen, C.G.P.H.; Boom, R.M.

    2014-01-01

    Electrospraying is a novel technique for the application of coating to foods. In this study, thin lipid-based coatings were prepared by electrospraying on model surface and evaluated for their moisture barrier functionality. Sunflower oil and chocolate based coating materials were electrosprayed at

  6. Anti-browning and barrier properties of edible coatings prepared with electrospraying

    NARCIS (Netherlands)

    Khan, M.K.I.; Cakmak, I.; Tavman, S.; Schutyser, M.A.I.; Schroen, C.G.P.H.

    2014-01-01

    Electrospraying is a novel technique for the application of coating to foods. In this study, thin lipid-based coatings were prepared by electrospraying on model surface and evaluated for their moisture barrier functionality. Sunflower oil and chocolate based coating materials were electrosprayed at

  7. Design of a Nickel-Based Bond-Coat Alloy for Thermal Barrier Coatings on Copper Substrates

    Directory of Open Access Journals (Sweden)

    Torben Fiedler

    2014-11-01

    Full Text Available To increase the lifetime of rocket combustion chambers, thermal barrier coatings (TBC may be applied on the copper chamber wall. Since standard TBC systems used in gas turbines are not suitable for rocket-engine application and fail at the interface between the substrate and bond coat, a new bond-coat material has to be designed. This bond-coat material has to be chemically compatible to the copper substrate to improve the adhesion and needs a coefficient of thermal expansion close to that of copper to reduce thermal stresses. One approach to achieve this is to modify the standard NiCrAlY alloy used in gas turbines by adding copper. In this work, the influence of copper on the microstructure of NiCrAlY-alloys is investigated with thermodynamical calculations, optical microscopy, SEM, EDX and calorimetry. Adding copper leads to the formation of a significant amount of \\(\\beta\\ and \\(\\alpha\\ Reducing the aluminum and chromium content leads furthermore to a two-phase fcc microstructure.

  8. Residual Stress Analysis of Laser-Drilled Thermal Barrier Coatings Involving Various Bond Coats

    Science.gov (United States)

    Guinard, C.; Montay, G.; Guipont, V.; Jeandin, M.; Girardot, J.; Schneider, M.

    2015-01-01

    The gas turbine combustion chamber of aero-engines requires a thermal barrier coating (TBC) by thermal spraying. Further heat protection is achieved by laser drilling of cooling holes. The residual stresses play an important role in the mechanical behaviour of TBC. It could also affect the TBC response to delamination during laser drilling. In this work, studies of the cracking behaviour after laser drilling and residual stress distribution have been achieved for different bond coats by plasma spray or cold spray. From interface crack length measured pulse-by-pulse after laser percussion drilling at 20° angle, the role of the various bond coats on crack initiation and propagation are investigated. It is shown that the bond coat drastically influences the cracking behaviour. The residual stresses profiles were also determined by the incremental hole-drilling method involving speckle interferometry. An original method was also developed to measure the residual stress profiles around a pre-drilled zone with a laser beam at 90°. The results are discussed to highlight the influence of TBCs interfaces on the resulting residual stresses distribution before laser drilling, and also to investigate the modification around the hole after laser drilling. It is shown that laser drilling could affect the residual stress state.

  9. High-Heat-Flux Cyclic Durability of Thermal and Environmental Barrier Coatings

    Science.gov (United States)

    Zhu, Dongming; Ghosn, Louis L.; Miller, Robert A.

    2007-01-01

    Advanced ceramic thermal and environmental barrier coatings will play an increasingly important role in future gas turbine engines because of their ability to protect the engine components and further raise engine temperatures. For the supersonic vehicles currently envisioned in the NASA fundamental aeronautics program, advanced gas turbine engines will be used to provide high power density thrust during the extended supersonic flight of the aircraft, while meeting stringent low emission requirements. Advanced ceramic coating systems are critical to the performance, life and durability of the hot-section components of the engine systems. In this work, the laser and burner rig based high-heat-flux testing approaches were developed to investigate the coating cyclic response and failure mechanisms under simulated supersonic long-duration cruise mission. The accelerated coating cracking and delamination mechanism under the engine high-heat-flux, and extended supersonic cruise time conditions will be addressed. A coating life prediction framework may be realized by examining the crack initiation and propagation in conjunction with environmental degradation under high-heat-flux test conditions.

  10. Mechanical Properties of Air Plasma Sprayed Environmental Barrier Coating (EBC) Materials

    Science.gov (United States)

    Richards, Bradley; Zhu, Dongming; Ghosn, Louis; Wadley, Haydn

    2015-01-01

    Development work in Environmental Barrier Coatings (EBCs) for Ceramic Matrix Composites (CMCs) has focused considerably on the identification of materials systems and coating architectures to meet application needs. The evolution of these systems has occurred so quickly that modeling efforts and requisite data for modeling lag considerably behind development. Materials property data exists for many systems in the bulk form, but the effects of deposition on the critical properties of strength and fracture behavior are not well studied. We have plasma sprayed bulk samples of baseline EBC materials (silicon, ytterbium disilicate) and tested the mechanical properties of these materials to elicit differences in strength and toughness. We have also endeavored to assess the mixed-mode fracture resistance, Gc, of silicon in a baseline EBC applied to SiCSiC CMC via four point bend test. These results are compared to previously determined properties of the comparable bulk material.

  11. PLASMA THERMAL BARRIER COATINGS BASED ON ZIRCONIUM DIOXIDE WITH HIGH THERMAL STABILITY

    Directory of Open Access Journals (Sweden)

    O. G. Devoino

    2015-01-01

    Full Text Available The paper presents optimization of  processes for obtaining maximum content of tetragonal phase in the initial material and thermal barrier coatings (TBC based on zirconium dioxide and hafnium oxide.  Results of the investigations on phase composition of oxide HfO2 – ZrO2 – Y2O3  system have been given in the paper. The system represents  a microstructure which is similar to  zirconia dioxide and  transformed for its application at 1300 °C. The paper explains a mechanism of hafnium oxide influence on formation of the given microstructure. The research methodology has been based on complex metallography, X – ray diffraction and electron microscopic investigations of  structural elements of the composite plasma coating HfO2 – ZrO2 – Y2O system.In order to stabilize zirconium dioxide  dopant oxide should not only have an appropriate size of  metal ion, but also form a solid solution with the zirconia. This condition severely limits the number of possible stabilizers. In fact, such stabilization is possible only with the help of rare earth oxides (Y2O3, Yb2O3, CeO2, HfO2. Chemical purity of the applied materials plays a significant role for obtaining high-quality thermal barrier coatings. Hafnium oxide has been selected as powder for thermal barrier coatings instead of zirconium dioxide due to their similarities in structural modification, grating, chemical and physical properties and its high temperature structural transformations. It has been established that plasma thermal barrier HfO2 – ZrO2 – Y2O3 coatings consist of  one tetragonal phase. This phase is equivalent to a non-equilibrium tetragonal t' phase in the “zirconium dioxide stabilized with yttrium oxide” system. Affinity of  Hf+4 and Zr+4 cations leads to the formation of identical metastable phases during rapid quenching.

  12. Thermal barrier coatings: Coating methods, performance, and heat engine applications. (Latest citations from the EI Compendex*plus database). Published Search

    Energy Technology Data Exchange (ETDEWEB)

    NONE

    1997-02-01

    The bibliography contains citations concerning conference proceedings on coating methods, performance evaluations, and applications of thermal barrier coatings as protective coatings for heat engine components against high temperature corrosions and chemical erosions. The developments of thermal barrier coating techniques for high performance and reliable gas turbines, diesel engines, jet engines, and internal combustion engines are presented. Topics include plasma sprayed coating methods, yttria stabilized zirconia coatings, coating life models, coating failure and durability, thermal shock and cycling, and acoustic emission analysis of coatings. (Contains 50-250 citations and includes a subject term index and title list.) (Copyright NERAC, Inc. 1995)

  13. Mechanical and Barrier Properties of Epoxy/ultra-short Glass Fibers Composite Coatings

    Institute of Scientific and Technical Information of China (English)

    Yongsheng Hao; Fuchun Liu; En-Hou Han

    2012-01-01

    Epoxy coatings containing different volume fractions of ultra-short glass fibers were prepared successfully. Ultra-short glass fiber not only can improve the hardness, adhesion of the coating, and glass transition tem-perature (Tg), but also can decrease the coefficient of thermal expansion (CTE) of the coating. Electrochemical impedance spectroscopy (EIS) was used to evaluate the barrier properties of the coatings containing different volume fractions of ultra-short glass fibers. The EIS results showed that the coating had the best barrier property when it contained 20% (volume fraction) ultra-short glass fibers. The functions of the ultra-short glass fibers in epoxy coating are two fold: first, they can improve the coating mechanical properties as reinforcement materials; second, they parallel to the substrate and inhibit the corrosive medium to pass through the coating.

  14. Behavior of nanoporous thermal barrier coatings under cyclic thermal loading. Computer-aided simulation

    Energy Technology Data Exchange (ETDEWEB)

    Moiseenko, D. D., E-mail: mdd@ispms.tsc.ru; Maksimov, P. V., E-mail: mdd@ispms.tsc.ru [Institute of Strength Physics and Materials Sciences SB RAS, Tomsk, 634055 (Russian Federation); Panin, S. V., E-mail: svp@ispms.tsc.ru; Panin, V. E., E-mail: paninve@ispms.tsc.ru [Institute of Strength Physics and Materials Sciences SB RAS, Tomsk, 634055 (Russian Federation); Tomsk Polytechnic University, Tomsk, 634050 (Russian Federation); Berto, F., E-mail: berto@gest.unipd.it [University of Padua, Vicenza, 36100 Italy (Italy)

    2015-10-27

    The work presents the development of new algorithms for calculating the fraction of thermal energy dissipated during the irradiation on the inner surface of pores. On the basis of these algorithms, the simulation of heat transfer in three-layered systems was carried out taking into account the dissipation of thermal energy in specimens having different porosity. We have performed quantitative estimates of the portion of dissipating thermal energy and its influence on the distribution of thermal stresses in thermal barrier coating systems. It was demonstrated that the presence of pores with a large internal surface area in the intermediate layer material enables two-fold decrease of the internal thermal stresses.

  15. Thermal conductivity and thermal stability of zirconia and hafnia based thermal barrier coatings by EB-PVD for high temperature applications

    Energy Technology Data Exchange (ETDEWEB)

    Singh, J.; Wolfe, D.E.; Miller, R.; Eldridge, J.; Zhu Dong-Ming [Applied Research Lab., Penn State Univ., Univ. Park, PA and NASA-GRC, Cleveland, OH (United States)

    2004-07-01

    Zirconia and hafnia based thermal barrier coating materials were produced by industrial prototype electron beam-physical vapor deposition (EB-PVD). Columnar microstructure of the thermal barrier coatings were modified with controlled microporosity and diffuse sub-interfaces resulting in lower thermal conductivity (20-30% depending up on microporosity volume fraction), higher thermal reflectance (15-20%) and more strain tolerance as compared with standard thermal barrier coatings (TBC). The novel processed coating systems were examined by various techniques including scanning electron microscopy (SEM), X-ray diffraction, and thermal conductivity by laser technique, hemispherical reflectance and thermal cyclic tests. The test results showed the tailored-microstructural TBC offered superior performance over the conventional thermal barrier coatings (ZrO{sub 2} -8 wt.% Y{sub 2}O{sub 3}). (orig.)

  16. Degradation of Thermal Barrier Coatings from Deposits and Its Mitigation

    Energy Technology Data Exchange (ETDEWEB)

    Nitin Padture

    2011-12-31

    Ceramic thermal barrier coatings (TBCs) used in gas-turbine engines afford higher operating temperatures, resulting in enhanced efficiencies and performance. However, in the case of syngas-fired engines, fly ash particulate impurities that may be present in syngas can melt on the hotter TBC surfaces and form glassy deposits. These deposits can penetrate the TBCs leading to their failure. In experiments using lignite fly ash to simulate these conditions we show that conventional TBCs of composition 93wt% ZrO{sub 2} + 7wt% Y{sub 2}O{sub 3} (7YSZ) fabricated using the air plasma spray (APS) process are completely destroyed by the molten fly ash. The molten fly ash is found to penetrate the full thickness of the TBC. The mechanisms by which this occurs appear to be similar to those observed in degradation of 7YSZ TBCs by molten calcium-magnesium-aluminosilicate (CMAS) sand and by molten volcanic ash in aircraft engines. In contrast, APS TBCs of Gd{sub 2Zr{sub 2}O{sub 7} composition are highly resistant to attack by molten lignite fly ash under identical conditions, where the molten ash penetrates ~25% of TBC thickness. This damage mitigation appears to be due to the formation of an impervious, stable crystalline layer at the fly ash/Gd{sub 2}Zr{sub 2}O{sub 7} TBC interface arresting the penetrating moltenfly- ash front. Additionally, these TBCs were tested using a rig with thermal gradient and simultaneous accumulation of ash. Modeling using an established mechanics model has been performed to illustrate the modes of delamination, as well as further opportunities to optimize coating microstructure. Transfer of the technology was developed in this program to all interested parties.

  17. Multilayer Thermal Barrier Coating (TBC) Architectures Utilizing Rare Earth Doped YSZ and Rare Earth Pyrochlores

    Science.gov (United States)

    Schmitt, Michael P.; Rai, Amarendra K.; Bhattacharya, Rabi; Zhu, Dongming; Wolfe, Douglas E.

    2014-01-01

    To allow for increased gas turbine efficiencies, new insulating thermal barrier coatings (TBCs) must be developed to protect the underlying metallic components from higher operating temperatures. This work focused on using rare earth doped (Yb and Gd) yttria stabilized zirconia (t' Low-k) and Gd2Zr2O7 pyrochlores (GZO) combined with novel nanolayered and thick layered microstructures to enable operation beyond the 1200 C stability limit of current 7 wt% yttria stabilized zirconia (7YSZ) coatings. It was observed that the layered system can reduce the thermal conductivity by approximately 45 percent with respect to YSZ after 20 hr of testing at 1316 C. The erosion rate of GZO is shown to be an order to magnitude higher than YSZ and t' Low-k, but this can be reduced by almost 57 percent when utilizing a nanolayered structure. Lastly, the thermal instability of the layered system is investigated and thought is given to optimization of layer thickness.

  18. Compilation of diamond-like carbon properties for barriers and hard coatings

    Energy Technology Data Exchange (ETDEWEB)

    Outka, D.A.; Hsu, Wen L.; Phillips, K.; Boehme, D.R.; Yang, N.Y.C.; Ottesen, D.K.; Johnsen, H.A.; Clift, W.M. [Sandia National Labs., Livermore, CA (United States); Headley, T.J. [Sandia National Labs., Albuquerque, NM (United States)

    1994-05-01

    Diamond-like carbon (DLC) is an amorphous form of carbon which resembles diamond in its hardness, lubricity, and resistance to chemical attack. Such properties make DLC of interest for use in barrier and hard coating technology. This report examines a variety of properties of DLC coatings. This includes examining substrates on which DLC coatings can be deposited; the resistance of DLC coatings to various chemical agents; adhension of DLC coatings; and characterization of DLC coatings by electron microscopy, FTIR, sputter depth profiling, stress measurements and nanoindentation.

  19. Microstructure Analysis of Laser Remelting for Thermal Barrier Coatings on the Surface of Titanium Alloy

    Directory of Open Access Journals (Sweden)

    Lu Bin

    2016-01-01

    Full Text Available In this paper, the preparation and organization performance of thermal barrier coatings (TCBs on the surface of titanium were studied experimentally. Nanostructured 8 wt% yttria partially stabilized zirconia coatings were deposited by air plasma spraying. The microstructure of nanostructured and the conventional coating was studied after laser remelting. It has shown that formed a network of micro-cracks and pits after laser remelting on nanostructured coatings. With the decrease of the laser scanning speed, mesh distribution of micro cracks was gradually thinning on nanostructured coatings. Compared with conventional ceramic layers, the mesh cracks of nanostructured coating is dense and the crack width is small.

  20. Optimization Design Model of Functional Gradient Thermal Barrier Coating Material by Using Parallel Computation

    Directory of Open Access Journals (Sweden)

    Chen Zhao

    2016-01-01

    Full Text Available It is important for huge ship to find the ceramic/metal functional gradient thermal barrier coating materials. A parallel computation model is built for optimization design of three-dimensional ceramic/metal functionally gradient thermal barrier coating material. According to the control equation and initial-boundary conditions, the heat transfer problem is considered, and numerical algorithms of optimization design is constructed by adapting difference method. The numerical results shows that gradient thermal barrier coating material can improve the function of material.

  1. Factors Influencing Residual Stresses in Yttria Stabilized Zirconia Thermal Barrier Coatings

    Science.gov (United States)

    McGrann, Roy T. R.; Rybicki, Edmund F.; Shadley, John R.; Brindley, William J.

    1997-01-01

    To improve gas turbine and diesel engine performance using thermal barrier coatings (TBC's) requires an understanding of the factors that influence the in-service behavior of thermal barrier coatings. One of the many factors related to coating performance is the state of stress in the coating. The total stress state is composed of the stresses due to the in-service loading history and the residual stresses. Residual stresses have been shown to affect TBC life, the bond strength of thermal spray coatings, and the fatigue life of tungsten carbide coatings. Residual stresses are first introduced in TBC's by the spraying process due to elevated temperatures during processing and the difference in coefficients of thermal expansion of the top coat, bond coat, and substrate. Later, the residual stresses can be changed by the in-service temperature history due to a number of time and temperature dependent mechanisms, such as oxidation, creep, and sintering. Silica content has also been shown to affect sintering and the cyclic life of thermal barrier coatings. Thus, it is important to understand how the spraying process, the in-service thermal cycles, and the silica content can create and alter residual stresses in thermal barrier coatings.

  2. Durability and Design Issues of Thermal/environmental Barrier Coatings on Sic/sic Ceramic Matrix Composites Under 1650 C Test Conditions

    Science.gov (United States)

    Zhu, Dong-Ming; Choi, Sung R.; Ghosn, Louis J.; Miller, Robert A.

    2004-01-01

    Ceramic thermal/environmental barrier coatings for SiC-based ceramics will play an increasingly important role in future gas turbine engines because of their ability to effectively protect the engine components and further raise engine temperatures. However, the coating durability remains a major concern with the ever-increasing temperature requirements. Currently, advanced T/EBC systems, which typically include a high temperature capable zirconia- (or hahia-) based oxide top coat (thermal barrier) on a less temperature capable mullite/barium-strontium-aluminosilicate (BSAS)/Si inner coat (environmental barrier), are being developed and tested for higher temperature capability Sic combustor applications. In this paper, durability of several thermal/environmental barrier coating systems on SiC/SiC ceramic matrix composites was investigated under laser simulated engine thermal gradient cyclic, and 1650 C (3000 F) test conditions. The coating cracking and delamination processes were monitored and evaluated. The effects of temperature gradients and coating configurations on the ceramic coating crack initiation and propagation were analyzed using finite element analysis (FEA) models based on the observed failure mechanisms, in conjunction with mechanical testing results. The environmental effects on the coating durability will be discussed. The coating design approach will also be presented.

  3. Thick Thermal Barrier Coatings (TTBCs) for Low Emission, High Efficiency Diesel Engine Components

    Energy Technology Data Exchange (ETDEWEB)

    M. Brad Beardsley, Caterpillar Inc.; Dr. Darrell Socie, University of Illinois; Dr. Ed Redja, University of Illinois; Dr. Christopher Berndt, State University of New York at Stony Brook

    2006-03-02

    The objective of this program was to advance the fundamental understanding of thick thermal barrier coating (TTBC) systems for application to low heat rejection diesel engine combustion chambers. Previous reviews of thermal barrier coating technology concluded that the current level of understanding of coating system behavior is inadequate and the lack of fundamental understanding may impede the application of thermal barrier coating to diesel engines.(1) Areas of TTBC technology examined in this program include powder characteristics and chemistry; bond coating composition, coating design, microstructure and thickness as they affect properties, durability, and reliability; and TTBC "aging" effects (microstructural and property changes) under diesel engine operating conditions. Fifteen TTBC ceramic powders were evaluated. These powders were selected to investigate the effects of different chemistries, different manufacturing methods, lot-to-lot variations, different suppliers and varying impurity levels. Each of the fifteen materials has been sprayed using 36 parameters selected by a design of experiments (DOE) to determine the effects of primary gas (Ar and N2), primary gas flow rate, voltage, arc current, powder feed rate, carrier gas flow rate, and spraying distance. The deposition efficiency, density, and thermal conductivity of the resulting coatings were measured. A coating with a high deposition efficiency and low thermal conductivity is desired from an economic standpoint. An optimum combination of thermal conductivity and disposition efficiency was found for each lot of powder in follow-on experiments and disposition parameters were chosen for full characterization.(2) Strengths of the optimized coatings were determined using 4-point bending specimens. The tensile strength was determined using free-standing coatings made by spraying onto mild steel substrates which were subsequently removed by chemical etching. The compressive strengths of the coatings

  4. Atmospheric Plasma Spraying of Single Phase Lanthanum Zirconate Thermal Barrier Coatings with Optimized Porosity

    Directory of Open Access Journals (Sweden)

    Georg Mauer

    2016-10-01

    Full Text Available The shortcomings at elevated operation temperatures of the standard material yttria-stabilized zirconia (YSZ for thermal barrier coatings (TBCs have initiated many research activities seeking alternatives. One candidate is the pyrochlore lanthanum zirconate La2Zr2O7 (LZ, which is phase-stable to its melting point. At the same time, it shows a lower thermal conductivity and a lower sintering tendency when compared to YSZ. Because of its low thermal expansion coefficient and poor toughness, it is applied in combination with YSZ in double layer TBC systems. It is the current state of knowledge that LZ is prone to lanthanum depletion if processed by plasma spraying. The process conditions have to be selected carefully to avoid this. Furthermore, the amount and morphology of the coating porosity is essential for a good thermo-mechanical performance. In this work, the development and testing of LZ/YSZ double layer TBC systems is described. Initially, suitable basic parameters (torch, plasma gas composition, and power were tested with respect to coating stoichiometry. Then, microstructures were optimized by adjusting feed rate, spray distance, and by selecting a more appropriate feedstock. Powder particles and coatings were characterized by digital image analysis.

  5. Study on Stress Development in the Phase Transition Layer of Thermal Barrier Coatings

    Directory of Open Access Journals (Sweden)

    Yijun Chai

    2016-09-01

    Full Text Available Stress development is one of the significant factors leading to the failure of thermal barrier coating (TBC systems. In this work, stress development in the two phase mixed zone named phase transition layer (PTL, which grows between the thermally grown oxide (TGO and the bond coat (BC, is investigated by using two different homogenization models. A constitutive equation of the PTL based on the Reuss model is proposed to study the stresses in the PTL. The stresses computed with the proposed constitutive equation are compared with those obtained with Voigt model-based equation in detail. The stresses based on the Voigt model are slightly higher than those based on the Reuss model. Finally, a further study is carried out to explore the influence of phase transition proportions on the stress difference caused by homogenization models. Results show that the stress difference becomes more evident with the increase of the PTL thickness ratio in the TGO.

  6. Crack prediction in EB-PVD thermal barrier coatings based on the simulation of residual stresses

    Science.gov (United States)

    Chen, J. W.; Zhao, Y.; Liu, S.; Zhang, Z. Z.; Ma, J.

    2016-07-01

    Thermal barrier coatings systems (TBCs) are widely used in the field of aerospace. The durability and insulating ability of TBCs are highly dependent on the residual stresses of top coatings, thus the investigation of the residual stresses is helpful to understand the failure mechanisms of TBCs. The simulation of residual stresses evolution in electron beam physical vapor deposition (EB-PVD) TBCs is described in this work. The interface morphology of TBCs subjected to cyclic heating and cooling is observed using scanning electron microscope (SEM). An interface model of TBCs is established based on thermal elastic-plastic finite method. Residual stress distributions in TBCs are obtained to reflect the influence of interfacial roughness. Both experimental and simulation results show that it is feasible to predict the crack location by stress analysis, which is crucial to failure prediction.

  7. NASA's Advanced Environmental Barrier Coatings Development for SiC/SiC Ceramic Matrix Composites: Understanding Calcium Magnesium Alumino-Silicate (CMAS) Degradations and Resistance

    Science.gov (United States)

    Zhu, Dongming

    2014-01-01

    Environmental barrier coatings (EBCs) and SiCSiC ceramic matrix composites (CMCs) systems will play a crucial role in next generation turbine engines for hot-section component applications because of their ability to significantly increase engine operating temperatures with improved efficiency, reduce engine weight and cooling requirements. The development of prime-reliant environmental barrier coatings is essential to the viability and reliability of the envisioned CMC engine component applications, ensuring integrated EBC-CMC system durability and designs are achievable for successful applications of the game-changing component technologies and lifing methodologies.This paper will emphasize recent NASA environmental barrier coating developments for SiCSiC turbine airfoil components, utilizing advanced coating compositions, state-of-the-art processing methods, and combined mechanical and environment testing and durability evaluations. The coating-CMC degradations in the engine fatigue-creep and operating environments are particularly complex; one of the important coating development aspects is to better understand engine environmental interactions and coating life debits, and we have particularly addressed the effect of Calcium-Magnesium-Alumino-Silicate (CMAS) from road sand or volcano-ash deposits on the durability of the environmental barrier coating systems, and how the temperature capability, stability and cyclic life of the candidate rare earth oxide and silicate coating systems will be impacted in the presence of the CMAS at high temperatures and under simulated heat flux conditions. Advanced environmental barrier coating systems, including HfO2-Si with rare earth dopant based bond coat systems, will be discussed for the performance improvements to achieve better temperature capability and CMAS resistance for future engine operating conditions.

  8. Measurements of the interfacial fracture energy of thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Shaw, L.L.; Barber, B; Jordan, E.H.; Gell, M.

    1998-10-13

    Thermal barrier coatings (TBCs) have been extensively used in aircraft engines for improved durability and performance for more than 15 years. In this study, chevron-notched sandwich specimens proposed recently by Shaw are chosen for the study of the interfacial fracture energy of TBCs. The specimen of this kind has been successfully used to quantify the fracture energy of TBCs. The specimen of this kind has been successfully used to quantify the fracture energy of several metal/oxide and metal/silicide interfaces. The main advantages of this test specimen are: (1) it provides a rigorous fracture mechanics quantification for the bimaterial interface; (2) the fracture energy obtained arises mainly from the chemical bonding at the interface; (3) the test specimen is easy to fabricate (either diffusion or adhesive bonding), and the test is easy to implement (e.g., neither fatigue precracking nor crack length monitoring is needed); (4) no special compliance calibration of specimens is necessary because previously developed compliance calibrations for homogeneous materials can be utilized directly; (5) the test specimen is suitable for the fracture energy measurement of a single interface as well as for interfacial regions composed of several discrete interfaces, which is often the case for TBCs; and (6) the test method allows the interfacial fracture energy of TBCs to be found independent of the poorly characterized TBCs' elastic modulus as to which there is great uncertainty (e.g., the modulus in tension may be different then in compression). As will be shown in this study, all the aforementioned advantages are maintained for TBCs. Furthermore, the failure location using the chevron notched sandwich specimen duplicates the service failure mode. Thus, the data obtained can be utilized directly for lifetime prediction modeling.

  9. Curvature behaviour of multilayer specimens of thermal barrier systems

    Energy Technology Data Exchange (ETDEWEB)

    Blandin, G.; Bruenings, S.E.; Steinbrech, R.W.; Singheiser, L. [Forschungszentrum Juelich GmbH (Germany). Inst. fuer Werkstoffe und Verfahren der Energietechnik

    2000-07-01

    The impact of residual stresses on the elastic and plastic deformation behavior of plasma sprayed and physical vapor deposited thermal barrier systems was studied. In particular, multilayer specimen strips composed of plasma sprayed partially stabilized zirconia, oxidation resistant NiCoCrAlY bond-coat and Ni-based superalloy substrate were tested. The experiments focused on the in-situ observation of specimen curvature during thermal cycling between room temperature and 1000 C. The mechanical response of specimens with different layer thickness was analyzed with a thermoelastic model to derive elastic modulus and thermal expansion of the ceramic top coat, both parameters as a function of temperature. With the thermoelastic data of all three layers, the residual stress distribution could be calculated analytically. The results of the two coating variants are compared. The deviation from thermoelastic behavior at higher temperature is discussed in terms of stress relaxation in the bond coat due to plastic deformation. (orig.)

  10. Application of thermal barrier coating in a Diesel engine

    Energy Technology Data Exchange (ETDEWEB)

    Buyukkaya, E. [Dept. of Mechanical Engineering, Sakarya Univ., Sakarya (Turkey); Demirkiran, A.S. [Dept. of Metallurgical and Materials Science Engineering, Sakarya Univ., Sakarya (Turkey); Cerit, M.

    2004-07-01

    In this study, an investigation of the effects of ceramic coatings on Diesel engine performance and exhaust emissions was presented. Tests were carried out a range of engine speeds at low, middle and high load conditions for a standard engine and a ceramic-coated engine. Cylinder head and valves of an engine were coated with a 0.35 mm thickness of CaZrO{sub 3} over a 0.15 mm thickness of NiCrAl bond coat. Pistons were also coated with MgZrO{sub 3}. The coatings were produced using atmospheric plasma spray technique. Specific fuel consumption values of insulated engine were lower than standard engine (about 1-6%). Due to the better combustion efficiency in the coated engine, particulate emissions were lower than the standard engine (about 48%). (orig.)

  11. Finite Element Model Characterization Of Nano-Composite Thermal And Environmental Barrier Coatings

    Science.gov (United States)

    Yamada, Yoshiki; Zhu, Dongming

    2011-01-01

    Thermal and environmental barrier coatings have been applied for protecting Si based ceramic matrix composite components from high temperature environment in advanced gas turbine engines. It has been found that the delamination and lifetime of T/EBC systems generally depend on the initiation and propagation of surface cracks induced by the axial mechanical load in addition to severe thermal loads. In order to prevent T/EBC systems from surface cracking and subsequent delamination due to mechanical and thermal stresses, T/EBC systems reinforced with nano-composite architectures have showed promise to improve mechanical properties and provide a potential crack shielding mechanism such as crack bridging. In this study, a finite element model (FEM) was established to understand the potential beneficial effects of nano-composites systems such as SiC nanotube-reinforced oxide T/EBC systems.

  12. Failure Mechanisms and Life Prediction of Thermal and Environmental Barrier Coatings under Thermal Gradients

    Science.gov (United States)

    Zju, Dongming; Ghosn, Louis J.; Miller, Robert A.

    2008-01-01

    Ceramic thermal and environmental barrier coatings (TEBCs) will play an increasingly important role in gas turbine engines because of their ability to further raise engine temperatures. However, the issue of coating durability is of major concern under high-heat-flux conditions. In particular, the accelerated coating delamination crack growth under the engine high heat-flux conditions is not well understood. In this paper, a laser heat flux technique is used to investigate the coating delamination crack propagation under realistic temperature-stress gradients and thermal cyclic conditions. The coating delamination mechanisms are investigated under various thermal loading conditions, and are correlated with coating dynamic fatigue, sintering and interfacial adhesion test results. A coating life prediction framework may be realized by examining the crack initiation and propagation driving forces for coating failure under high-heat-flux test conditions.

  13. Evaluation of the Hot-Corrosion Behavior of Thermal Barrier Coatings

    Science.gov (United States)

    1974-11-01

    coat the components with an insulating material. Ceramic thermal barriers intended for this application must be resistant to thermal shock, spalling...corrosive environment found in a gas turbine. 4428 APPROACH The purpose of using thermal barriers is to allow t-he utilization of high gas

  14. Analytical investigation of thermal barrier coatings on advanced power generation gas turbines

    Science.gov (United States)

    Amos, D. J.

    1977-01-01

    An analytical investigation of present and advanced gas turbine power generation cycles incorporating thermal barrier turbine component coatings was performed. Approximately 50 parametric points considering simple, recuperated, and combined cycles (including gasification) with gas turbine inlet temperatures from current levels through 1644K (2500 F) were evaluated. The results indicated that thermal barriers would be an attractive means to improve performance and reduce cost of electricity for these cycles. A recommended thermal barrier development program has been defined.

  15. Thermochemistry of Rare Earth Silicates for Environmental Barrier Coatings

    Science.gov (United States)

    Costa, Gustavo; Jacobson, Nathan

    2015-01-01

    Rare earth silicates are promising candidates as environmental protective coatings (EBCs) for silica-forming ceramics and composites in combustion environments since they are predicted to have lower reactivity with the water vapor combustion products. The reactivity of rare earth silicates is assessed by the thermodynamic activity of the silica component which is best measured by Knudsen effusion mass spectrometry (KEMS). Here, we discuss a novel method based on a reducing agent to increase the partial pressure of SiO(g) which is then used to calculate thermodynamic activity of silica in Y2O3-SiO2 and Yb2O3-SiO2 systems. After the KEMS measurements, samples were probed by X-ray diffraction and their phase content was calculated from Rietveld refinement.

  16. Potential benefits of a ceramic thermal barrier coating on large power generation gas turbine

    Science.gov (United States)

    Clark, J. S.; Nainiger, J. J.

    1977-01-01

    Thermal barrier coating design option offers benefit in terms of reduced electricity costs when used in utility gas turbines. Options considered include: increased firing temperature, increased component life, reduced cooling air requirements, and increased corrosion resistance (resulting in increased tolerance for dirty fuels). Performance and cost data were obtained. Simple, recuperated and combined cycle applications were considered, and distillate and residual fuels were assumed. The results indicate that thermal barrier coatings could produce large electricity cost savings if these coatings permit turbine operation with residual fuels at distillate-rated firing temperatures. The results also show that increased turbine inlet temperature can result in substantial savings in fuel and capital costs.

  17. Mechanisms of spallation of electron beam physical vapor deposited thermal barrier coatings with and without platinum aluminide bond coat ridges

    Energy Technology Data Exchange (ETDEWEB)

    Vaidyanathan, K.; Gell, M. [Connecticut Univ., Storrs, CT (United States). Dept. of Metallurgy; Jordan, E. [Dept. Mechanical Engineering, University of Connecticut, CT-06269, Storrs (United States)

    2000-11-01

    Grain boundary ridges, that form on the surface of platinum aluminide [(Ni,Pt)Al] bond coats prior to the deposition of the yttria stabilized zirconia ceramic layer by the electron beam physical vapor deposition (EB-PVD) process, were shown to be the sites for spallation damage initiation in (Ni,Pt)Al/EB-PVD thermal barrier coatings. When these ridges are removed prior to deposition of the ceramic layer, a 3 x life improvement is achieved. This study compares the spallation mechanisms in specimens with and without bond coat ridges, in order to explain the improvement in spallation life. (orig.)

  18. Microstructure and properties of sputtered thermal barrier coatings

    Institute of Scientific and Technical Information of China (English)

    Yang Gao; Lun Xie; Feng Pan; Mengcheng Chen

    2004-01-01

    A 3 kW radio frequency (RF) magnetron-sputtering unit was used to produce zirconia ceramic coatings on hollow turbine blades and vanes, which had been deposited a NiCrAlY bond coat layer by cathodic arc deposition. The NiCrAlY coating surface was shot-peened, and the residual stress in the bond coat layer and the effects of heat treatment on the residual stress are presented.After shot peening porosities and microgaps disappear in the NiCrAlY bond coat, the whole depth profile is residual compressive stress. Coarseness tests show that the roughness value (Rz) decreases from 16.4 to 3.3 μm. The microstructure and phase composition of the coatings were investigated using electron probe microanalysis (EPMA) and X-ray diffraction (XRD). The results show that the NiCrAlY bond coat is composed of γ' and Cr phases, and the Al2O3 scales are formed near the interface between the ZrO2 ceramic layer and the NiCrAlY bond coat. No degradation occurred to RF sputtered ceramic coatings after oxidating at 1150℃ for 100 h,heating at 1150℃ for 5 min and then air-cooling for 500 thermal cycles.

  19. Beeswax–chitosan emulsion coated paper with enhanced water vapor barrier efficiency

    Energy Technology Data Exchange (ETDEWEB)

    Zhang, Weiwei [Department of Chemical Engineering, University of New Brunswick, 15 Dineen Drive, Fredericton, NB E3B 5A3 (Canada); State Key Laboratory of Pulp and Paper Engineering, South China University of Technology, Guangzhou, Guangdong 510640 (China); Xiao, Huining, E-mail: hxiao@unb.ca [Department of Chemical Engineering, University of New Brunswick, 15 Dineen Drive, Fredericton, NB E3B 5A3 (Canada); Qian, Liying [State Key Laboratory of Pulp and Paper Engineering, South China University of Technology, Guangzhou, Guangdong 510640 (China)

    2014-05-01

    Graphical abstract: - Highlights: • The water vapor barrier efficiency of paper was enhanced via green-based emulsion coating. • Extremely high lipid content in the emulsion coating layer was firstly utilized to reduce WVTR in emulsion-based film. • A controlled WVTR of beeswax–chitosan emulsion coating could be obtained by dying at specific temperature. - Abstract: For lipid–hydrocolloid emulsion based film, the increase of lipid amount would improve its water vapor barrier property, but also reduce the mechanical strength of the film in the meantime thus leading to a compromised lipid content in the film. However, when the emulsion is coated on paper surface, more lipid could be used for emulsion preparation to enhance the moisture resistance without considering the weakened strength of the film induced by lipid, because the mechanical properties of emulsion coated paper is mainly governed by the strength of base paper instead of the coating layer. In this study, beeswax–chitosan emulsion was first prepared and then coated on paper surface to improve paper's water vapor barrier and water resistance properties. The range and variance analysis of orthogonal test design showed that the order of priorities of the factors accordingly was beeswax solid content, drying temperature and chitosan concentration. The effect of drying temperature on water vapor transmission rate (WVTR) and water contact angle of coated paper was further investigated using 1.2 wt% chitosan and 96% beeswax solid content in the coating layer. The results indicated that water vapor barrier property was in accordance with the density of the coating layer. Atomic force microscope (AFM) was also used to characterize the surface morphology and explain the hydrophobicity of beeswax–chitosan coated paper. It was found that surface beeswax particles melted to wrinkle at high drying temperatures, while roughness values maintained at micro-scale over the temperature range investigated.

  20. Hafnia-Based Materials Developed for Advanced Thermal/Environmental Barrier Coating Applications

    Science.gov (United States)

    Zhu, Dongming; Miller, Robert A.

    2004-01-01

    Thermal and environmental barrier coatings (T/EBCs) will play a crucial role in advanced gas turbine engine systems because of their ability to significantly increase engine operating temperatures and reduce cooling requirements, and thus help achieve engine goals of low emissions and high efficiency. Under the NASA Ultra-Efficient Engine Technology (UEET) Project, advanced T/EBCs are being developed for low-emission SiC/SiC ceramic matrix composite (CMC) combustor applications by extending the CMC liner and vane temperature capability to 1650 C (3000 F) in oxidizing and water-vaporcontaining combustion environments. The coating system is required to have increased phase stability, lower lattice and radiation thermal conductivity, and improved sintering and thermal stress resistance under high-heat-flux and thermal-cycling engine conditions. Advanced heat-flux testing approaches (refs. 1 to 4) have been established at the NASA Glenn Research Center for 1650 C coating developments. The simulated combustion water-vapor environment is also being incorporated into the heat-flux test capabilities (ref. 3).

  1. Calcium-Magnesium-Aluminosilicate (CMAS) Reactions and Degradation Mechanisms of Advanced Environmental Barrier Coatings

    Science.gov (United States)

    Ahlborg, Nadia L.; Zhu, Dongming

    2013-01-01

    The thermochemical reactions between calcium-magnesium-aluminosilicate- (CMAS-) based road sand and several advanced turbine engine environmental barrier coating (EBC) materials were studied. The phase stability, reaction kinetics and degradation mechanisms of rare earth (RE)-silicates Yb2SiO5, Y2Si2O7, and RE-oxide doped HfO2 and ZrO2 under the CMAS infiltration condition at 1500 C were investigated, and the microstructure and phase characteristics of CMAS-EBC specimens were examined using Scanning Electron Microscopy (SEM) and X-ray Diffraction (XRD). Experimental results showed that the CMAS dissolved RE-silicates to form crystalline, highly non-stoichiometric apatite phases, and in particular attacking the silicate grain boundaries. Cross-section images show that the CMAS reacted with specimens and deeply penetrated into the EBC grain boundaries and formed extensive low-melting eutectic phases, causing grain boundary recession with increasing testing time in the silicate materials. The preliminary results also showed that CMAS reactions also formed low melting grain boundary phases in the higher concentration RE-oxide doped HfO2 systems. The effect of the test temperature on CMAS reactions of the EBC materials will also be discussed. The faster diffusion exhibited by apatite and RE-doped oxide phases and the formation of extensive grain boundary low-melting phases may limit the CMAS resistance of some of the environmental barrier coatings at high temperatures.

  2. Residual stresses and phase transformations in Ytterbium silicate environmental barrier coatings

    Science.gov (United States)

    Stolzenburg, Fabian

    Due to their high melting temperature, low density, and good thermomechanical stability, silicon-based ceramics (SiC, Si3N4) are some of the most promising materials systems for high temperature structural applications in gas turbine engines. However, their silica surface layer reacts with water vapor contained in combustion environments. The resulting hydroxide layer volatilizes, leading to component recession. Environmental barrier coatings (EBCs) have been developed to shield the substrate from degradation. Next generation coatings for silicon-based ceramics based on ytterbium silicates have shown a promising combination of very low and good thermomechanical properties. The focus of this thesis is threefold: In the first part, phase transformations in plasma sprayed ytterbium silicates were investigated. Plasma sprayed materials are known to contain large amounts of amorphous material. Phase changes during the conversion from amorphous to crystalline materials were investigated as they have been known to lead to failure in many coatings. The second part of this work focused on measuring residual stresses in multilayer EBCs using synchrotron X-ray diffraction (XRD). Strains were resolved spatially, with probe sizes as small as 20 um. Stresses were calculated using mechanical properties of ytterbium silicates, determined with in-situ loading and heating experiments. In-situ and ex-situ heating experiments allowed for the study of changes in stress states that occur in these EBC materials during heating and cooling cycles. Lastly, the interaction of ytterbium silicates with low-melting environmental calcium-magnesium-aluminosilicate (CMAS) glasses was studied. Synchrotron XRD was used to study the influence of CMAS on the stress state in the coating, X-ray computed tomography was used to provide 3D images of coatings, and EDS and TEM analysis were used to study the interactions at the CMAS/ytterbium silicate interface in detail.

  3. Preparation and characterization of enamel coating on pure titanium as a hydrogen penetration barrier

    Energy Technology Data Exchange (ETDEWEB)

    Tao, Jie, E-mail: taojie@nuaa.edu.cn [College of Material Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu 210016 (China); Guo, Xunzhong [College of Material Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu 210016 (China); Huang, Zhendong [Graduate School of Human and Environmental Studies, Kyoto University, oshida-Nihonmatsu-Cho, Sakyo-Ku, Kyoto shi 606-8501 (Japan); Liu, Hongbing [Shanghai Aircraft Manufacturing Co,. Ltd, Shanghai 200436 (China); Wang, Tao [College of Material Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu 210016 (China)

    2013-06-15

    Highlights: ► The enamel coating was prepared by spin-coating and enameling method. ► The dense enamel coatings were chemically bonded with TA1 substrate. ► The coatings possessed better thermal shock resistance property. ► The coatings had excellent ball-dropping impact properties. ► The enamel coating exhibited a good barrier effect to hydrogen isotope penetration. -- Abstract: The enamel coating with a thickness of 90–110 × 10{sup −6} m was prepared on TA1 substrate by spin-coating and enameling to solve the problems of hydrogen isotope penetration for commercial pure titanium TA1. The microstructure and the interfacial morphology of the samples were characterized respectively by X-ray diffraction, optical and scanning electron microscopy. The profiles of main elements at the interface were analyzed by EDS line-scanning. The experimental results indicated that the dense enamel coatings were chemically bonded with TA1 substrate, and possessed better thermal shock resistance and ball-dropping impact properties. It was concluded from the results of hydrogen charging test with Vickers microhardness measurement and deuterium penetration experiments that the as-prepared dense enamel coating exhibited a good barrier effect to hydrogen isotope penetration.

  4. Ultrasonic characterization of thermally grown oxide in thermal barrier coating by reflection coefficient amplitude spectrum.

    Science.gov (United States)

    Ma, Zhiyuan; Zhao, Yang; Luo, Zhongbing; Lin, Li

    2014-04-01

    The thermally grown oxide (TGO) growth at the interface of ceramic coating/bond coating in thermal barrier coatings (TBCs) was evaluated by ultrasonic reflection coefficient amplitude spectrum (URCAS). A theoretical analysis was performed about the influence of acoustic impedance match relationship between the ceramic coating and its adjacent media on URCAS. The immersion ultrasonic narrow pulse echo method was carried out on the TBC specimen before and after oxidation under 1050°C×1h for 15cycles. The resonant peaks of URCAS obtained before and after oxidation showed that TGO which generated between the ceramic coating and bond coating due to the oxidation, changed the acoustic impedance match between the ceramic coating and its adjacent media. This method is able to nondestructively characterize the generation of TGO in TBCs, and is important to practical engineering application.

  5. Beeswax-chitosan emulsion coated paper with enhanced water vapor barrier efficiency

    Science.gov (United States)

    Zhang, Weiwei; Xiao, Huining; Qian, Liying

    2014-05-01

    For lipid-hydrocolloid emulsion based film, the increase of lipid amount would improve its water vapor barrier property, but also reduce the mechanical strength of the film in the meantime thus leading to a compromised lipid content in the film. However, when the emulsion is coated on paper surface, more lipid could be used for emulsion preparation to enhance the moisture resistance without considering the weakened strength of the film induced by lipid, because the mechanical properties of emulsion coated paper is mainly governed by the strength of base paper instead of the coating layer. In this study, beeswax-chitosan emulsion was first prepared and then coated on paper surface to improve paper's water vapor barrier and water resistance properties. The range and variance analysis of orthogonal test design showed that the order of priorities of the factors accordingly was beeswax solid content, drying temperature and chitosan concentration. The effect of drying temperature on water vapor transmission rate (WVTR) and water contact angle of coated paper was further investigated using 1.2 wt% chitosan and 96% beeswax solid content in the coating layer. The results indicated that water vapor barrier property was in accordance with the density of the coating layer. Atomic force microscope (AFM) was also used to characterize the surface morphology and explain the hydrophobicity of beeswax-chitosan coated paper. It was found that surface beeswax particles melted to wrinkle at high drying temperatures, while roughness values maintained at micro-scale over the temperature range investigated.

  6. Influence of Water Vapor on the Isothermal Oxidation Behavior of Thermal Barrier Coatings

    Institute of Scientific and Technical Information of China (English)

    Chungen ZHOU; Jingsheng YU; Shengkai GONG; Huibin XU

    2004-01-01

    The oxidation of specimens with thermal barrier coating (TBC) consisted of nickel-base superalloy, low-pressure plasma sprayed Ni-28Cr-6Al-0.4Y (wt pct) bond coating and electron beam physical vapor deposited 7.5 wt pct yttria stabilized zirconia (YSZ) top coating was studied at 1050℃ respectively in flows of O2, and mixture of O2 and 5%H2O under atmospheric pressure. The thermal barrier coating has relatively low oxidation rate at 1050℃ in pure O2. Oxidation rate of thermal barrier coating in the atmosphere of O2 and 5%H2O is increased The oxidation kinetics obeys almost linear law after long exposure time in the presence of 5% water vapor. Oxide formed along the interface between bond coat and top coat after oxidation at 1050℃ in pure O2 consisted of Al2O3, whereas interfacial scales formed after oxidation at 1050℃ in a mixture of O2 and 5%H2O were mainly composed of Ni(Al,Cr)2O4,NiO and Al2O3. It is suggested that the effect of water vapor on the oxidation of the NiCrAlY coating may be attributed to the increase in Ni and Cr ions transport in the oxides.

  7. Monitoring thermally grown oxides under thermal barrier coatings using photoluminescence piezospectroscopy (PLPS)

    Energy Technology Data Exchange (ETDEWEB)

    Del Corno, A.; De Maria, L.; Rinaldi, C. [ERSE, Milan (Italy); Nalin, L.; Simms, N.J. [Cranfield Univ., Bedford (United Kingdom). Energy Technology Centre

    2010-07-01

    The use of thermal barrier coatings (TBCs) on cooled components in industrial gas turbine has enabled higher inlet gas temperatures to be used and hence higher efficiencies to be achieved, without increasing component metal temperatures. However TBCs have a complex coating structure that during high temperature exposure and thermal cycling modifies until TBC spalling which can result in dangerous over-heating of components. This paper reports the results of a TBC exposure programme planned to monitor TGOs development in an example TBC system in terms of both stress evolution within the TGOs and TGO growth. The COST538 reference TBC system was used: an yttria stabilised zirconia TBC applied to an Amdry 995 bond coat on an CMSX-4 substrate. Samples were in the form of 10 mm diameter bars, with the TBC applied to their curved surface. Coated samples were exposed in simulated combustion gases at temperatures 850, 900 and 950 C for periods of up to 10,000 hours. Every 1000 hours samples were cooled and weighed to monitor the progression of the oxidation: selected samples NDT inspected using PLPS and/or destructive examination. Cross-sections were prepared and examined in a scanning electron microscope (SEM) at multiple locations to determine TGO thickness distributions. PLPS spectra were measured and elaborated with a system self developed in ERSE, able to calculate and map the TGO residual stress values under columnar TBCs. So the positions could be evidenced where the damage of the TBC /TGO/BC interface is higher on the exposed bars. The data of TGO thickness distributions and PLPS stress measurement distributions were compared to the exposures carried out on samples to identify and quantify trends in their development. Metallography confirmed that the PLPs technique can reliably detect interface cracking before visible EB-PVD TBC spalling. (orig.)

  8. Bond strength, bond stress and spallation mechanisms of thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Gell, M.; Krishnakumar, V.; McCarron, K.; Barber, B.; Sohn, Y.-H. [Connecticut Univ., Storrs, CT (United States). Dept. of Metall. and Mater. Eng.; Eric, J. [Connecticut Univ., Storrs, CT (United States). Dept. of Mechanical Engineering; Tolpygo, V.K.

    1999-11-01

    Five production thermal barrier coatings were thermally cycled between room temperature and 1121 C (2050 F) to determine relative spallation life. Bond strength measurements were made using a modified ASTM direct pull-test. Bond stress measurements were made in the thermally grown oxide using a laser photoluminescence technique. Bond strength and bond stress measurements were conducted on two electron beam physical vapor deposition coatings as a function of thermal cycling. Each coating showed characteristic values of as-coated strength and stress and changes in strength and stress with thermal cycling. These variations in strength and stress with thermal cycling are related to oxidation and micro-debonding effects. (orig.)

  9. History of Thermal Barrier Coatings for Gas Turbine Engines: Emphasizing NASA's Role from 1942 to 1990

    Science.gov (United States)

    Miller, Robert A.

    2009-01-01

    NASA has played a central role in the development of thermal barrier coatings (TBCs) for gas turbine applications. This report discusses the history of TBCs emphasizing the role NASA has played beginning with (1) frit coatings in the 1940s and 1950s; (2) thermally sprayed coatings for rocket application in the 1960s and early 1970s; (3) the beginnings of the modern era of turbine section coatings in the mid 1970s; and (4) failure mechanism and life prediction studies in the 1980s and 1990s. More recent efforts are also briefly discussed.

  10. Thermal Cycling Assessment of Steel-Based Thermal Barrier Coatings for Al Protection

    Science.gov (United States)

    Poirier, Dominique; Lamarre, Jean-Michel; Legoux, Jean-Gabriel

    2015-01-01

    There is a strong interest from the transportation industry to achieve vehicle weight reduction through the replacement of steel components by aluminum parts. For some applications, aluminum requires protective coatings due to its limited wear and lower temperature resistance compared to steel. The objective of this study was to assess the potential of amorphous-type plasma-sprayed steel coatings and conventional arc-sprayed steel coatings as thermal barrier coatings, mainly through the evaluation of their spalling resistance under thermal cycling. The microstructures of the different coatings were first compared via SEM. The amorphicity of the coatings produced via plasma spraying of specialized alloyed steel and the crystalline phases of the conventional arc-sprayed steel coatings were confirmed through x-ray diffraction. The thermal diffusivity of all coatings produced was measured to be about a third of that of bulk stainless steel. Conventional arc-sprayed steel coatings typically offered better spalling resistance under thermal cycling than steel-based amorphous coatings due probably to their higher initial bond strength. However, the presence of vertical cracks in the steel-based amorphous coatings was found to have a beneficial effect on their thermal cycling resistance. The amorphous plasma-sprayed steel coatings presented indications of recrystallization after their exposure to high temperature.

  11. Multilayer stacks obtained by ion assisted EB PVD aimed at thermal barrier coating

    Energy Technology Data Exchange (ETDEWEB)

    Roos, E.; Maile, K.; Lyutovich, A. [Stuttgart Univ. (DE). Materialpruefungsanstalt (MPA)

    2010-07-01

    Thermal Barrier Coating (TBC) using Electron Beam Physical Vapour Deposition (EB PVD) is widely implemented, especially for aero-engine turbine blades. Generally, multilayer stacks are used for these aims. For the additional improvement of intermediate layers with graded transitions to the initial Ni-based alloy, the use of accelerated ions in the EBPVD-process is advantageous. The effect of the substrate bias potential, ion current density and deposition temperature on the structure and properties of Ti and Zr intermediate layers are investigated. The morphology of the films is studied using optical microscopy, scanning electron microscopy (SEM) and atomic force microscopy (AFM). It is found that the surface morphology becomes smoother with rising bias potential and decreasing ion current density. Measurements of Vicker's micro-hardness performed on these coatings have shown its increase with higher values of the bias and its reduction with the growing temperature. This effect is caused by the observed decrease in grain size and higher porosity of the films. A multilayer coating system Ni (based substrate)-Si-Si{sub x}Al{sub y}-Al with graded transitions between the layers is obtained using ion assisted EBPVD. Architecture of a multilayer stack for TBC with graded transitions is proposed. (orig.)

  12. The Use of Feature Parameters to Asses Barrier Properties of ALD coatings for Flexible PV Substrates

    Science.gov (United States)

    Blunt, Liam; Robbins, David; Fleming, Leigh; Elrawemi, Mohamed

    2014-03-01

    This paper reports on the recent work carried out as part of the EU funded NanoMend project. The project seeks to develop integrated process inspection, cleaning, repair and control systems for nano-scale thin films on large area substrates. In the present study flexible photovoltaic films have been the substrate of interest. Flexible PV films are the subject of significant development at present and the latest films have efficiencies at or beyond the level of Si based rigid PV modules. These flexible devices are fabricated on polymer film by the repeated deposition, and patterning, of thin layer materials using roll-to-roll processes, where the whole film is approximately 3um thick prior to encapsulation. Whilst flexible films offer significant advantages in terms of mass and the possibility of building integration (BIPV) they are at present susceptible to long term environmental degradation as a result of water vapor transmission through the barrier layers to the CIGS (Copper Indium Gallium Selenide CuInxGa(1-x)Se2) PV cells thus causing electrical shorts and efficiency drops. Environmental protection of the GIGS cell is provided by a thin (40nm) barrier coating of Al2O3. The highly conformal aluminium oxide barrier layer is produced by atomic layer deposition (ALD) where, the ultra-thin Al2O3 layer is deposited onto polymer thin films before these films encapsulate the PV cell. The surface of the starting polymer film must be of very high quality in order to avoid creating defects in the device layers. Since these defects reduce manufacturing yield, in order to prevent them, a further thin polymer coating (planarization layer) is generally applied to the polymer film prior to deposition. The presence of surface irregularities on the uncoated film can create defects within the nanometre-scale, aluminium oxide, barrier layer and these are measured and characterised. This paper begins by reporting the results of early stage measurements conducted to characterise

  13. Design of barrier coatings on kink-resistant peripheral nerve conduits

    Directory of Open Access Journals (Sweden)

    Basak Acan Clements

    2016-02-01

    Full Text Available Here, we report on the design of braided peripheral nerve conduits with barrier coatings. Braiding of extruded polymer fibers generates nerve conduits with excellent mechanical properties, high flexibility, and significant kink-resistance. However, braiding also results in variable levels of porosity in the conduit wall, which can lead to the infiltration of fibrous tissue into the interior of the conduit. This problem can be controlled by the application of secondary barrier coatings. Using a critical size defect in a rat sciatic nerve model, the importance of controlling the porosity of the nerve conduit walls was explored. Braided conduits without barrier coatings allowed cellular infiltration that limited nerve recovery. Several types of secondary barrier coatings were tested in animal studies, including (1 electrospinning a layer of polymer fibers onto the surface of the conduit and (2 coating the conduit with a cross-linked hyaluronic acid-based hydrogel. Sixteen weeks after implantation, hyaluronic acid-coated conduits had higher axonal density, displayed higher muscle weight, and better electrophysiological signal recovery than uncoated conduits or conduits having an electrospun layer of polymer fibers. This study indicates that braiding is a promising method of fabrication to improve the mechanical properties of peripheral nerve conduits and demonstrates the need to control the porosity of the conduit wall to optimize functional nerve recovery.

  14. Oxygen Barrier Coating Deposited by Novel Plasma-enhanced Chemical Vapor Deposition

    DEFF Research Database (Denmark)

    Jiang, Juan; Benter, M.; Taboryski, Rafael Jozef

    2010-01-01

    We report the use of a novel plasma-enhanced chemical vapor deposition chamber with coaxial electrode geometry for the SiOx deposition. This novel plasma setup exploits the diffusion of electrons through the inner most electrode to the interior samples space as the major energy source. This confi......We report the use of a novel plasma-enhanced chemical vapor deposition chamber with coaxial electrode geometry for the SiOx deposition. This novel plasma setup exploits the diffusion of electrons through the inner most electrode to the interior samples space as the major energy source....... This configuration enables a gentle treatment of sensitive materials like low-density polyethylene foils and biodegradable materials. SiOx coatings deposited in the novel setup were compared with other state of the art plasma coatings and were found to possess equally good or better barrier properties. The barrier...... effect of single-layer coatings deposited under different reaction conditions was studied. The coating thickness and the carbon content in the coatings were found to be the critical parameters for the barrier property. The novel barrier coating was applied on different polymeric materials...

  15. Design of barrier coatings on kink-resistant peripheral nerve conduits.

    Science.gov (United States)

    Clements, Basak Acan; Bushman, Jared; Murthy, N Sanjeeva; Ezra, Mindy; Pastore, Christopher M; Kohn, Joachim

    2016-01-01

    Here, we report on the design of braided peripheral nerve conduits with barrier coatings. Braiding of extruded polymer fibers generates nerve conduits with excellent mechanical properties, high flexibility, and significant kink-resistance. However, braiding also results in variable levels of porosity in the conduit wall, which can lead to the infiltration of fibrous tissue into the interior of the conduit. This problem can be controlled by the application of secondary barrier coatings. Using a critical size defect in a rat sciatic nerve model, the importance of controlling the porosity of the nerve conduit walls was explored. Braided conduits without barrier coatings allowed cellular infiltration that limited nerve recovery. Several types of secondary barrier coatings were tested in animal studies, including (1) electrospinning a layer of polymer fibers onto the surface of the conduit and (2) coating the conduit with a cross-linked hyaluronic acid-based hydrogel. Sixteen weeks after implantation, hyaluronic acid-coated conduits had higher axonal density, displayed higher muscle weight, and better electrophysiological signal recovery than uncoated conduits or conduits having an electrospun layer of polymer fibers. This study indicates that braiding is a promising method of fabrication to improve the mechanical properties of peripheral nerve conduits and demonstrates the need to control the porosity of the conduit wall to optimize functional nerve recovery.

  16. Low Thermal Conductivity, High Durability Thermal Barrier Coatings for IGCC Environments

    Energy Technology Data Exchange (ETDEWEB)

    Jordan, Eric [Univ. of Connecticut, Storrs, CT (United States); Gell, Maurice [Univ. of Connecticut, Storrs, CT (United States)

    2015-01-15

    Advanced thermal barrier coatings (TBC) are crucial to improved energy efficiency in next generation gas turbine engines. The use of traditional topcoat materials, e.g. yttria-stabilized zirconia (YSZ), is limited at elevated temperatures due to (1) the accelerated undesirable phase transformations and (2) corrosive attacks by calcium-magnesium-aluminum-silicate (CMAS) deposits and moisture. The first goal of this project is to use the Solution Precursor Plasma Spray (SPPS) process to further reduce the thermal conductivity of YSZ TBCs by introducing a unique microstructural feature of layered porosity, called inter-pass boundaries (IPBs). Extensive process optimization accompanied with hundreds of spray trials as well as associated SEM cross-section and laser-flash measurements, yielded a thermal conductivity as low as 0.62 Wm⁻¹K⁻¹ in SPPS YSZ TBCs, approximately 50% reduction of APS TBCs; while other engine critical properties, such as cyclic durability, erosion resistance and sintering resistance, were characterized to be equivalent or better than APS baselines. In addition, modifications were introduced to SPPS TBCs so as to enhance their resistance to CMAS under harsh IGCC environments. Several mitigation approaches were explored, including doping the coatings with Al₂O₃ and TiO₂, applying a CMAS infiltration-inhibiting surface layer, and filling topcoat cracks with blocking substances. The efficacy of all these modifications was assessed with a set of novel CMAS-TBC interaction tests, and the moisture resistance was tested in a custom-built high-temperature moisture rig. In the end, the optimal low thermal conductivity TBC system was selected based on all evaluation tests and its processing conditions were documented. The optimal coating consisted on a thick inner layer of YSZ coating made by the SPPS process having a thermal conductivity 50% lower than standard YSZ coatings topped with a high temperature tolerant CMAS resistant gadolinium

  17. One Component Encapsulating Material Matrix as High Barrier Coating Project

    Data.gov (United States)

    National Aeronautics and Space Administration — To address the NASA need for new flexible food packaging materials with effective high barrier against oxygen and moisture to protect food, minimize weight and...

  18. Investigation on surface figuration and microstructure of laser glazed nanostructure zirconia thermal barrier coatings

    Institute of Scientific and Technical Information of China (English)

    HUANG Binghua; WANG Hongying; HAO Yunfei; TANG Weijie

    2009-01-01

    CO2 continuous wave laser beam had been applied to the laser glazing of plasma sprayed nanostructure zirconia thermal barrier coatings. The effects of luser glazing processing parameters on the surface figuration and microstructure change had been carried out, the microstructure and phase composition of the coatings had been evaluated by the scanning electron microscope (SEM) and the X-ray diffraction (XRD). SEM observation indicates that the microstructure of the as-glazed coating could be altered from single columnar structure to a combination of the columnar grain and fine equiaxed grain with the different laser glazing conditions. XRD analysis illustrates that the predominance phase of the as-glazed coating is the metastable tetragonal phase, and the glazed coating with the single columnar structure has shown the clear orientation in (220) and (400) peaks while the other coatings do not show that.

  19. Systems study on engineered barriers: barrier performance analysis

    Energy Technology Data Exchange (ETDEWEB)

    Stula, R.T.; Albert, T.E.; Kirstein, B.E.; Lester, D.H.

    1980-09-01

    A performance assessment model for multiple barrier packages containing unreprocessed spent fuel has been modified and applied to several package designs. The objective of the study was to develop information to be used in programmatic decision making concerning engineered barrier package design and development. The assessment model, BARIER, was developed in previous tasks of the System Study on Engineered Barriers (SSEB). The new version discussed in this report contains a refined and expanded corrosion rate data base which includes pitting, crack growth, and graphitization as well as bulk corrosion. Corrosion rates for oxic and anoxic conditions at each of the two temperature ranges are supplied. Other improvements include a rigorous treatment of radionuclide release after package failure which includes resistance of damaged barriers and backfill, refined temperature calculations that account for convection and radiation, a subroutine to calculate nuclear gamma radiation field at each barrier surface, refined stress calculations with reduced conservatism and various coding improvements to improve running time and core usage. This report also contains discussion of alternative scenarios to the assumed flooded repository as well as the impact of water exclusion backfills. The model was used to assess post repository closure performance for several designs which were all variation of basic designs from the Spent Unreprocessed Fuel (SURF) program. Many designs were found to delay the onset of leaching by at least a few hundreds of years in all geologic media. Long delay times for radionuclide release were found for packages with a few inches of sorption backfill. Release of uranium, plutonium, and americium was assessed.

  20. Thermal barrier coatings of new rare-earth composite oxide by EB-PVD

    Energy Technology Data Exchange (ETDEWEB)

    Xu, Z.H., E-mail: zhxubiam@sina.com; Zhou, X.; Wang, K.; Dai, J.W.; He, L.M.

    2014-02-25

    Highlights: • 3Y-LZ7C3 coating has a cyclic lifetime longer than that of LZ7C3 coating. • Y{sub 2}O{sub 3} helps to moderate the excessive vapor pressure condition during deposition. • 3Y-LZ7C3 coating is a mixture of pyrochlore and fluorite structures. • 3Y-LZ7C3 coating has a low sintering ability as compared with LZ7C3 coating. -- Abstract: Thermal barrier coatings (TBCs) of La{sub 2}(Zr{sub 0.7}Ce{sub 0.3}){sub 2}O{sub 7} (LZ7C3) with the addition of 3 wt.% Y{sub 2}O{sub 3} (3Y-LZ7C3) were deposited by electron beam-physical vapor deposition (EB-PVD). The phase structures, surface and cross-sectional morphologies, thermal cycling behaviors of these coatings were studied in detail. The thermal cycling test at 1373 K in an air furnace indicates that the 3Y-LZ7C3 coating has a lifetime of 1134 cycles which is about 18% longer than that of LZ7C3 coating. The improvement of chemical homogeneity of the coating, the superior growth behavior of columns and the favorable mechanical properties are all very helpful to the prolongation of thermal cycling life of 3Y-LZ7C3 coating. The failure of 3Y-LZ7C3 coating is probably a result of the reduction–oxidation of cerium oxide (Ce{sub 2}O{sub 3} and CeO{sub 2}), the solid solution reactions between La{sub 2}O{sub 3} and Y{sub 2}O{sub 3} (or ZrO{sub 2}), the visible cracks initiation, propagation and extension, the abnormal oxidation of bond coat and the thermal expansion mismatch between ceramic coating and bond coat.

  1. Surface pre-treatment for barrier coatings on polyethylene terephthalate

    Science.gov (United States)

    Bahre, H.; Bahroun, K.; Behm, H.; Steves, S.; Awakowicz, P.; Böke, M.; Hopmann, Ch; Winter, J.

    2013-02-01

    Polymers have favourable properties such as light weight, flexibility and transparency. Consequently, this makes them suitable for food packaging, organic light-emitting diodes and flexible solar cells. Nonetheless, raw plastics do not possess sufficient barrier functionality against oxygen and water vapour, which is of paramount importance for most applications. A widespread solution is to deposit thin silicon oxide layers using plasma processes. However, silicon oxide layers do not always fulfil the requirements concerning adhesion and barrier performance when deposited on films. Thus, plasma pre-treatment is often necessary. To analyse the influence of a plasma-based pre-treatment on barrier performance, different plasma pre-treatments on three reactor setups were applied to a very smooth polyethylene terephthalate film before depositing a silicon oxide barrier layer. In this paper, the influence of oxygen and argon plasma pre-treatments towards the barrier performance is discussed examining the chemical and topological change of the film. It was observed that a short one-to-ten-second plasma treatment can reduce the oxygen transmission rate by a factor of five. The surface chemistry and the surface topography change significantly for these short treatment times, leading to an increased surface energy. The surface roughness rises slowly due to the development of small spots in the nanometre range. For very long treatment times, surface roughness of the order of the barrier layer's thickness results in a complete loss of barrier properties. During plasma pre-treatment, the trade-off between surface activation and roughening of the surface has to be carefully considered.

  2. A high performance ceria based interdiffusion barrier layer prepared by spin-coating

    DEFF Research Database (Denmark)

    Plonczak, Pawel; Joost, Mario; Hjelm, Johan

    2011-01-01

    A multiple spin-coating deposition procedure of Ce0.9Gd0.1O1.95 (CGO) for application in solid oxide fuel cells (SOFCs) was developed. The thin and dense CGO layer can be employed as a barrier layer between yttria stabilised zirconia (YSZ) electrolyte and a (La, Sr)(Co, Fe)O3 based cathode....... The decomposition of the polymer precursor used in the spin-coating process was studied. The depositions were performed on anode supported half cells. By controlling the sintering temperature between each spin-coating process, dense and crack-free CGO films with a thickness of approximately 1 μm were obtained....... The successive steps of dense layer production was investigated by scanning electron microscopy. X-ray diffraction was employed to monitor the crystal structure of the CGO layer sintered at different temperatures. The described spin coated barrier layer was evaluated using an anode supported cell...

  3. Finite Element Analysis of Thermal Stresses in Ceramic/Metal Gradient Thermal Barrier Coatings

    Institute of Scientific and Technical Information of China (English)

    MING Pingshun; XIAO Jinsheng; LIU Jie; ZHOU Xiaoqin

    2005-01-01

    This paper studied the thermal stresses of ceramic/metal gradient thermal barrier coating which combines the conceptions of ceramic thermal barrier coating (TBC) and functionally gradient material (FGM). Thermal stresses and residual thermal stresses were calculated by an ANSYS finite element analysis software. Negative thermal expansion coefficient method was proposed and element birth and death method was applied to analyze the residual thermal stresses which have non-uniform initial temperature field. The numerical results show a good agreement with the analytical results and the experimental results.

  4. Thermal Fatigue Behavior of Air-Plasma Sprayed Thermal Barrier Coating with Bond Coat Species in Cyclic Thermal Exposure

    Directory of Open Access Journals (Sweden)

    Ungyu Paik

    2013-08-01

    Full Text Available The effects of the bond coat species on the delamination or fracture behavior in thermal barrier coatings (TBCs was investigated using the yclic thermal fatigue and thermal-shock tests. The interface microstructures of each TBC showed a good condition without cracking or delamination after flame thermal fatigue (FTF for 1429 cycles. The TBC with the bond coat prepared by the air-plasma spray (APS method showed a good condition at the interface between the top and bond coats after cyclic furnace thermal fatigue (CFTF for 1429 cycles, whereas the TBCs with the bond coats prepared by the high-velocity oxygen fuel (HVOF and low-pressure plasma spray (LPPS methods showed a partial cracking (and/or delamination and a delamination after 780 cycles, respectively. The TBCs with the bond coats prepared by the APS, HVOF and LPPS methods were fully delaminated (>50% after 159, 36, and 46 cycles, respectively, during the thermal-shock tests. The TGO thickness in the TBCs was strongly dependent on the both exposure time and temperature difference tested. The hardness values were found to be increased only after the CFTF, and the TBC with the bond coat prepared by the APS showed the highest adhesive strength before and after the FTF.

  5. Thermal failure of nanostructured thermal barrier coatings with cold sprayed nanostructured NiCrAlY bond coat

    Energy Technology Data Exchange (ETDEWEB)

    Zhang, Q.; Li, Y.; Zhang, S.L.; Wang, X.R.; Yang, G.J.; Li, C.X.; Li, C.J. [Xi' an Jiaotong Univ., Xi' an (China)

    2008-07-01

    Nanostructured YSZ is expected to exhibit a high strain tolerability due to its low Young's modulus and consequently high durability. In this study, a porous YSZ as the thermal barrier coating was deposited by plasma spraying using an agglomerated nanostructured YSZ powder on a Ni-based superalloy Inconel 738 substrate with a cold-sprayed nanostructured NiCrAlY as the bond coat. The heat treatment in Ar atmosphere was applied to the cold-sprayed bond coat before deposition of YSZ. The isothermal oxidation and thermal cycling tests were applied to examine failure modes of plasma-sprayed nanostructured YSZ. The results showed that YSZ coating was deposited by partially melted YSZ particles. The nonmelted fraction of spray particles retains the porous nanostructure of the starting powder into the deposit. YSZ coating exhibits a bimodal microstructure consisting of nanosized particles retained from the powder and micro-columnar grains formed through the solidification of the melted fraction in spray particles. The oxidation of the bond coat occurs during the heat treatment in Ar atmosphere. The uniform oxide at the interface between the bond coat and YSZ can be formed during isothermal test. The cracks were observed at the interface between TGO/BC or TGO/YSZ after thermal cyclic test. However, the failure of TBCs mainly occurred through spalling of YSZ within YSZ coating. The failure characteristics of plasma-sprayed nanostructured YSZ are discussed based on the coating microstructure and formation of TGO on the bond coat surface. (orig.)

  6. FEM ANALYSIS OF THERMAL STRESSES IN GRADIENT THERMAL BARRIER COATINGS PRODUCED BY EB-PVD

    Institute of Scientific and Technical Information of China (English)

    H.B. Guo; H.B. Xu; S.K. Gong

    2001-01-01

    Gradient thermal barrier coatings (GTBCs) produced by co-deposition of mixtures ofAl-Al2 O3-YSZ onto metallic bond coat exhibited longer lifetimes than the two-layeredTBCs. The finite element method (FEM) numerical models were used to investigatestress and strain states in the GTBCs and traditional two-layered TBCs as they cooledto 750℃ from a stress-free state at 850℃.

  7. Thermal barrier coatings issues in advanced land-based gas turbines

    Science.gov (United States)

    Parks, William P.; Hoffman, Eugene E.; Lee, Woo Y.; Wright, Ian G.

    1995-01-01

    The Department of Energy's Advanced Turbine Systems (ATS) program is aimed at fostering the development of a new generation of land-based gas turbine systems with overall efficiencies significantly beyond those of current state-of-the-art machines, as well as greatly increased times between inspection and refurbishment, improved environmental impact, and decreased cost. The proposed duty cycle of ATS machines will emphasize different criteria in the selection of materials for the critical components. In particular, thermal barrier coatings (TBC's) will be an essential feature of the hot gas path components in these machines. In fact, the goals of the ATS will require significant improvements in TBC technology, since these turbines will be totally reliant on TBC's, which will be required to function on critical components such as the first stage vanes and blades for times considerably in excess of those experienced in current applications. Issues that assume increased importance are the mechanical and chemical stability of the ceramic layer and of the metallic bond coat; the thermal expansion characteristics and compliance of the ceramic layer; and the thermal conductivity across the thickness of the ceramic layer. Obviously, the ATS program provides a very challenging opportunity for TBC's, and involves some significant opportunities to extend this technology. A significant TBC development effort is planned in the ATS program which will address these key issues.

  8. THE EFFECT OF LASER GLAZING PROCESS ON MICROSTRUCTURE OF PLASMA SPRAYED THERMAL BARRIER COATINGS

    Directory of Open Access Journals (Sweden)

    Seyid Fehmi DİLTEMİZ

    2011-12-01

    Full Text Available Thermal barrier coatings (TBCs are widely used by aero and land based gas turbines to protect hot section parts from oxidation and reducing component temperature thereby increase life. TBCs aregenerally a combination of multiple layers of coating (usually two with each layer having a specific function [Aktaa et al., 2005]. In this study air plasma sprayed TBCs were deposited on 304 stainlesssteel substrates then ceramic surfaces were glazed using Nd-YAG laser. Both glazed and as-coated samples were subjected to metallographic examination to investigate microstructural changes inglazed ceramic layer. Laser glazing provides a remelting and subsequent solidification of the surface, resulting on new top layer microstructure.

  9. Mixed Mode Fracture of Plasma Sprayed Thermal Barrier Coatings: Effects of Anisotropy and Heterogeneity

    Science.gov (United States)

    Zhu, Dongming; Choi, Sung R.; Ghosn, Louis L.

    2008-01-01

    The combined mode I-mode II fracture behavior of anisotropic ZrO2-8wt%Y2O3 thermal barrier coatings was determined in asymmetric flexure loading at both ambient and elevated temperatures. A fracture envelope of KI versus KII was determined for the coating material at ambient and elevated temperatures. Propagation angles of fracture as a function of KI/KII were also determined. The mixed-mode fracture behavior of the microsplat coating material was modeled using Finite Element approach to account for anisotropy and micro cracked structures, and predicted in terms of fracture envelope and propagation angle using mixed-mode fracture theories.

  10. Evaluation of properties and thermal stress field for thermal barrier coatings

    Institute of Scientific and Technical Information of China (English)

    王良; 齐红宇; 杨晓光; 李旭

    2008-01-01

    In order to get thermal stress field of the hot section with thermal barrier coating (TBCs), the thermal conductivity and elastic modulus of top-coat are the physical key properties. The porosity of top-coat was tested and evaluated under different high temperatures. The relationship between the microstructure (porosity of top-coat) and properties of TBCs were analyzed to predict the thermal properties of ceramic top-coat, such as thermal conductivity and elastic modulus. The temperature and stress field of the vane with TBCs were simulated using two sets of thermal conductivity data and elastic modulus, which are from literatures and this work, respectively. The results show that the temperature and stress distributions change with thermal conductivity and elastic modulus. The differences of maximum temperatures and stress are 6.5% and 8.0%, respectively.

  11. Enhanced water vapour barrier and grease resistance of paper bilayer-coated with chitosan and beeswax.

    Science.gov (United States)

    Zhang, Weiwei; Xiao, Huining; Qian, Liying

    2014-01-30

    In order to overcome the deficiencies of single layer coating, bilayer coated papers were prepared by two separate coating procedures using various combinations of proteins or polysaccharides with beeswax. Among those combinations, chitosan-beeswax bilayer coated paper showed the best water vapour barrier property. It was observed that as the concentration of chitosan solution increased from 1.0 to 3.0 wt%, its water vapour transport rate (WVTR) decreased from 171.6 to 52.8 g/m(2)/d but using reduced beeswax coating weight (from 10.1 to 4.9 g/m(2)). It also displayed an enhanced performance of grease resistance. Scanning electron microscopy (SEM) showed that beeswax layer was fitted to chitosan layer so closely that these two layers are indistinguishable. Confocal laser scanning microscope (CLSM) further confirmed the existence of an integrated chitosan film between beeswax layer and paper base and a thin composite layer consisting of chitosan and beeswax.

  12. Sintering Characteristics of Multilayered Thermal Barrier Coatings Under Thermal Gradient and Isothermal High Temperature Annealing Conditions

    Science.gov (United States)

    Rai, Amarendra K.; Schmitt, Michael P.; Bhattacharya, Rabi; Zhu, Dongming; Wolfe, Douglas E.

    2014-01-01

    Pyrochlore oxides have most of the relevant attributes for use as next generation thermal barrier coatings such as phase stability, low sintering kinetics and low thermal conductivity. One of the issues with the pyrochlore oxides is their lower toughness and therefore higher erosion rate compared to the current state-of-the-art TBC material, yttria (6 to 8 wt%) stabilized zirconia (YSZ). In this work, sintering characteristics were investigated for novel multilayered coating consisted of alternating layers of pyrochlore oxide viz Gd2Zr2O7 and t' low k (rare earth oxide doped YSZ). Thermal gradient and isothermal high temperature (1316 C) annealing conditions were used to investigate sintering and cracking in these coatings. The results are then compared with that of relevant monolayered coatings and a baseline YSZ coating.

  13. Inelastic deformation behavior of thermal barrier coatings exposed at a high-temperature environment

    Directory of Open Access Journals (Sweden)

    Arai M.

    2010-06-01

    Full Text Available Thermal barrier coatings (TBCs are usually deposited onto the surface of the high-temperature component such as gas turbine, in order to protect it from a hightemperature environment. Coating stress generated by such a high-temperature brings serious damages in TBCs in service. For predicting numerically it, it is necessary to develop the constitutive equation suite to plasam-sprayed TBCs. Previous studies have made clear that the freestanding ceramic coat peeled from TBC coated substrate deforms nonlinearly with a mechanical loading, however the results there have been restricted to the test done using as-sprayed sample. In this study, effect of deposition parameter and high-temperature exposure condition on stress-strain curve of the freestanding ceramic coating sample was examined. The associated deformation process was discussed with the microstructure changes observed after performing a bending test for the exposed sample.

  14. Fabrication of Nanosized Lanthanum Zirconate Powder and Deposition of Thermal Barrier Coating by Plasma Spray Process

    Science.gov (United States)

    Mishra, S. K.; Jagdeesh, N.; Pathak, L. C.

    2016-07-01

    The present manuscript discusses our findings on fabrication of nanosized lanthanum zirconate powder for thermal barrier coating application and its coating by plasma spray on nickel-based superalloy substrate. Single-phase La2Zr2O7 coating of thickness of the order of 45 µm on the Ni-Cr-Al bond coat coated Ni-based superalloy substrate was deposited by plasma spray process. The layers at the interface did not show spallation and inter diffusion was very less. The microstructure, interface, porosity, and mechanical properties of different layers are investigated. The lanthanum zirconate hardness and modulus were 10.5 and 277 GPa, respectively. The load depth curve for lanthanum zirconate showed good elastic recovery around 74%.

  15. Analysis of Plasma-Sprayed Thermal Barrier Coatings With Homogeneous and Heterogeneous Bond Coats Under Spatially Uniform Cyclic Thermal Loading

    Science.gov (United States)

    Arnold, Steven M.; Pindera, Marek-Jerzy; Aboudi, Jacob

    2003-01-01

    This report summarizes the results of a numerical investigation into the spallation mechanism in plasma-sprayed thermal barrier coatings observed under spatially-uniform cyclic thermal loading. The analysis focuses on the evolution of local stress and inelastic strain fields in the vicinity of the rough top/bond coat interface during thermal cycling, and how these fields are influenced by the presence of an oxide film and spatially uniform and graded distributions of alumina particles in the metallic bond coat aimed at reducing the top/bond coat thermal expansion mismatch. The impact of these factors on the potential growth of a local horizontal delamination at the rough interface's crest is included. The analysis is conducted using the Higher-Order Theory for Functionally Graded Materials with creep/relaxation constituent modeling capabilities. For two-phase bond coat microstructures, both the actual and homogenized properties are employed in the analysis. The results reveal the important contributions of both the normal and shear stress components to the delamination growth potential in the presence of an oxide film, and suggest mixed-mode crack propagation. The use of bond coats with uniform or graded microstructures is shown to increase the potential for delamination growth by increasing the magnitude of the crack-tip shear stress component.

  16. Investigation on plasma-sprayed ZrO2 thermal barrier coating on nickel alloy substrate

    Institute of Scientific and Technical Information of China (English)

    卢安贤; 常鹰; 蔡小梅

    2002-01-01

    The thermal barrier coatings with NiCrAlY alloy bonding layer, NiCrAlY-Y2O3 stabilized ZrO2 transition layer and Y2O3 stabilized ZrO2 ceramic layer are prepared on nickel alloy substrates using the plasma spray technique. The relationship among the composition, structure and property of the coatings are investiga-ted by means of optical microscope, scanning electronic microscope and the experiments of thermal shock resistance cycling and high temperature oxidation resistance. The results show that the structure design of introdu-cing a transition layer between Ni alloy substrate and ZrO2 ceramic coating guarantees the high quality and properties of the coatings; ZrO2 coatings doped with a little SiO2 possesses better thermal shock resistance and more excellent hot corrosion resistance as compared with ZrO2 coating materials without SiO2 ;the improvement in performance of ZrO2 coating doped with SiO2 is due to forming more dense coating structure by self- closing effects of the flaws and pores in the ZrO2 coatings.

  17. Test validation of environmental barrier coating (EBC) durability and damage tolerance modeling approach

    Science.gov (United States)

    Abdul-Aziz, Ali; Najafi, Ali; Abdi, Frank; Bhatt, Ramakrishna T.; Grady, Joseph E.

    2014-03-01

    Protection of Ceramic Matrix Composites (CMCs) is rather an important element for the engine manufacturers and aerospace companies to help improve the durability of their hot engine components. The CMC's are typically porous materials which permits some desirable infiltration that lead to strength enhancements. However, they experience various durability issues such as degradation due to coating oxidation. These concerns are being addressed by introducing a high temperature protective system, Environmental Barrier Coating (EBC) that can operate at temperature applications1, 3 In this paper, linear elastic progressive failure analyses are performed to evaluate conditions that would cause crack initiation in the EBC. The analysis is to determine the overall failure sequence under tensile loading conditions on different layers of material including the EBC and CMC in an attempt to develop a life/failure model. A 3D finite element model of a dogbone specimen is constructed for the analyses. Damage initiation, propagation and final failure is captured using a progressive failure model considering tensile loading conditions at room temperature. It is expected that this study will establish a process for using a computational approach, validated at a specimen level, to predict reliably in the future component level performance without resorting to extensive testing.

  18. Loadings in thermal barrier coatings of jet engine turbine blades an experimental research and numerical modeling

    CERN Document Server

    Sadowski, Tomasz

    2016-01-01

    This book discusses complex loadings of turbine blades and protective layer Thermal Barrier Coating (TBC), under real working airplane jet conditions. They obey both multi-axial mechanical loading and sudden temperature variation during starting and landing of the airplanes. In particular, two types of blades are analyzed: stationary and rotating, which are widely applied in turbine engines produced by airplane factories.

  19. The porosity assessment of thermal barrier coatings obtained by APS method

    Directory of Open Access Journals (Sweden)

    G. Moskal

    2007-01-01

    Full Text Available Purpose: The article presents the outline of methods and range of microstructural assessment of ceramiccoatings, using the example of thermal barrier coatings. The major structural parameters describing the qualityof the barrier layers have been characterised as well as the problems related to the correct metallographicspecimen preparation and the methodology of their assessment.Design/methodology/approach: A procedure of porosity assessment, employing quantative metallographicprinciples and automatic image analysis has been propounded, together with types of quantitative parametersand methods of their application.Findings: It was found that the application of the quantitative metallographic methods combined with automaticimage analysis can form an effective tool of both quantitative and qualitative assessment such parameters ofstructural ceramic layers as porosity.Research limitations/implications: This type of assessment enables obtaining more than just the absolute valueof the porosity of the given area: it provides the means for determining a number of other quantitative parameters,e.g. the surface area of the pores, their elongation and shape together with the whole statistical analysis.Practical implications: The application of scanning microscopy, especially observation techniques such as BSE,BSETOPO or BSE3D enables a precise differentiation of the areas constituting pores from other artefacts.Originality/value: Description of procedure of porosity assessments in APS TBC system by use of thequantitative metallographic methods combined with automatic image analysis, and possibility of applicationsspecial techniques of scanning microscopy.

  20. Effect of Composition of Bond Coating on the Durability of the Plasma Sprayed Zr O[sub 2]-Ce O[sub 2]-Y[sub 2] O[sub 3] Thermal Barrier Coating

    Energy Technology Data Exchange (ETDEWEB)

    Kim, H.S. (Korea Institute of Science and Technology, Seoul (Korea, Republic of)); Kim, B.H.; Suhr, D.S. (Chungnam National University, Taejon (Korea, Republic of))

    1999-01-01

    The effect of alloy compositions of the bond coating on the plasma sprayed-thermal barrier coatings was investigated. The performance of the coating composed of Rene 80/NiCrAl/ZrO[sub 2]-CeO[sub 2]-Y[sub 2]O[sub 3] and Rene 80/CoNiCrAlY/ZrO[sub 2]-CeO[sub 2]-Y[sub 2]O[sub 3] was evaluated by isothermal and thermal cyclic test in an ambient atmosphere at 1150 deg. C. The failure of Rene 80/NiCrAl/ZrO[sub 2]-CeO[sub 2]-Y[sub 2]O[sub 3] coatings was occurred at the bond coating/ceramic coating interface while Rene 80/CoNiCrAlY/ZrO[sub 2]-CeO[sub 2]-Y[sub 2]O[sub 3] coating was failed at the substrate/bond coating interface after thermal cyclic test. The lifetime of Rene 80/NiCrAl/ZrO[sub 2]-CeO[sub 2]-Y[sub 2]O[sub 3] coatings was longer than Rene 80/CoNiCrAlY/ZrO[sub 2]-CeO[sub 2]-Y[sub 2]O[sub 3] coating. The oxidation rate of the NiCrAl bond coating examined by TGA was lower than CoNiCrAlY bond coating. In summary, these results suggest that Rene 80/CoNiCrAlY/ZrO[sub 2]-CeO[sub 2]-Y[sub 2]O[sub 3] system as thermal barrier coating be not suitable considering the durability of the coating layer for high temperature oxidation and thermal stress. (author). 12 refs., 14 figs., 2 tabs.

  1. Effect of Composition of Bond Coating on the Durability of the Plasma Sprayed Zr O{sub 2}-Ce O{sub 2}-Y{sub 2} O{sub 3} Thermal Barrier Coating

    Energy Technology Data Exchange (ETDEWEB)

    Kim, H.S. [Korea Institute of Science and Technology, Seoul (Korea, Republic of); Kim, B.H.; Suhr, D.S. [Chungnam National University, Taejon (Korea, Republic of)

    1999-01-01

    The effect of alloy compositions of the bond coating on the plasma sprayed-thermal barrier coatings was investigated. The performance of the coating composed of Rene 80/NiCrAl/ZrO{sub 2}-CeO{sub 2}-Y{sub 2}O{sub 3} and Rene 80/CoNiCrAlY/ZrO{sub 2}-CeO{sub 2}-Y{sub 2}O{sub 3} was evaluated by isothermal and thermal cyclic test in an ambient atmosphere at 1150 deg. C. The failure of Rene 80/NiCrAl/ZrO{sub 2}-CeO{sub 2}-Y{sub 2}O{sub 3} coatings was occurred at the bond coating/ceramic coating interface while Rene 80/CoNiCrAlY/ZrO{sub 2}-CeO{sub 2}-Y{sub 2}O{sub 3} coating was failed at the substrate/bond coating interface after thermal cyclic test. The lifetime of Rene 80/NiCrAl/ZrO{sub 2}-CeO{sub 2}-Y{sub 2}O{sub 3} coatings was longer than Rene 80/CoNiCrAlY/ZrO{sub 2}-CeO{sub 2}-Y{sub 2}O{sub 3} coating. The oxidation rate of the NiCrAl bond coating examined by TGA was lower than CoNiCrAlY bond coating. In summary, these results suggest that Rene 80/CoNiCrAlY/ZrO{sub 2}-CeO{sub 2}-Y{sub 2}O{sub 3} system as thermal barrier coating be not suitable considering the durability of the coating layer for high temperature oxidation and thermal stress. (author). 12 refs., 14 figs., 2 tabs.

  2. Influence of the Thermal Barrier Coatings Design on the Oxidation Behavior

    Institute of Scientific and Technical Information of China (English)

    B.Saeedi; A.Sabour; A.Ebadi; A.M.Khoddami

    2009-01-01

    The properties of two different types of thermal barrier coatings (TBCs) were compared to improve the surface characteristics on high temperature components. These TBCs consisted of a duplex TBC and a five-layered functionally graded TBC. NiCrAlY bond coats were deposited on a number of Inconel-738LC specimens using high velocity oxy-fuel spraying (HVOF) technique. For duplex coating, a group of these specimens were coated with yttria stabilized zirconia (YSZ) using plasma spray technique. Functionally graded NiCrAlY/YSZ coatings were fabricated by plasma spray using co-injection of the two different powders in a single plasma torch. The amount of zirconia in functionally graded coatings were gradually increased from 30 to 100 vol. pct. Microstructural changes, thermally grown oxide (TGO) layer growth and damage initiation of the coatings were investigated as a function of isothermal oxidation test at 970℃. As a complementary test, the performance of the fabricated coatings by the optimum processing conditions was evaluated as a function of intense thermal cycling test at 1100℃. Also the strength of the adhesive coatings of the substrate was also measured. Microstructural characterization was analyzed by scanning electron microscopy (SEM) and optical microscopy whereas phase analysis and chemical composition changes of the coatings and oxides formed during the tests were studied by XRD (X-ray diffraction) and EDS (energy dispersive spectrometer). The results showed that microstructure and compositions gradually varied in the functionally graded coatings. By comparison of duplex and functionally graded TBCs oxidation behavior (duplex failure after 1700 h and funcitionally graded TECs failure after 2000 h), thermal shock test and adhesion strength of the coatings, the functionally graded TBC had better performance and more durability.

  3. Durability of zirconia thermal-barrier ceramic coatings on air-cooled turbine blades in cyclic jet engine operation

    Science.gov (United States)

    Liebert, C. H.; Jacobs, R. E.; Stecura, S.; Morse, C. R.

    1976-01-01

    Thermal barrier ceramic coatings of stabilized zirconia over a bond coat of Ni Cr Al Y were tested for durability on air cooled turbine rotor blades in a research turbojet engine. Zirconia stabilized with either yttria, magnesia, or calcia was investigated. On the basis of durability and processing cost, the yttria stabilized zirconia was considered the best of the three coatings investigated.

  4. Improving oxidation resistance and thermal insulation of thermal barrier coatings by intense pulsed electron beam irradiation

    Energy Technology Data Exchange (ETDEWEB)

    Mei Xianxiu, E-mail: xxmei@dlut.edu.cn [Key Laboratory of Materials Modification by Laser, Ion and Electron Beams, Dalian University of Technology, Ministry of Education, Dalian 116024 (China); Liu Xiaofei; Wang Cunxia; Wang Younian; Dong Chuang [Key Laboratory of Materials Modification by Laser, Ion and Electron Beams, Dalian University of Technology, Ministry of Education, Dalian 116024 (China)

    2012-12-15

    Highlights: Black-Right-Pointing-Pointer Pulsed electron beam was used for sealing ZrO{sub 2} thermal barrier coating prepared by electron beam-physical vapor deposition. Black-Right-Pointing-Pointer At irradiation energy densities above 8 J/cm{sup 2}, ZrO{sub 2} ceramic coating surface was fully re-melted and became smooth, dense and shiny. Black-Right-Pointing-Pointer The thermal diffusion rate of the irradiated coating was decreased. Black-Right-Pointing-Pointer Thermal insulation properties and high temperature oxidation resistance were improved. - Abstract: In this paper, intense pulsed electron beam was used for the irradiation treatment of 6-8% Y{sub 2}O{sub 3}-stablized ZrO{sub 2} thermal barrier coating prepared by electron beam-physical vapor deposition to achieve the 'sealing' of columnar crystals, thus improving their thermal insulation properties and high temperature oxidation resistance. The electron beam parameters used were: pulse duration 200 {mu}s, electron voltage 15 kV, energy density 3, 5, 8, 15, 20 J/cm{sup 2}, and pulsed numbers 30. 1050 Degree-Sign C cyclic oxidation and static oxidation experiments were used for the research on oxidation resistance of the coatings. When the energy density of the electron beam was larger than 8 J/cm{sup 2}, ZrO{sub 2} ceramic coating surface was fully re-melted and became smooth, dense and shiny. The coating changed into a smooth polycrystalline structure, thus achieving the 'sealing' effect of the columnar crystals. After irradiations with the energy density of 8-15 J/cm{sup 2}, the thermally grown oxide coating thickness decreased significantly in comparison with non-irradiated coatings, showing that the re-melted coating improved the oxidation resistance of the coatings. The results of thermal diffusivity test by laser flash method showed that the thermal diffusion rate of the irradiated coating was lower than that of the coating without irradiation treatment, and the thermal

  5. Computational Design and Experimental Validation of New Thermal Barrier Systems

    Energy Technology Data Exchange (ETDEWEB)

    Guo, Shengmin; Yang, Shizhong; Khosravi, Ebrahim

    2014-04-01

    This project (10/01/2010-9/30/2014), “Computational Design and Experimental Validation of New Thermal Barrier Systems”, originates from Louisiana State University (LSU) Mechanical Engineering Department and Southern University (SU) Department of Computer Science. This project will directly support the technical goals specified in DE-FOA-0000248, Topic Area 3: Turbine Materials, by addressing key technologies needed to enable the development of advanced turbines and turbine-based systems that will operate safely and efficiently using coal-derived synthesis gases. In this project, the focus is to develop and implement novel molecular dynamics method to improve the efficiency of simulation on novel TBC materials; perform high performance computing (HPC) on complex TBC structures to screen the most promising TBC compositions; perform material characterizations and oxidation/corrosion tests; and demonstrate our new thermal barrier coating (TBC) systems experimentally under integrated gasification combined cycle (IGCC) environments.

  6. Preparation of SrZrO3 Thermal Barrier Coating by Solution Precursor Plasma Spray

    Science.gov (United States)

    Li, Xinhui; Ma, Wen; Wen, Jing; Bai, Yu; Sun, Li; Chen, Baodong; Dong, Hongying; Shuang, Yingchai

    2017-02-01

    The solution precursor plasma spray (SPPS) process is capable of depositing highly durable thermal barrier coatings (TBCs). In this study, an aqueous chemical precursor feedstock was injected into the plasma jet to deposit SrZrO3 thermal barrier coating on metal substrate. Taguchi design of experiments was employed to optimize the SPPS process. The thermal characteristics and phase evolution of the SrZrO3 precursor, as well as the influence of various spray parameters on the coating deposition rate, microhardness, microstructure, and phase stability, were investigated. The experimental results showed that, at given spray distance, feedstock flow rate, and atomization pressure, the optimized spray parameters were arc current of 600 A, argon flow rate of 40 L/min, and hydrogen flow rate of 10 L/min. The SrZrO3 coating prepared using the optimized spray parameters had single-pass thickness of 6.0 μm, porosity of 18%, and microhardness of 6.8 ± 0.1 GPa. Phase stability studies indicated that the as-sprayed SrZrO3 coating had good phase stability in the temperature range from room temperature to 1400 °C, gradually exhibiting a phase transition from t'-ZrO2 to m-ZrO2 in the SrZrO3 coating at 1450 °C with increasing time, while the SrZrO3 phase did not change.

  7. HOT DIPPING ALUMINIZED COATING AS HYDROGEN PERMEATION BARRIER

    Institute of Scientific and Technical Information of China (English)

    Z.Y. Yao; M. Chini; A. Aiello; Benamati

    2001-01-01

    The hydrogen permeation experiment of MANET II with hot dipping aluminized 1oat-ing was performed in temperature range of 573 to 623K, in gas phase and in liquiaPb-17Li phase. The hydrogen permeation reduction factor (PRF) evaluated in gasphase is 620 at 573K and 260 at 623K, and in liquid Pb-17Li phase is 24 45 at 573Kand 12-30 at 623K. The self-healing of coating is obvious and effective above 673K.The pressure dependence of permeation flux indicates strong surface contribution. Theway of filling hydrogen by continuous flow and/or bubble can increase permeation flux.The result of SEM-EDS shows that the microcrack is on the surface of the wetted part,but not on the not wetted part. The crack is superficial and affects only thin outsidelayer not penetrate aluminized layer. The surface elemental analysis shows that Al/Oatomic ratio changes from 2/3 of not wetted part to about 1 of wetted part. Thedamage of coating surface seems to be related to the interaction of outside layer withliquid Pb-17Li and thermal stress during heating sample.

  8. Impact Resistance of Environmental Barrier Coated SiC/SiC Composites

    Science.gov (United States)

    Bhatt, Ramakrishna T.; Choi, Sung R.; Cosgriff, Laura M.; Fox, Dennis S.; Lee, Kang N.

    2008-01-01

    Impact performance of 2D woven SiC/SiC composites coated with 225 and 525 microns thick environmental barrier coating (EBC) was investigated. The composites were fabricated by melt infiltration and the EBC was deposited by plasma spray. Impact tests were conducted at room temperature and at 1316 C in air using 1.59 mm diameter steel-balls at projectile velocities ranging from 110 to 375 m/s . Both microscopy and non-destructive evaluation (NDE) methods were used to determine the extent of damage in the substrate and coating with increasing projectile velocity. The impacted specimens were tensile tested at room temperature to determine their residual mechanical properties. At projectile velocities less than 125 m/s , no detectable internal damage was noticed in the MI SiC/SiC composites coated with 525 microns EBC. With increase in projectile velocity beyond this value, spallation of EBC layers, delamination of fiber plies, and fiber fracture were detected. At a fixed projectile velocity, the composites coated with 525 microns EBC showed less damage than those coated with 225 microns EBC. Both types of coated composites retained a large fraction of the baseline properties of the as-fabricated composites and exhibited non-brittle failure after impact testing. Furnace exposure of impacted specimens in a moisture environment at 1316 C for 500 h indicated that the through-the-thickness cracks in the coating and delamination cracks in the substrate generated after impact testing acted as conduits for internal oxidation.

  9. Phase composition and residual stresses in thermal barrier coatings

    Science.gov (United States)

    Lozovan, A. A.; Betsofen, S. Ya; Ashmarin, A. A.; Ryabenko, B. V.; Ivanova, S. V.

    2016-07-01

    X-ray study of the phase composition and residual stresses distribution in two-layer APS coatings showed that the ceramic layer consists of t-ZrO2 phase with tetragonal lattice and the metal underlayer γ-solid solution based on nickel. In the transition zone thickness of ∼ 100 pm as the distance from the surface was revealed a gradual transition from t-ZrO2 to γ-solid solution. Increase in the specific volume of the metal underlayer resulting TGO growing leads to the formation of this layer high compressive stresses up to 600 MPa. In this case, the ceramic layer contains tensile stress up to 200 MPa.

  10. Design and optimization of coating structure for the thermal barrier coatings fabricated by atmospheric plasma spraying via finite element method

    Directory of Open Access Journals (Sweden)

    L. Wang

    2014-06-01

    Full Text Available The first prerequisite for fabricating the thermal barrier coatings (TBCs with excellent performance is to find an optimized coating structure with high thermal insulation effect and low residual stress. This paper discusses the design and optimization of a suitable coating structure for the TBCs prepared by atmospheric plasma spraying (APS using the finite element method. The design and optimization processes comply with the rules step by step, as the structure develops from a simple to a complex one. The research results indicate that the suitable thicknesses of the bond-coating and top-coating are 60–120 μm and 300–420 μm, respectively, for the single ceramic layer YSZ/NiCoCrAlY APS-TBC. The embedded interlayer (50 wt.%YSZ + 50 wt.%NiCoCrAlY will further reduce the residual stress without sacrificing the thermal insulation effect. The double ceramic layer was further considered which was based on the single ceramic layer TBC. The embedded interlayer and the upper additional ceramic layer will have a best match between the low residual stress and high thermal insulation effect. Finally, the optimized coating structure was obtained, i.e., the La2Ce2O7(LC/YSZ/Interlayer/NiCoCrAlY coating structure with appropriate layer thickness is the best choice. The effective thermal conductivity of this optimized LC/YSZ/IL/BL TBC is 13.2% lower than that of the typical single ceramic layer YSZ/BL TBC.

  11. Oxidation and Hot Corrosion of Gradient Thermal Barrier Coatings Prepared by EB-PVD

    Institute of Scientific and Technical Information of China (English)

    2002-01-01

    The performances of gradient thermal barrier coatings (GTBCs) produced by EB-PVD were evaluated by isothermaloxidation and cyclic hot corrosion (HTHC) tests. Compared with conventional two-layered TBCs, the GTBCs exhibitebetter resistance to not only oxidation but also hot-corrosion. A dense Al2O3 layer in the GTBCs effectively prohibitesinward diffusion of O and S and outward diffusion of Al and Cr during the tests. On the other hand, an "inlaid"interface, resulting from oxidation of the Al along the columnar grains of the bond coat, enhances the adherence ofAl2O3 layer. Failure of the GTBC finally occurred by cracking at the interface between the bond coat and Al2O3layer, due to the combined effect of sulfidation of the bond coat and thermal cycling.

  12. Acoustic Emission Analysis of Damage Progression in Thermal Barrier Coatings Under Thermal Cyclic Conditions

    Science.gov (United States)

    Appleby, Matthew; Zhu, Dongming; Morscher, Gregory

    2015-01-01

    Damage evolution of electron beam-physical vapor deposited (EBVD-PVD) ZrO2-7 wt.% Y2O3 thermal barrier coatings (TBCs) under thermal cyclic conditions was monitored using an acoustic emission (AE) technique. The coatings were heated using a laser heat flux technique that yields a high reproducibility in thermal loading. Along with AE, real-time thermal conductivity measurements were also taken using infrared thermography. Tests were performed on samples with induced stress concentrations, as well as calcium-magnesium-alumino-silicate (CMAS) exposure, for comparison of damage mechanisms and AE response to the baseline (as-produced) coating. Analysis of acoustic waveforms was used to investigate damage development by comparing when events occurred, AE event frequency, energy content and location. The test results have shown that AE accumulation correlates well with thermal conductivity changes and that AE waveform analysis could be a valuable tool for monitoring coating degradation and provide insight on specific damage mechanisms.

  13. X-ray residual stress analysis of a ceramic thermal barrier coating undergoing thermal cycling

    Energy Technology Data Exchange (ETDEWEB)

    Jordan, D.W. (Dept. of Materials Science and Engineering, Northwestern Univ., Evanston, IL (United States)); Faber, K.T. (Dept. of Materials Science and Engineering, Northwestern Univ., Evanston, IL (United States))

    1993-11-25

    The residual stress of a ZrO[sub 2]-8%Y[sub 2]O[sub 3] thermal barrier coating was determined as a function of thermal cycling. Samples were thermally cycled from 400 C to 1000 C in air. After a few cycles the samples exhibited a value of compressive residual stress consistent with that determined by considering the thermal expansion coefficients of the coating and substrate. Stress relief occurs in the ZrO[sub 2]-Y[sub 2]O[sub 3] coating, increasing in both frequency and magnitude with increasing number of thermal cycles. This behavior is explained in terms of a model of failure of coatings in compression. (orig.)

  14. Numerical and Experimental Investigation of Residual Stress in Thermal Barrier Coatings During APS Process

    Science.gov (United States)

    Wu, Lifu; Zhu, Jianguo; Xie, Huimin

    2014-04-01

    Thermal barrier coating (TBC) system is widely used in modern gas turbines to protect the internals and enable them to service in higher temperature environment. Residual stress in the TBC system can be induced during its production procedure, such as air plasma spraying (APS) process, and affect its performance to a large extent. The temperature history and the evolution of residual stress in the TBC system during APS process were studied in this paper by finite element simulation and hole-drilling experiment. A five-layered TBC specimen model was established, and a thermo-mechanical-coupled analysis was conducted in the simulation. The "modified element birth-death technique" was used to represent the formation of TBC. In addition, experimental validation of the simulation result was carried out on a TBC specimen using hole-drilling technique combined with moiré interferometry. The experimental data agreed well with the simulation results and the study of this paper could provide a reference for the production of the TBC system.

  15. Large-scale, thick, self-assembled, nacre-mimetic brick-walls as fire barrier coatings on textiles

    Science.gov (United States)

    Das, Paramita; Thomas, Helga; Moeller, Martin; Walther, Andreas

    2017-01-01

    Highly loaded polymer/clay nanocomposites with layered structures are emerging as robust fire retardant surface coatings. However, time-intensive sequential deposition processes, e.g. layer-by-layer strategies, hinders obtaining large coating thicknesses and complicates an implementation into existing technologies. Here, we demonstrate a single-step, water-borne approach to prepare thick, self-assembling, hybrid fire barrier coatings of sodium carboxymethyl cellulose (CMC)/montmorillonite (MTM) with well-defined, bioinspired brick-wall nanostructure, and showcase their application on textile. The coating thickness on the textile is tailored using different concentrations of CMC/MTM (1–5 wt%) in the coating bath. While lower concentrations impart conformal coatings of fibers, thicker continuous coatings are obtained on the textile surface from highest concentration. Comprehensive fire barrier and fire retardancy tests elucidate the increasing fire barrier and retardancy properties with increasing coating thickness. The materials are free of halogen and heavy metal atoms, and are sourced from sustainable and partly even renewable building blocks. We further introduce an amphiphobic surface modification on the coating to impart oil and water repellency, as well as self-cleaning features. Hence, our study presents a generic, environmentally friendly, scalable, and one-pot coating approach that can be introduced into existing technologies to prepare bioinspired, thick, fire barrier nanocomposite coatings on diverse surfaces.

  16. Spectral Modeling of Residual Stress and Stored Elastic Strain Energy in Thermal Barrier Coatings

    Energy Technology Data Exchange (ETDEWEB)

    Donegan, Sean; Rolett, Anthony

    2013-12-31

    Solutions to the thermoelastic problem are important for characterizing the response under temperature change of refractory systems. This work extends a spectral fast Fourier transform (FFT) technique to analyze the thermoelastic behavior of thermal barrier coatings (TBCs), with the intent of probing the local origins of failure in TBCs. The thermoelastic FFT (teFFT) approach allows for the characterization of local thermal residual stress and strain fields, which constitute the origins of failure in TBC systems. A technique based on statistical extreme value theory known as peaks-over-threshold (POT) is developed to quantify the extreme values ("hot spots") of stored elastic strain energy (i.e., elastic energy density, or EED). The resolution dependence of the teFFT method is assessed through a sensitivity study of the extreme values in EED. The sensitivity study is performed both for the local (point-by-point) eld distributions as well as the grain scale eld distributions. A convergence behavior to a particular distribution shape is demonstrated for the local elds. The grain scale fields are shown to exhibit a possible convergence to a maximum level of EED. To apply the teFFT method to TBC systems, 3D synthetic microstructures are created to approximate actual TBC microstructures. The morphology of the grains in each constituent layer as well as the texture is controlled. A variety of TBC materials, including industry standard materials and potential future materials, are analyzed using the teFFT. The resulting hot spots are quantified using the POT approach. A correlation between hot spots in EED and interface rumpling between constituent layers is demonstrated, particularly for the interface between the bond coat (BC) and the thermally grown oxide (TGO) layer.

  17. Revisiting the Birth of 7YSZ Thermal Barrier Coatings: Steve Stecura

    Science.gov (United States)

    Smialek, James L.; Miller, Robert A.

    2017-01-01

    Thermal barrier coatings are widely used in all turbine engines, typically using a 7 wt% Y2O3-ZrO2 formulation. Extensive research and development over many decades have refined the processing and structure of these coatings for increased durability and reliability. New compositions demonstrate some unique advantages and are gaining in application. However, the "7YSZ" formulation predominates and is still in widespread use. This special composition has been universally found to produce nanoscale precipitates of metastable t' tetragonal phase, giving rise to a unique toughening mechanism via ferro-elastic switching under stress. This note recalls the original study that identified superior properties of 6 to 8 wt% YSZ plasma sprayed thermal barrier coatings, published in 1978. The impact of this discovery, arguably, continues in some form to this day. At one point, 7YSZ thermal barrier coatings were used in every new aircraft and ground power turbine engine produced worldwide. It is a tribute to its inventor, Dr. Stephan J. Stecura, NASA retiree.

  18. Development of Diffusion barrier coatings and Deposition Technologies for Mitigating Fuel Cladding Chemical Interactions (FCCI)

    Energy Technology Data Exchange (ETDEWEB)

    Sridharan, Kumar; Allen, Todd; Cole, James

    2013-02-27

    The goal of this project is to develop diffusion barrier coatings on the inner cladding surface to mitigate fuel-cladding chemical interaction (FCCI). FCCI occurs due to thermal and radiation enhanced inter-diffusion between the cladding and fuel materials, and can have the detrimental effects of reducing the effective cladding wall thickness and lowering the melting points of the fuel and cladding. The research is aimed at the Advanced Burner Reactor (ABR), a sodium-cooled fast reactor, in which higher burn-ups will exacerbate the FCCI problem. This project will study both diffusion barrier coating materials and deposition technologies. Researchers will investigate pure vanadium, zirconium, and titanium metals, along with their respective oxides, on substrates of HT-9, T91, and oxide dispersion-strengthened (ODS) steels; these materials are leading candidates for ABR fuel cladding. To test the efficacy of the coating materials, the research team will perform high-temperature diffusion couple studies using both a prototypic metallic uranium fuel and a surrogate the rare-earth element lanthanum. Ion irradiation experiments will test the stability of the coating and the coating-cladding interface. A critical technological challenge is the ability to deposit uniform coatings on the inner surface of cladding. The team will develop a promising non-line-of-sight approach that uses nanofluids . Recent research has shown the feasibility of this simple yet novel approach to deposit coatings on test flats and inside small sections of claddings. Two approaches will be investigated: 1) modified electrophoretic deposition (MEPD) and 2) boiling nanofluids. The coatings will be evaluated in the as-deposited condition and after sintering.

  19. Influence of Experimental Parameters Using the Dip-Coating Method on the Barrier Performance of Hybrid Sol-Gel Coatings in Strong Alkaline Environments

    Directory of Open Access Journals (Sweden)

    Rita B. Figueira

    2015-04-01

    Full Text Available Previous studies have shown that the barrier effect and the performance of organic-inorganic hybrid (OIH sol-gel coatings are highly dependent on the coating deposition method as well as on the processing conditions. However, studies on how the coating deposition method influences the barrier properties in alkaline environments are scarce. The aim of this experimental research was to study the influence of experimental parameters using the dip-coating method on the barrier performance of an OIH sol-gel coating in contact with simulated concrete pore solutions (SCPS. The influence of residence time (Rt, a curing step between each dip step and the number of layers of sol-gel OIH films deposited on hot-dip galvanized steel to prevent corrosion in highly alkaline environments was studied. The barrier performance of these OIH sol-gel coatings, named U(400, was assessed in the first instants of contact with SCPS, using electrochemical impedance spectroscopy and potentiodynamic methods. The durability and stability of the OIH coatings in SCPS was monitored during eight days by macrocell current density. The morphological characterization of the surface was performed by Scanning Electronic Microscopy before and after exposure to SCPS. Glow Discharge Optical Emission Spectroscopy was used to investigate the thickness of the U(400 sol-gel coatings as a function of the number of layers deposited with and without Rt in the coatings thickness.

  20. Thermal Barrier Coatings Chemically and Mechanically Resistant to High Temperature Attack by Molten Ashes

    Science.gov (United States)

    Gledhill, Andrew

    Thermal barrier coatings (TBCs) are ceramic coatings used on component in the hottest sections of gas turbine engines, used for power generation and aviation. These coatings insulate the underlying metal components and allow for much higher engine operating temperatures, improving the engine efficiency. These increase temperatures engender a new set of materials problems for TBCs. Operating temperatures in engines are now high enough for silicate impurities, either present in the fuel or ingested into the engines, to melt and adhere to the surface of the TBCs. The effects of four such impurities, two coal fly ashes, a petroleum coke-fly ash blend, and volcanic ash from the Eyjafjallajokull volcano were tested with conventional yttria-stabilized zirconia (YSZ) coatings, and found to penetrate through the entire thickness of the coating. This penetration reduces the strain tolerance of the coatings, and can result in premature failure. Testing on a newly built thermal gradient burner rig with simultaneous injection of ash impurities has shown a reduction of life up to 99.6% in these coatings when ash is present. Coatings of an alternative ceramic, gadolinium zirconate (Gd2Zr 2O7), were found to form a dense reaction layer with each of these impurities, preventing further penetration of the molten ash. This dense layer also reduces the strain tolerance, but these coatings were found to have a significantly higher life than the YSZ coatings. Testing with a small amount of ash baked onto the samples showed thirteen times the life of YSZ coatings. When the ash is continuously sprayed onto the hot sample, the life of the Gd2Zr2O7 coatings was nearly twice that of the YSZ. Finally, a delamination model was employed to explain the degradation of both types of coatings. This elastic model that takes into account the degree of penetration, differential cooling in thermal gradient testing, and thermal expansion mismatch with the underlying substrate, predicted the failure of

  1. Optimization of the NiCrAl-Y/ZrO-Y2O3 thermal barrier system

    Science.gov (United States)

    Stecura, S.

    1985-01-01

    The effects of bond and thermal barrier coating compositions, thicknesses, and densities on air plasma spray deposited Ni-Cr-Al-Y/ZrO2-Y2O3 life were evaluated in cyclic furnace oxidation tests at temperatures from 1110 to 1220 C. An empirical relation was developed to give life as a function of the above parameters. The thermal barrier system tested which had the longest life consisted of Ni-35.0 wt% Cr-5.9 wt% Al-0.95 wt% Y bond coating and ZrO2-6.1 wt% Y2O3 thermal barrier coating.

  2. Environmental Barrier Coating (EBC) Durability Modeling; An Overview and Preliminary Analysis

    Science.gov (United States)

    Abdul-Aziz, A.; Bhatt, R. T.; Grady, J. E.; Zhu, D.

    2012-01-01

    A study outlining a fracture mechanics based model that is being developed to investigate crack growth and spallation of environmental barrier coating (EBC) under thermal cycling conditions is presented. A description of the current plan and a model to estimate thermal residual stresses in the coating and preliminary fracture mechanics concepts for studying crack growth in the coating are also discussed. A road map for modeling life and durability of the EBC and the results of FEA model(s) developed for predicting thermal residual stresses and the cracking behavior of the coating are generated and described. Further initial assessment and preliminary results showed that developing a comprehensive EBC life prediction model incorporating EBC cracking, degradation and spalling mechanism under stress and temperature gradients typically seen in turbine components is difficult. This is basically due to mismatch in thermal expansion difference between sub-layers of EBC as well as between EBC and substrate, diffusion of moisture and oxygen though the coating, and densification of the coating during operating conditions as well as due to foreign object damage, the EBC can also crack and spall from the substrate causing oxidation and recession and reducing the design life of the EBC coated substrate.

  3. ON-LINE THERMAL BARRIER COATING MONITORING FOR REAL-TIME FAILURE PROTECTION AND LIFE MAXIMIZATION

    Energy Technology Data Exchange (ETDEWEB)

    Dennis H. LeMieux

    2003-10-01

    Under the sponsorship of the U. S. Department of Energy's National Energy Laboratory, Siemens Westinghouse Power Corporation proposes a four year program titled, ''On-Line Thermal Barrier Coating (TBC) Monitor for Real-Time Failure Protection and Life Maximization,'' to develop, build and install the first generation of an on-line TBC monitoring system for use on land-based advanced gas turbines (AGT). Federal deregulation in electric power generation has accelerated power plant owner's demand for improved reliability, availability, and maintainability (RAM) of the land-based advanced gas turbines. As a result, firing temperatures have been increased substantially in the advanced turbine engines, and the TBCs have been developed for maximum protection and life of all critical engine components operating at these higher temperatures. Losing TBC protection can, therefore, accelerate the degradation of substrate component materials and eventually lead to a premature failure of critical components and costly unscheduled power outages. This program seeks to substantially improve the operating life of high cost gas turbine components using TBC; thereby, lowering the cost of maintenance leading to lower cost of electricity. Siemens Westinghouse Power Corporation has teamed with Indigo Systems, a supplier of state-of-the-art infrared camera systems, and Wayne State University, a leading research organization in the field of infrared non-destructive examination (NDE), to complete the program.

  4. On-Line Thermal Barrier Coating Monitoring for Real-Time Failure Protection and Life Maximization

    Energy Technology Data Exchange (ETDEWEB)

    Dennis H. LeMieux

    2005-04-01

    Under the sponsorship of the U. S. Department of Energy's National Energy Laboratory, Siemens Westinghouse Power Corporation proposes a four year program titled, ''On-Line Thermal Barrier Coating (TBC) Monitor for Real-Time Failure Protection and Life Maximization'', to develop, build and install the first generation of an on-line TBC monitoring system for use on land-based advanced gas turbines (AGT). Federal deregulation in electric power generation has accelerated power plant owner's demand for improved reliability availability maintainability (RAM) of the land-based advanced gas turbines. As a result, firing temperatures have been increased substantially in the advanced turbine engines, and the TBCs have been developed for maximum protection and life of all critical engine components operating at these higher temperatures. Losing TBC protection can therefore accelerate the degradation of substrate components materials and eventually lead to a premature failure of critical component and costly unscheduled power outages. This program seeks to substantially improve the operating life of high cost gas turbine components using TBC; thereby, lowering the cost of maintenance leading to lower cost of electricity. Siemens Westinghouse Power Corporation has teamed with Indigo Systems, a supplier of state-of-the-art infrared camera systems, and Wayne State University, a leading research organization in the field of infrared non-destructive examination (NDE), to complete the program.

  5. On-Line Thermal Barrier Coating Monitoring for Real-Time Failure Protection and Life Maximization

    Energy Technology Data Exchange (ETDEWEB)

    Dennis H. LeMieux

    2004-10-01

    Under the sponsorship of the U. S. Department of Energy's National Energy Laboratory, Siemens Westinghouse Power Corporation proposes a four year program titled, ''On-Line Thermal Barrier Coating (TBC) Monitor for Real-Time Failure Protection and Life Maximization'', to develop, build and install the first generation of an on-line TBC monitoring system for use on land -based advanced gas turbines (AGT). Federal deregulation in electric power generation has accelerated power plant owner's demand for improved reliability availability maintainability (RAM) of the land-based advanced gas turbines. As a result, firing temperatures have been increased substantially in the advanced turbine engines, and the TBCs have been developed for maximum protection and life of all critical engine components operating at these higher temperatures. Losing TBC protection can therefore accelerate the degradation of substrate components materials and eventually lead to a premature failure of critical component and costly unscheduled power outages. This program seeks to substantially improve the operating life of high cost gas turbine components using TBC; thereby, lowering the cost of maintenance leading to lower cost of electricity. Siemens Westinghouse Power Corporation has teamed with Indigo Systems; a supplier of state-of-the-art infrared camera systems, and Wayne State University, a leading research organization.

  6. ON-LINE THERMAL BARRIER COATING MONITORING FOR REAL-TIME FAILURE PROTECTION AND LIFE MAXIMIZATION

    Energy Technology Data Exchange (ETDEWEB)

    Dennis H. LeMieux

    2003-07-01

    Under the sponsorship of the U. S. Department of Energy's National Energy Laboratory, Siemens Westinghouse Power Corporation proposes a four year program titled, ''On-Line Thermal Barrier Coating (TBC) Monitor for Real-Time Failure Protection and Life Maximization,'' to develop, build and install the first generation of an on-line TBC monitoring system for use on land-based advanced gas turbines (AGT). Federal deregulation in electric power generation has accelerated power plant owner's demand for improved reliability, availability, and maintainability (RAM) of the land-based advanced gas turbines. As a result, firing temperatures have been increased substantially in the advanced turbine engines, and the TBCs have been developed for maximum protection and life of all critical engine components operating at these higher temperatures. Losing TBC protection can, therefore, accelerate the degradation of substrate component materials and eventually lead to a premature failure of critical components and costly unscheduled power outages. This program seeks to substantially improve the operating life of high cost gas turbine components using TBC; thereby, lowering the cost of maintenance leading to lower cost of electricity. Siemens Westinghouse Power Corporation has teamed with Indigo Systems, a supplier of state-of-the-art infrared camera systems, and Wayne State University, a leading research organization in the field of infrared non-destructive examination (NDE), to complete the program.

  7. Coating-Substrate Systems for Thermomechanically Durable Turbine Airfoils

    Science.gov (United States)

    2015-06-30

    Department Building 503, Room 1355 Santa Barbara, CA 93106 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) Office of Naval Research 8...approach has been to study in detail degradation mechanisms during thermomechanical cycling under isothermal fatigue conditions with sustained ...layers of surface protection. For example, yttria-stabilized zirconia (YSZ) thermal barrier coating systems are applied to nickel-base single crystals

  8. A study of the barrier properties of polyethylene coated with a nanocellulose/magnetite composite film

    Directory of Open Access Journals (Sweden)

    Đorđević Nenad

    2016-01-01

    Full Text Available The morphological, thermal and barrier properties of low-density polyethylene/polycaprolactone-modified nanocellulose hybrid materials were investigated in this paper. Nanonocelulose/magnetite (NC-Fe3O4 nanocomposite and maleic acid functionalized NC/magnetite (NCMA-Fe3O4 nanocomposite were prepared and used as filler at various concentrations (5, 10 and 15 wt. % in polycaprolactone (PCL layer. PE was coated with PCL/NC/magnetite layer. The addition of the filler did not unfavorably affect the inherent properties of the polymer, especially its barrier properties. Oxygen permeation measurements show that the oxygen barrier properties of magnetite enriched PCL film were improved due to chemical activity of added material. The highest level of barrier capacity was observed for PE samples coated with PCL based composite with NCMA-Fe3O4 micro/-nanofiller, which implies the significant contribution of nanocellulose surface modification with maleic anhydride residue to improved barrier properties. [Projekat Ministarstva nauke Republike Srbije, br. III45019 i br. OI172013

  9. Analysis on Residual Stress in Electron Beam-Physical Vapor Deposited Thermal Barrier Coating using Hard Synchrotron X-Rays

    OpenAIRE

    鈴木, 賢治; 松本, 一秀; 久保, 貴博; 町屋, 修太郎; 田中, 啓介; 秋庭, 義明; SUZUKI, Kenji; MATSUMOTO, Kazuhide; Kubo, Takahiro; Machiya, Syutaro; Tanaka, Keisuke; Akiniwa, Yoshiaki

    2005-01-01

    The distribution of the residual stress in the thermal barrier coating, which was made by an electron beam-physical vapor deposition (EB-PVD) method, was determined using X-ray stress measurements. As the bond coating, NiCoCrAlY was low-pressure plasma sprayed on the substrate of austenitic stainless steel. The 8 mass% Y_2O_3-ZrO_2 was coated on the bond coating using the EB-PVD method as the top coating. The top coating had the preferred orientation with the axis direction perpendicular to ...

  10. An advance process of aluminum rich coating as tritium permeation barrier on 321 steel workpiece

    Energy Technology Data Exchange (ETDEWEB)

    Zhang, G.K., E-mail: Guikaizhang712@163.com [China Academy of Engineering Physics, Mianyang, 621900 (China) and College of Nuclear Science and Technology, University of Science and Technology of China, Hefei, 230026 (China); Chen, C.A.; Luo, D.L. [China Academy of Engineering Physics, Mianyang, 621900 (China); Wang, X.L. [China Academy of Engineering Physics, Mianyang, 621900 (China); College of Nuclear Science and Technology, University of Science and Technology of China, Hefei, 230026 (China)

    2012-08-15

    Highlights: Black-Right-Pointing-Pointer An advance process of tritium permeation barrier was applied to 321 steel workpiece. Black-Right-Pointing-Pointer Tritium permeation barrier consisted of an outer Al{sub 2}O{sub 3} layer and an inner FeAl alloy layer. Black-Right-Pointing-Pointer Deuterium permeation reduction factor of coated piece increased by 2 orders of magnitude. Black-Right-Pointing-Pointer Tritium permeation barriers were flexibly achieved in high reproducibility. - Abstract: We have proposed an advance three-step process, Al-electroplating in ionic liquid followed by heat treating and selectively oxidation, preparing aluminum rich coating as tritium permeation barrier (TPB). In present work, the advance process was applied to 321 steel workpieces. In the Al-electroplating, pieces were coated by galvanostatic electrodeposition at 20 mA/cm{sup 2} in aluminum chloride (AlCl{sub 3})-1-ethyl-3-methylimidazolium chloride (EMIC) ionic liquid. The Al coating on those pieces all displayed attractive brightness and well adhered to surface of pieces. Within the aluminizing time from 1 to 30 h, a series of experiments were carried out to aluminize 321 steel pieces with Al 20 {mu}m coating at 700 Degree-Sign C. After heat treated for 8 h, a 30 {mu}m thick aluminized coating on piece appeared homogeneous, free of porosity, and mainly consisted of (Fe, Cr, Ni)Al{sub 2}, and then was selectively oxidized in argon gas at 700 Degree-Sign C for 50 h to form Al{sub 2}O{sub 3} scale. The finally fabricated aluminum rich coating, without any visible defects, had a double-layered structure consisting of an outer {gamma}-Al{sub 2}O{sub 3} layer with thickness of 0.2 {mu}m and inner (Fe, Cr, Ni)Al/(Fe, Cr, Ni){sub 3}Al layer of 50 {mu}m thickness. The deuterium permeation reduction factor, PRF, of piece ({Phi} 80 Multiplication-Sign 2, L 150 mm) with such coating increased by 2 orders of magnitude at 600-727 Degree-Sign C. The reproducibility of the process was also showed.

  11. Thermomechanical and Environmental Durability of Environmental Barrier Coated Ceramic Matrix Composites Under Thermal Gradients

    Science.gov (United States)

    Zhu, Dongming; Bhatt, Ramakrishna T.; Harder, Bryan

    2016-01-01

    This paper presents the developments of thermo-mechanical testing approaches and durability performance of environmental barrier coatings (EBCs) and EBC coated SiCSiC ceramic matrix composites (CMCs). Critical testing aspects of the CMCs will be described, including state of the art instrumentations such as temperature, thermal gradient, and full field strain measurements; materials thermal conductivity evolutions and thermal stress resistance; NDE methods; thermo-mechanical stress and environment interactions associated damage accumulations. Examples are also given for testing ceramic matrix composite sub-elements and small airfoils to help better understand the critical and complex CMC and EBC properties in engine relevant testing environments.

  12. Physicochemical characterization and failure analysis of military coating systems

    Science.gov (United States)

    Keene, Lionel Thomas

    Modern military coating systems, as fielded by all branches of the U.S. military, generally consist of a diverse array of organic and inorganic components that can complicate their physicochemical analysis. These coating systems consist of VOC-solvent/waterborne automotive grade polyurethane matrix containing a variety of inorganic pigments and flattening agents. The research presented here was designed to overcome the practical difficulties regarding the study of such systems through the combined application of several cross-disciplinary techniques, including vibrational spectroscopy, electron microscopy, microtomy, ultra-fast laser ablation and optical interferometry. The goal of this research has been to determine the degree and spatial progression of weathering-induced alteration of military coating systems as a whole, as well as to determine the failure modes involved, and characterizing the impact of these failures on the physical barrier performance of the coatings. Transmission-mode Fourier Transform Infrared (FTIR) spectroscopy has been applied to cross-sections of both baseline and artificially weathered samples to elucidate weathering-induced spatial gradients to the baseline chemistry of the coatings. A large discrepancy in physical durability (as indicated by the spatial progression of these gradients) has been found between older and newer generation coatings. Data will be shown implicating silica fillers (previously considered inert) as the probable cause for this behavioral divergence. A case study is presented wherein the application of the aforementioned FTIR technique fails to predict the durability of the coating system as a whole. The exploitation of the ultra-fast optical phenomenon of femtosecond (10-15S) laser ablation is studied as a potential tool to facilitate spectroscopic depth profiling of composite materials. Finally, the interferometric technique of Phase Shifting was evaluated as a potential high-sensitivity technique applied to the

  13. Microstructures and Mechanical Properties of Ceramic/Metal Gradient Thermal Barrier Coatings

    Institute of Scientific and Technical Information of China (English)

    XIAO Jin-sheng; JIANG Bing; LIU Jie; HUANG Shi-yong

    2003-01-01

    The ceramic/metal gradient thermal barrier coatings (CMGTBCs) which combined the conceptions of thermal barrier coatings ( TBG ) and functional gradient materials ( FGMs ) are investigated. The structure model studied in this paper is a general model which includes four different layers: pure ceramic layer , ceramic/metal gradient layer, pure metal layer, and substrate layer. The microstructures of gradient layer have different ceramics and metal volume fraction profile along with the direction of thickness. The profile function used to describe the gradient microstructures can be expressed in power-law or polynomial expression. The mechanical properties of CMGTBCs are obtained by means of microscopic mechanics. As special cases, the interactive solutions are given by Mori- Tanaka method, and the non- interactive solutions by dilute solution. The Young's modulus calculated by these methods are compared with those by other methods , e g, the rule of mixtures.

  14. Pulsed-terahertz reflectometry for health monitoring of ceramic thermal barrier coatings.

    Science.gov (United States)

    Chen, Chia-Chu; Lee, Dong-Joon; Pollock, Tresa; Whitaker, John F

    2010-02-15

    Terahertz time-domain reflectometry was used to monitor the progress of a thermally grown oxide layer and stress-induced, air-filled voids at the interface of an Yttria-stabilized-zirconia ceramic thermal-barrier coating and a metal surface. The thicknesses of these internal layers, observed in scanning-electron-microscope images to increase with thermal-exposure time, have been resolved - even when changing on the order of only a few micrometers - by distinguishing not only increased delays in the arrival times of terahertz pulses reflected from this multilayer structure, but also changes in the width and shape of the pulses. These unique features can be used to predict the lifetime of thermal-barrier coatings and to indicate or warn of spallation conditions. The trends of the experimental results are also confirmed through Fresnel-reflection time-domain simulations.

  15. Improving anti-corrosion property of thermal barrier coatings by intense pulsed ion beam irradiation

    Energy Technology Data Exchange (ETDEWEB)

    Yan, S., E-mail: syan@pku.edu.cn [State Key Laboratory of Nuclear Physics and Technology, Institute of Heavy Ion Physics, Peking University, Beijing 100871 (China); Shang, Y.J., E-mail: shangyijun@pku.edu.cn [State Key Laboratory of Nuclear Physics and Technology, Institute of Heavy Ion Physics, Peking University, Beijing 100871 (China); Xu, X.F., E-mail: reandy123@126.com [State Key Laboratory of Nuclear Physics and Technology, Institute of Heavy Ion Physics, Peking University, Beijing 100871 (China); Yi, X., E-mail: xyle@buaa.edu.com [Department of Applied Physics, School of Science, Beihang University, Beijing 100083 (China); Le, X.Y., E-mail: xyle@buaa.edu.cn [Department of Applied Physics, School of Science, Beihang University, Beijing 100083 (China)

    2012-02-01

    Anticorrosion behavior is an important factor for the reliability and durability of thermal barrier coatings (TBCs). Intense pulsed ion beam (ion species: 70% H{sup +} + 30% C{sup +}; current density: 150 A/cm{sup 2} and 250 A/cm{sup 2}; accelerate voltage: 300 kV; pulse duration: 65 ns) irradiation were used to improve the anticorrosion behavior of the Y{sub 2}O{sub 3}-stabilized ZrO{sub 2} (YSZ) /NiCoCrAlY thermal barrier coating. The anticorrosion property of the TBCs was evaluated with polarization curves method. A quite good result was obtained. Further analysis show that IPIB irradiation can seal the pores in YSZ layer, and block the penetration channels of corrosive fluid, therefore, improves the anticorrosion behavior.

  16. Adhesion and Long-Term Barrier Restoration of Intrinsic Self-Healing Hybrid Sol-Gel Coatings.

    Science.gov (United States)

    Abdolah Zadeh, Mina; van der Zwaag, Sybrand; Garcia, Santiago J

    2016-02-17

    Self-healing polymeric coatings aiming at smart and on-demand protection of metallic substrates have lately attracted considerable attention. In the present paper, the potential application of a dual network hybrid sol-gel polymer containing reversible tetrasulfide groups as a protective coating for the AA2024-T3 substrate is presented. Depending on the constituent ratio, the developed polymer exhibited a hydrophobic surface, high adhesion strength, and an effective long-term corrosion protection in 0.5 M NaCl solution. Upon thermal treatment, the healable hybrid sol-gel coating demonstrated full restoration of the barrier properties as well as recovery of the coating adhesion and surface properties (e.g., hydrophobicity and surface topology) necessary for lifetime extension of corrosion protective coatings. Excellent long-term barrier restoration of the coating was only obtained if the scratch width was less than the coating thickness.

  17. An Experimental Characterization of Damping Properties of Thermal Barrier Coatings at Elevated Temperatures

    Science.gov (United States)

    2011-03-01

    ladle lining applications (Racher, unknown). The magnesium aluminate spinels are used as a thermal barrier coating for molten steel crucibles and...2007. 513 Racher, R. P. Magnesium Aluminate Spinel Raw Materials for High Performance Refractories for Steel Ladles. Almatis Inc. Leetsdale, PA...study, including magnesium aluminate spinels ("mag spinel"), and chromium stabilized aluminum oxide (Al2O3 · Cr2O3) (Tamarin, 2002). High cycle

  18. X-Ray Elastic Constants and Residual Stress Distributions of Zirconia Thermal Barrier Coating

    OpenAIRE

    鈴木, 賢治; 町屋, 修太郎; 田中, 啓介; 坂井田, 喜久; SUZUKI, Kenji; Machiya, Syutaro; Tanaka, Keisuke; Sakaida, Yoshihisa

    2001-01-01

    Accurate values of X-ray elastic constants are required for a reliable stress measurement of thermal barrier coating films (TBC films). In this paper, atmosphere and pressureless plasma sprayed TBC films were removed from substrates, then X-ray elastic constants of both TBC films were determained by using newly developed tensile jig. For the atmosphere plasma sprayed film, the value of the mechanical elastic constant was much smaller than the X-ray elastic constant owing to cracks or pores ex...

  19. Environmental and Mechanical Stability of Environmental Barrier Coated SA Tyrannohex SiC Composites Under Simulated Turbine Engine Environments

    Science.gov (United States)

    Zhu, Dongming; Halbig, Michael Charles; Sing, Mrityunjay

    2014-01-01

    The environmental stability and thermal gradient cyclic durability performance of SA Tyrannohex composites were investigated for turbine engine component applications. The work has been focused on investigating the combustion rig recession, cyclic thermal stress resistance and thermomechanical low cycle fatigue of uncoated and environmental barrier coated Tyrannohex SiC SA composites in simulated turbine engine combustion water vapor, thermal gradients, and mechanical loading conditions. Flexural strength degradations have been evaluated, and the upper limits of operating temperature conditions for the SA composite material systems are discussed based on the experimental results.

  20. Computational Design and Experimental Validation of New Thermal Barrier Systems

    Energy Technology Data Exchange (ETDEWEB)

    Guo, Shengmin; Yang, Shizhong; Khosravi, Ebrahim

    2011-12-31

    This project (10/01/2010-9/30/2013), “Computational Design and Experimental Validation of New Thermal Barrier Systems”, originates from Louisiana State University (LSU) Mechanical Engineering Department and Southern University (SU) Department of Computer Science. This proposal will directly support the technical goals specified in DE-FOA-0000248, Topic Area 3: Turbine Materials, by addressing key technologies needed to enable the development of advanced turbines and turbine-based systems that will operate safely and efficiently using coal-derived synthesis gases. We will develop novel molecular dynamics method to improve the efficiency of simulation on novel TBC materials; we will perform high performance computing (HPC) on complex TBC structures to screen the most promising TBC compositions; we will perform material characterizations and oxidation/corrosion tests; and we will demonstrate our new Thermal barrier coating (TBC) systems experimentally under Integrated gasification combined cycle (IGCC) environments. The durability of the coating will be examined using the proposed High Temperature/High Pressure Durability Test Rig under real syngas product compositions.

  1. Comparison of thermal shock behaviors between plasma-sprayed nanostructured and conventional zirconia thermal barrier coatings

    Institute of Scientific and Technical Information of China (English)

    LIU Chun-bo; ZHANG Zhi-min; JIANG Xian-liang; LIU Min; ZHU Zhao-hui

    2009-01-01

    NiCoCrAlTaY bond coat was deposited on pure nickel substrate by low pressure plasma spraying(LPPS), and ZrO2-8%Y2O3 (mass fraction) nanostructured and ZrO2-7%Y2O3 (mass fraction) conventional thermal barrier coatings(TBCs) were deposited by air plasma spraying(APS). The thermal shock behaviors of the nanostructured and conventional TBCs were investigated by quenching the coating samples in cold water from 1 150, 1 200 and 1 250 ℃, respectively. Scanning electron microscopy(SEM) was used to examine the microstructures of the samples after thermal shock testing. Energy dispersive analysis of X-ray(EDAX) was used to analyze the interface diffusion behavior of the bond coat elements. X-ray diffractometry(XRD) was used to analyze the constituent phases of the samples. Experimental results indicate that the nanostructured TBC is superior to the conventional TBC in thermal shock performance. Both the nanostructured and conventional TBCs fail along the bond coat/substrate interface. The constituent phase of the as-sprayed conventional TBC is diffusionless-transformed tetragonal(t′). However, the constituent phase of the as-sprayed nanostructured TBC is cubic(c). There is a difference in the crystal size at the spalled surfaces of the nanostructured and conventional TBCs. The constituent phases of the spalled surfaces are mainly composed of Ni2.88Cr1.12 and oxides of bond coat elements.

  2. Interface conjunction factors of thermal barrier coatings and the relationship between factors and composition

    Institute of Scientific and Technical Information of China (English)

    LI; Zhilin; (李志林); XU; Huibin; (徐惠彬); GONG; Shengkai; (宫声凯)

    2003-01-01

    In thermal barrier coatings (TBC), ceramics is covered on the metal matrix as coatings in order to raise its temperature endurance. Today most of the TBCs are of the double-layer-struc- ture of Ni base heat-resistant alloy matrix + the bonding layer of MCrAlY alloy (M = Ni, Co, Ni + Co) + ZrO2. In this paper, the concept of interface conjunction factor (ICF) in the biphase interface of alloys is expanded to coatings. The ICFs of the interface between the ceramics and the bonding layers with various compositions, such as the electron density ρ, the electron density difference △ρ, and the number of atom state group which keeps the electron density continuous σ are calculated. From the calculation results, the following estimations can be deduced. When Al content is less than 6 wt% it improves the mechanical properties of the coatings; when the content is 6 wt%-12 wt% it will not worsen the properties; when the content is greater than 12 wt% it will have disadvantageous effect. The estimations accord well with the experiment results of the properties and the service time of the coatings. Therefore the concept of ICF has the same important meaning in coatings, and the valence electron structure of the interface can be a possible theoretical guide for the content optimization of TBCs.

  3. Formation and behavior of thermal barrier coatings on nickel-base superalloys

    Institute of Scientific and Technical Information of China (English)

    高阳; 解仑; 曾飞

    2004-01-01

    Plasma-sprayed thermal barrier coatings (TBCs) have been used to extend the life of combustors. Electron beam physical vapor deposited (EB-PVD) ceramic coating has been developed for more demanding rotating as well as stationary turbine components. Here 3 kW RF magnetron sputtering equipment was used to gain zirconia ceramic coatings on hollow turbine blades and vanes, which had been deposited NiCrAlY by cathodic arc deposition.NiCrAlY coating surface was treated by shot peening; the effects of shot peening on the residual stress are presented. The results show that RF sputtered TBCs are columnar ceramics, strongly bonded to metal substrates. NiCrAlY bond coat is made of β, γ′ and Cr phases, ZrO2 ceramic layer consists of t' and c phases. No degradation occursto RF ceramic coatings after 100 h high temperature oxidation at 1 150 ℃ and 500 thermal cycles at 1 150 ℃ for 2 min,air-cooling.

  4. Effect of laser remelting on the tribological performance of thermal barrier coatings.

    Science.gov (United States)

    Rico, A; Sevillano, F; Múnez, C J; López, M D; Utrilla, V; Rodríguez, J; Poza, P

    2012-06-01

    Gas turbine's efficiency improves as operating temperature is increased. For this reason, metallic components used in turbine engines, for propulsion and power generation, are protected by thermal barrier coatings (TBC). Laser glazing has been used to enhance the oxidation and corrosion resistance of thermally sprayed TBC, but there is no information about the effect of this treatment on the tribological performance. ZrO2(CaO) top coat and NiAIMo bond coating were flame sprayed onto an AlSI 1045 carbon steel. The top coat was laser remelted and a densified ceramic layer was induced in the top surface of the ceramic coating. Both, the as sprayed and the laser remelted top coatings, were formed by cubic ZrO2 with some tetragonal precipitates. The grain size was reduced by the laser treatment. The mechanical properties and the local wear rate were evaluated by depth sensing indentation and scratch tests respectively. The nanoscale wear behaviour was always improved by the laser treatment.

  5. Facile approach in the development of icephobic hierarchically textured coatings as corrosion barrier

    Energy Technology Data Exchange (ETDEWEB)

    Momen, G., E-mail: gmomen@uqac.ca; Farzaneh, M.

    2014-04-01

    Highlights: • A superhydrophobic coating is developed via a simple environmental-friendly method. • This coating can be used on the surface of various metals such as copper, magnesium. • The superhydrophobic aluminum surface showed the excellent corrosion resistance. • The fabricated surface revealed a drastically reduction of ice adhesion strength. • Such surfaces can advantageously be used in cold climate regions. - Abstract: An anti-corrosion superhydrophobic film with water contact angle greater than 160° on aluminum alloy 6061 substrate was fabricated simply through the spin-coating method applied to Al{sub 2}O{sub 3} nanoparticles doped in silicone rubber solution. The as-obtained sample was characterized by scanning electron microscopy (SEM) and water contact angle/surface energy measurement. The corrosion behaviour of such coating in the NaCl solutions was investigated using the potentiodynamic polarization. The results show that the corrosion resistance of the developed superhydrophobic surface is improved greatly due to the composite wetting states or interfaces with numerous air pockets between its surface and the NaCl solution. This superhydrophobic coating could serve as an effective barrier against aggressive medium. Ice adhesion strength of the as-prepared superhydrophobic coating was also evaluated by measuring its ice adhesion force which was found to have reduced by 4.8 times compared to that of aluminum substrate as reference test.

  6. Effect of Young's modulus evolution on residual stress measurement of thermal barrier coatings by X-ray diffraction

    Science.gov (United States)

    Chen, Q.; Mao, W. G.; Zhou, Y. C.; Lu, C.

    2010-09-01

    Subjected to thermal cycling, the apparent Young's modulus of air plasma-sprayed (APS) 8 wt.% Y 2O 3-stabilized ZrO 2 (8YSZ) thermal barrier coatings (TBCs) was measured by nanoindentation. Owing to the effects of sintering and porous microstructure, the apparent Young's modulus follows a Weibull distribution and changes from 50 to 93 GPa with an increase of thermal cycling. The evolution of residual stresses in the top coating of an 8YSZ TBC system was determined by X-ray diffraction (XRD). The residual stresses derived from the XRD data are well consistent with that obtained by the Vickers indention. It is shown that the evolution of Young's modulus plays an important role in improving the measurement precision of residual stresses in TBCs by XRD.

  7. Preparation of cross-sectional specimens of ceramic thermal barrier coatings for transmission electron microscopy.

    Science.gov (United States)

    Unal, O; Heuer, A H; Mitchell, T E

    1990-04-01

    During the microstructural examination of ceramic thermal barrier coatings by transmission electron microscopy (TEM), initial efforts for the preparation of cross-sectional thin foils from interface regions by conventional means were mostly failures. Delamination of the Y2O3-stabilized ZrO2 ceramic coating from the nickel-base alloy substrate sometimes occurred during fine polishing at around 80 microns thickness but mostly occurred during dimpling. Because of this sensitivity, special techniques for mechanical handling were developed so that ion milling could give thin enough regions of the metal-ceramic interface. TEM showed convincingly that the highly fragile nature of the coatings is in fact due to the extensive porosity at the interface developed as a result of heat treatment.

  8. Effects of Thermal Exposure on Structures of DD6 Single Crystal Superalloy with Thermal Barrier Coatings

    Directory of Open Access Journals (Sweden)

    DONG Jianmin

    2016-10-01

    Full Text Available In order to investigate the effect of water grit-blasting and high temperature thermal exposure on the microstructures of DD6 alloy with TBCs, DD6 single crystal superalloy specimens were water grit-blasted with 0.3 MPa pressure, then the specimens were coated with thermal barrier coatings by electron beam physical vapor deposition (EB-PVD. Specimens with TBCs were exposed at 1100℃ for 50 and 100 hours in the air respectively, and then these specimens were subjected to stress-rupture tests under the condition of 1100℃/130 MPa. The results show that grit-blasting doesn't lead into the recrystallization, thermal exposure can induce element interdiffusion between the bond coat and alloy substrate, the residual stress and element diffusion lead into the changes of γ' phase coarsing direction. After stress rupture tests, the secondary reaction zone emerges into a local area.

  9. Substrate Effects on the High-Temperature Oxidation Behavior of Thermal Barrier Coatings

    Institute of Scientific and Technical Information of China (English)

    Limin He; Zhenhua Xu; Jianping Li; Rende Mu; Shimei He; Guanghong Huang

    2009-01-01

    The high-temperature oxidation behaviors of the NiCrAIYSi/P-YSZ thermal barrier coatings (TBCs) pro-duced by electron beam-physical vapor deposition (EB-PVD) on directionally solidified (DS) and single crys-talline (SC) Ni-based superalloy substrates were investigated. The cross-sectional microstructure investigation, isothermal and cyclic oxidation tests were conducted for the comparison of oxidation behaviors of TBCs on different substrates. Although TBC on DS substrate has a relatively higher oxidation rate, it has a longer thermal cycling lifetime than that on SC substrate. The primary factor for TBC spallation is the mismatch of thermal expansion coefficient (TEC) of the bond coat and substrate. The morphological feature of thermally grown oxide (TGO) has a strong influence on the TBC performance. By optimizing the elemental interdiffusion between bond coat and substrate, a high quality TGO layer is formed on the DS substrate, and therefore the TBC oxidation behavior is improved.

  10. Impedance Analysis of 7YSZ Thermal Barrier Coatings During High-Temperature Oxidation

    Science.gov (United States)

    Chen, Wen-Long; Liu, Min; Zhang, Ji-Fu

    2016-12-01

    ZrO2-7 wt.%Y2O3 (7YSZ) thermal barrier coatings (TBCs) were prepared by atmospheric plasma spraying. High-temperature oxidation of 7YSZ TBCs was accomplished at 950 °C and characterized by impedance spectroscopy and scanning electron microscopy with energy-dispersive spectrometry. The results indicated that the thermally grown oxide (TGO) mainly contained alumina. The increase of the thickness of the TGO layer appeared to follow a parabolic law. Impedance analysis demonstrated that the resistance of the TGO increased with increasing oxidation time, also following a parabolic law, and that characterization of the TGO thickness based on fitting an equivalent circuit to its measured resistance is feasible. The YSZ grain-boundary resistance increased due to increasing cracks within the coating for oxidation time less than 50 h. However, beyond 150 h, the YSZ grain-boundary resistance slightly decreased, mainly due to sintering of the coating during the oxidation process.

  11. Thermoelastic characteristics of thermal barrier coatings with layer thickness and edge conditions through mathematical analysis.

    Science.gov (United States)

    Go, Jaegwi; Myoung, Sang-Won; Lee, Je-Hyun; Jung, Yeon-Gil; Kim, Seokchan; Paik, Ungyu

    2014-10-01

    The thermoelastic behaviors of such as temperature distribution, displacements, and stresses in thermal barrier coatings (TBCs) are seriously influenced by top coat thickness and edge conditions, which were investigated based on the thermal and mechanical properties of plasma-sprayed TBCs. A couple of governing partial differential equations were derived based on the thermoelastic theory. Since the governing equations are too involved to solve analytically, a finite volume method was developed to obtain approximations. The thermoelastic characteristics of TBCs with the various thicknesses and microstructures were estimated through mathematical approaches with different edge conditions. The results demonstrated that the top coat thickness and the edge condition in theoretical analysis are crucial factors to be considered in controlling the thermoelastic characteristics of plasma-sprayed TBCs.

  12. Permeation barrier coating and plasma sterilization of PET bottles and foils

    Science.gov (United States)

    Steves, Simon; Deilmann, Michael; Bibinov, Nikita; Awakowicz, Peter

    2009-10-01

    Modern packaging materials such as polyethylene terephthalate (PET) offer various advantages over glass or metal containers. Beside this they only offer poor barrier properties against gas permeation. Therefore, the shelf-live of packaged food is reduced. Additionally, common sterilization methods like heat, hydrogen peroxide or peracetic acid may not be applicable due to reduced heat or chemical resistance of the plastic packaging material. For the plasma sterilization and permeation barrier coating of PET bottles and foils, a microwave driven low pressure plasma reactor is developed based on a modified Plasmaline antenna. The dependencies of important plasma parameters, such as gas mixture, process pressure, power and pulse conditions on oxygen permeation through packaging foil are investigated. A residual permeation as low as J = 1.0 ±0.3 cm^3m-2day-1bar-1 for 60 nm thick silicon oxide (SiOx) coated PET foils is achieved. To discuss this residual permeation, coating defects are visualized by capacitively coupled atomic oxygen plasma etching of coated substrate. A defect density of 3000 mm-2 is revealed responsible for permeation. For plasma sterilization, optimized plasma parameters based on fundamental research of plasma sterilization mechanisms permit short treatment times of a few seconds.

  13. Indentations on Air Plasma Sprayed Thermal Barrier Coatings Prepared by Different Starting Granules

    Directory of Open Access Journals (Sweden)

    Yong Suk Heo

    2015-01-01

    Full Text Available The effect of starting granules on the indentation properties of air plasma sprayed thermal barrier coatings (TBCs is investigated in this paper. Various kinds of spray-dried granules are prepared from different processing conditions, especially varying solvent and dispersant, showing a deformed hollow-typed and a filled spherical-typed granule. The similar coating thicknesses are prepared by adjusting process parameters during air plasma spray. All XRD peaks in phase analysis are tetragonal and cubic phases without any monoclinic phase after the starting granules were heat-treated. A relatively porous microstructure of the coating layer could be obtained from the monodisperse granules, while a relatively dense microstructure resulted from the hollow-typed granules. The morphology and distribution of the granules crucially affect the microstructure of thermal barrier coatings and thus have influences on indentation properties such as indentation stress-strain curves, contact damage, and hardness. The implication concerning microstructure design of TBCs for gas turbine applications is considered.

  14. Key Durability Issues with Mullite-Based Environmental Barrier Coatings for Si-Based Ceramics

    Science.gov (United States)

    Lee, Kang N.

    2000-01-01

    Plasma-sprayed mullite (3Al2O3.2SiO2) and mullite/yttria-stabilized-zirconia (YSZ) dual layer coatings have been developed to protect silicon -based ceramics from environmental attack. Mullite-based coating systems show excellent durability in air. However, in combustion environments, corrosive species such as molten salt or water vapor penetrate through cracks in the coating and attack the Si-based ceramics along the interface. Thus the modification of the coating system for enhanced crack-resistance is necessary for long-term durability in combustion environments. Other key durability issues include interfacial contamination and coating/substrate bonding. Interfacial contamination leads to enhanced oxidation and interfacial pore formation, while a weak coating/substrate bonding leads to rapid attack of the interface by corrosive species, both of which can cause a premature failure of the coating. Interfacial contamination can be minimized by limiting impurities in coating and substrate materials. The interface may be modified to improve the coating/substrate bond.

  15. A Numerical Procedure to Obtain the Creep Parameters of the Thermal Barrier Coating

    Directory of Open Access Journals (Sweden)

    Shifeng Wen

    2014-05-01

    Full Text Available Three-point bending creep test was used to understand the creep behavior of typical thin film/substrate systems—thermal barrier coating (TBC systems. Firstly, a simplified model, which does not consider the local effect, has been set up to get an analytical relationship. The important result is that creep stress exponent of materials is equal to the creep load exponent of the steady-state deflection rate of BC specimens. Secondly, in order to consider the local effect of bending, the finite element method (FEM has been carried out. FEM calculation shows that there is a steady stage of the creep deflection under a constant applied load. And the exponent of the steady-state creep deflection rate to the applied load is found to be equal to the creep stress exponent of materials. The creep constant of the materials can be obtained by a set of trials with assumed creep constants of materials and can be finally determined by the best fit method. Finally, the finite element results show that the influences of the friction, the thickness of TBCs, and the modulus ratio of TBC to the substrate on stress distribution are important.

  16. Method and Process Development of Advanced Atmospheric Plasma Spraying for Thermal Barrier Coatings

    Science.gov (United States)

    Mihm, Sebastian; Duda, Thomas; Gruner, Heiko; Thomas, Georg; Dzur, Birger

    2012-06-01

    Over the last few years, global economic growth has triggered a dramatic increase in the demand for resources, resulting in steady rise in prices for energy and raw materials. In the gas turbine manufacturing sector, process optimizations of cost-intensive production steps involve a heightened potential of savings and form the basis for securing future competitive advantages in the market. In this context, the atmospheric plasma spraying (APS) process for thermal barrier coatings (TBC) has been optimized. A constraint for the optimization of the APS coating process is the use of the existing coating equipment. Furthermore, the current coating quality and characteristics must not change so as to avoid new qualification and testing. Using experience in APS and empirically gained data, the process optimization plan included the variation of e.g. the plasma gas composition and flow-rate, the electrical power, the arrangement and angle of the powder injectors in relation to the plasma jet, the grain size distribution of the spray powder and the plasma torch movement procedures such as spray distance, offset and iteration. In particular, plasma properties (enthalpy, velocity and temperature), powder injection conditions (injection point, injection speed, grain size and distribution) and the coating lamination (coating pattern and spraying distance) are examined. The optimized process and resulting coating were compared to the current situation using several diagnostic methods. The improved process significantly reduces costs and achieves the requirement of comparable coating quality. Furthermore, a contribution was made towards better comprehension of the APS of ceramics and the definition of a better method for future process developments.

  17. Brain barrier systems: a new frontier in metal neurotoxicological research

    OpenAIRE

    Zheng, Wei; Aschner, Michael; Ghersi-Egea, Jean-Francois

    2003-01-01

    The concept of brain barriers or a brain barrier system embraces the blood–brain interface, referred to as the blood–brain barrier, and the blood–cerebrospinal fluid (CSF) interface, referred to as the blood–CSF barrier. These brain barriers protect the CNS against chemical insults, by different complementary mechanisms. Toxic metal molecules can either bypass these mechanisms or be sequestered in and therefore potentially deleterious to brain barriers. Supportive evidence suggests that damag...

  18. BARRIERS TO THE USE OF RADIATION-CURABLE ADHESIVES IN THE COATED AND LAMINATED SUBSTRATE MANUFACTURING INDUSTRY

    Science.gov (United States)

    The paper gives results of an investigation of barriers to the use of radiation-cured technology in the coated and laminated substrate manufacturing industry. t presents information gathered from radiation-curable coating and equipment suppliers as well as technical publications....

  19. Combustion Control and Diagnostics Sensor Testing in a Thermal Barrier Coated Combustor

    Energy Technology Data Exchange (ETDEWEB)

    Chorpening, B.T.; Dukes, M.G.; Robey, E.H.; Thornton, J.D.

    2007-05-01

    The combustion control and diagnostics sensor (CCADS) continues to be developed as an in-situ combustion sensor, with immediate application to natural gas fired turbines. In-situ combustion monitoring is also expected to benefit advanced power plants of the future, fueled by coal-derived syngas, liquified natural gas (LNG), hydrogen, or hydrogen blend fuels. The in-situ monitoring that CCADS provides can enable the optimal operation of advanced, fuel-flexible turbines for minimal pollutant emissions and maximum efficiency over the full operating range of an advanced turbine. Previous work has demonstrated CCADS as a useful sensor for in-situ monitoring of natural gas combustion, including detection of important combustion events such as flashback and lean blowoff, in experimental combustors without thermal barrier coatings (TBC). Since typical TBC materials are electrical insulators at room temperature, and CCADS operation requires conduction of electrical current to the walls of the combustor, a TBC on the combustion liner was identified as a potential barrier to CCADS operation in commercial application. This paper reports on CCADS experiments in a turbulent lean premixed combustor with a yttria-stabilized zirconia (YSZ) thermal barrier coating on the combustor wall. The tests were conducted at 0.1 MPa (1 atm), with a 15V excitation voltage on the CCADS electrodes. The results confirm that for a typical thermal barrier coating, CCADS operates properly, and the total measured average resistance is close to that of an uncoated combustor. This result is consistent with previous materials studies that found the electrical resistance of typical TBC materials considerably decreases at combustor operating temperatures.

  20. THE EFFECT OF V2O5 MELT INFILTRATION ON THE FAILURE OF THERMAL BARRIER COATINGS

    Directory of Open Access Journals (Sweden)

    ABBA ABDULHAMID ABUBAKAR

    2017-02-01

    Full Text Available The use of low quality fuel in land based driven turbine in Saudi Arabia usually results in hot corrosion attack (Type 1 due to the penetration of V2O5 into the existing micro pores and cracks on the top coat of thermal barrier coatings (TBCs. As a result of dissolution-precipitation reaction, 4-5% volumetric expansion of the coating occurs due to the tetragonal-to-monoclinic (destabilization transformation of Zirconia. In the current work, a Phase Field Model that estimates the kinetics of micro-structural evolution during the diffusional tetragonal-to-monoclinic phase transformation in the Melt Infiltrated Reaction Zone of the top coat at 900ºC is developed. The model is sequentiallycoupled with constitutive model in order to determine the resulting stress field developed in the top coat. The results show that localized stresses are developed due to the Zirconia-destabilization transformation, and the stresses are found to be higher at the corners and curvatures formed by inter-lamella connection of the micro-pores and micro-cracks.

  1. Failure Behavior of Thermal Barrier Coatings on Cylindrical Superalloy Tube Under Thermomechanical Fatigue

    Institute of Scientific and Technical Information of China (English)

    Zhubing CHEN; Zhongguang WANG; Shijie ZHU

    2013-01-01

    Failure behavior of thermal barrier coatings on cylindrical superalloy tube was investigated under thermomechanical fatigue (TMF).Two types of TMF tests,i.e.in phase (IP) and out of phase (OP),were performed in the temperature range of 450-850 ℃.All tests were carried out under mechanical strain control at a given period of 300 s.The bond coat NiCrA1Y was produced by high velocity oxygen fuel (HVOF),and the top coat 7%Y2O3-ZrO2 was deposited by air plasma spraying (APS).The testing results showed that the OP TMF life was longer than the IP TMF one under the same mechanical strain amplitude.Observations of the fractured specimens revealed that the interface damage and cracking behavior in the two phasing conditions were different.In OP loading,the top coat was cracked and detached from the bond coat while no spallation was found in the IP loading.

  2. Evaluation of Thermal Barrier Coatings Exposed to Hot Corrosion Environment by Impedance Spectroscopy

    Institute of Scientific and Technical Information of China (English)

    LIU Chao; HUANG Hui; NI Liyong; ZHOU Chungen

    2011-01-01

    In this investigation,impedance spectroscopy(IS) is used,as a non-destructive tool,to examine the hot corrosion behavior of thermal barrier coatings(TBCs) exposed to a mixture of 25wt% NaC1 and 75wt% Na2SO4.The results show that the thermally grown oxide(TGO) formed along the top coat/bond coat interface is a mixed oxide layer,i.e.Cr2O3,(Ni,Co)(Cr,Al)2O4 spinel and NiO.The growth of TGO layer appears to follow the parabolic law.The resistance of TGO increases due to the increase of thickness when the number of cycles is less than 110.While for more than 110 cycles,the resistance of TGO decreases with the increase of porosity of TGO layer,even though the thickness of TGO layer increases.The nucleation and propagation of cracks within top coat increase the electrical resistance of top coat.The parameters in equivalent circuit could be used to characterize the degradation of TBCs.

  3. Factors affecting the microstructural stability and durability of thermal barrier coatings fabricated by air plasma spraying

    Energy Technology Data Exchange (ETDEWEB)

    Helminiak, M.A.; Yanar, N.M.; Pettit, F.S.; Meier, G.H. [National Energy Technology Laboratory, Pittsburgh, PA 15236 (United States); Department of Mechanical Engineering and Materials Science, University of Pittsburgh, 636 Benedum Hall, 3700 O& #x27; Hara Street, Pittsburgh, PA 15261 (United States); Taylor, T.A. [Praxair Surface Technologies, Inc., 1400 Polco Street, Indianapolis, IN 46224 (United States)

    2012-10-15

    The high-temperature behavior of high-purity, low-density (HP-LD) air plasma sprayed (APS) thermal barrier coatings (TBCs) with NiCoCrAlY bond coats deposited by argon-shrouded plasma spraying is described. The high purity yttria-stabilized zirconia resulted in top coats which are highly resistant to sintering and transformation from the metastable tetragonal phase to the equilibrium mixture of monoclinic and cubic phases. The thermal conductivity of the as-processed TBC is low but increases during high temperature exposure even before densification occurs. The porous topcoat microstructure also resulted in good spallation resistance during thermal cycling. The actual failure mechanisms of the APS coatings were found to depend on topcoat thickness, topcoat density, and the thermal cycle frequency. The failure mechanisms are described and the durability of the HP-LD coatings is compared with that of state-of-the-art electron beam physical vapor deposition TBCs. (Copyright copyright 2012 WILEY-VCH Verlag GmbH and Co. KGaA, Weinheim)

  4. Thermal barrier coating toughness: Measurement and identification of a bridging mechanism enabled by segmented microstructure

    Energy Technology Data Exchange (ETDEWEB)

    Donohue, Erin M., E-mail: erin_donohue@engineering.ucsb.edu [Materials Department, University of California, Santa Barbara (United States); Philips, Noah R. [Materials Department, University of California, Santa Barbara (United States); Begley, Matthew R.; Levi, Carlos G. [Materials Department, University of California, Santa Barbara (United States); Mechanical Engineering Department, University of California, Santa Barbara (United States)

    2013-03-01

    Failure mechanisms in thermal barrier coatings (TBCs) often involve the propagation of delamination cracks within the top coating. The work presented in this paper makes two principal contributions: first, the development of a straightforward testing geometry and analysis approach enables the accurate determination of the mode I fracture toughness of these coatings and second, the application of the approach to technologically relevant coatings produces new insights into the impact of the dense vertically cracked (DVC) microstructure on the toughness. Mode I toughness of air plasma-sprayed 8 wt% yttria-stabilized zirconia DVC TBCs is measured by sandwiching the freestanding coatings in a modified double cantilever beam configuration. Digital image correlation measurements and finite element analysis provide a pathway to quickly and accurately extract toughness values from displacement data alone. Results show R-curve behavior and unexpectedly high steady-state toughness values of G{sub ss}≈300–400J/m{sup 2}. The observation of this elevated toughness can be rationalized by a crack bridging model that is consistent with the TBC's starting microstructure and features of the fracture surfaces.

  5. Surface laser-glazing of plasma-sprayed thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Batista, C. [University of Minho, Physics Department, Campus de Gualtar, 4710-057 Braga (Portugal); Portinha, A. [University of Minho, Physics Department, Campus de Gualtar, 4710-057 Braga (Portugal); Ribeiro, R.M. [University of Minho, Physics Department, Campus de Gualtar, 4710-057 Braga (Portugal)]. E-mail: ricardo@fisica.uminho.pt; Teixeira, V. [University of Minho, Physics Department, Campus de Gualtar, 4710-057 Braga (Portugal); Costa, M.F. [University of Minho, Physics Department, Campus de Gualtar, 4710-057 Braga (Portugal); Oliveira, C.R. [Instituto de Desenvolvimentoe Inovacao Tecnologica (IDIT), 4520-102 Santa Maria da Feira (Portugal); University Lusiada, 4760-108 Vila Nova de Famalicao (Portugal)

    2005-07-15

    Atmospheric plasma-sprayed (APS) ZrO{sub 2}-8%WtY{sub 2}O{sub 3} thermal barrier coatings (TBCs) were subjected to a CO{sub 2} continuous wave laser-glazing process in order to generate an external dense layer produced by different processing parameters. For that purpose, different beam scanning speeds and track overlapping were chosen. Surface roughness has been reduced significantly after laser-glazing. Despite the surface crack network, all laser-glazed specimens presented a fully dense and porous free external layer with a columnar microstructure. Surface cracks along the densified layer were found to have tendency to be oriented in two perpendicular directions, one in the direction of the laser beam travel, the other perpendicular to it. Moreover, the cracks parallel to the beam moving direction are found to be on the overlapping zone, coinciding with the edge of the subsequent track. The cracks along the densified layer are vertical and tend to branch and deviate from the vertical direction within the porous PS coating. The largest overlapping allied to the smallest amount of irradiated energy generated the most uniform layer with the shortest crack branches within the PS coating. For the as-sprayed coating, the XRD results revealed mainly t' non-transformable tetragonal zirconia with a small percentage of residual monoclinic zirconia. All glazed coatings presented only t' non-transformable tetragonal zirconia with some variations on preferable crystal orientation.

  6. Microstructural Evolution and Residual Stresses of Air-Plasma Sprayed Thermal Barrier Coatings Under Thermal Exposure

    Science.gov (United States)

    Kwon, Jae-Young; Kim, Jae-Hyoun; Lee, Sang-Yeop; Jung, Yeon-Gil; Cho, Hyun; Yi, Dong-Kee; Paik, Ungyu

    Microstructural evolution and fracture behavior of zirconia (ZrO2)-based thermal barrier coatings (TBCs) were investigated under thermal exposure. New ZrO2 granule with 8 wt.% yttria (Y2O3) with a deformed hollow morphology was developed through a spray drying process and employed to prepare TBCs. The thermal exposure tests were conducted at 1210°C with a dwell time of 100 h till 800 h. The residual stress at the interface between top coat and thermally grown oxide (TGO) layer was measured using a nanoindentation technique before and after thermal exposure. Vertical cracks on the top coat were newly formed and interlamellar cracks at the interface were enhanced after the thermal exposure of 800 h. Especially, partial delamination was observed at the interface after the thermal exposure of 800 h in TBC samples tested. The microstructural evolution in the top coat could be defined through load-displacement curves, showing a higher load or a less displacement after the thermal exposure of 800 h. The stress state was strongly dependent on the TGO geometry, resulting in the compressive stresses at the "valleys" or the "troughs," and the tensile stresses at the "crests" or peak areas, in the ranges of -500 to -75 MPa and of +168 to + 24 MPa, respectively. These stress terms incorporated with resintering during thermal exposure affected the mechanical properties such as hardness and elastic modulus of the top coat.

  7. Engineered Barrier System: Physical and Chemical Environment

    Energy Technology Data Exchange (ETDEWEB)

    P. Dixon

    2004-04-26

    The conceptual and predictive models documented in this Engineered Barrier System: Physical and Chemical Environment Model report describe the evolution of the physical and chemical conditions within the waste emplacement drifts of the repository. The modeling approaches and model output data will be used in the total system performance assessment (TSPA-LA) to assess the performance of the engineered barrier system and the waste form. These models evaluate the range of potential water compositions within the emplacement drifts, resulting from the interaction of introduced materials and minerals in dust with water seeping into the drifts and with aqueous solutions forming by deliquescence of dust (as influenced by atmospheric conditions), and from thermal-hydrological-chemical (THC) processes in the drift. These models also consider the uncertainty and variability in water chemistry inside the drift and the compositions of introduced materials within the drift. This report develops and documents a set of process- and abstraction-level models that constitute the engineered barrier system: physical and chemical environment model. Where possible, these models use information directly from other process model reports as input, which promotes integration among process models used for total system performance assessment. Specific tasks and activities of modeling the physical and chemical environment are included in the technical work plan ''Technical Work Plan for: In-Drift Geochemistry Modeling'' (BSC 2004 [DIRS 166519]). As described in the technical work plan, the development of this report is coordinated with the development of other engineered barrier system analysis model reports.

  8. ENGINEERED BARRIER SYSTEM: PHYSICAL AND CHEMICAL ENVIRONMENT

    Energy Technology Data Exchange (ETDEWEB)

    R. Jarek

    2004-11-23

    The purpose of this report is to describe the evolution of the physical and chemical environmental conditions within the waste emplacement drifts of the repository, including the drip shield and waste package surfaces. The abstraction model is used in the total system performance assessment for the license application (TSPA LA) to assess the performance of the engineered barrier system and the waste form. This report develops and documents a set of these abstraction-level models that describe the engineered barrier system physical and chemical environment. Where possible, these models use information directly from other reports as input, which promotes integration among process models used for TSPA-LA. Specific tasks and activities of modeling the physical and chemical environment are included in ''Technical Work Plan for: Near-Field Environment and Transport In-Drift Geochemistry Model Report Integration'' (BSC 2004 [DIRS 171156], Section 1.2.2). As described in the technical work plan, the development of this report is coordinated with the development of other engineered barrier system reports.

  9. ENGINEERED BARRIER SYSTEM: PHYSICAL AND CHEMICAL ENVIRONMENT

    Energy Technology Data Exchange (ETDEWEB)

    G.H. Nieder-Westermann

    2005-04-07

    The purpose of this report is to describe the evolution of the physical and chemical environmental conditions within the waste emplacement drifts of the repository, including the drip shield and waste package surfaces. The abstraction model is used in the total system performance assessment for the license application (TSPA LA) to assess the performance of the engineered barrier system and the waste form. This report develops and documents a set of these abstraction-level models that describe the engineered barrier system physical and chemical environment. Where possible, these models use information directly from other reports as input, which promotes integration among process models used for TSPA-LA. Specific tasks and activities of modeling the physical and chemical environment are included in ''Technical Work Plan for: Near-Field Environment and Transport In-Drift Geochemistry Model Report Integration'' (BSC 2004 [DIRS 171156], Section 1.2.2). As described in the technical work plan, the development of this report is coordinated with the development of other engineered barrier system reports.

  10. Effect of particle in-flight behavior on the composition of thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Zhao, L. [State Key Laboratory for Mechanical Behavior of Materials, Xi’an Jiaotong University, Xi’an 710049 (China); Bai, Y., E-mail: byxjtu@gmail.com [State Key Laboratory for Mechanical Behavior of Materials, Xi’an Jiaotong University, Xi’an 710049 (China); School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049 (China); Tang, J.J.; Liu, K. [State Key Laboratory for Mechanical Behavior of Materials, Xi’an Jiaotong University, Xi’an 710049 (China); Ding, C.H. [State Key Laboratory for Strength and Vibration of Mechanical Structures, Xi’an Jiaotong University, Xi’an 710049 (China); Yang, J.F. [State Key Laboratory for Mechanical Behavior of Materials, Xi’an Jiaotong University, Xi’an 710049 (China); Han, Z.H., E-mail: zhhan1955@163.com [State Key Laboratory for Mechanical Behavior of Materials, Xi’an Jiaotong University, Xi’an 710049 (China)

    2013-12-01

    In this work, 6 to 11 mol% YO{sub 1.5}-stabilized zirconia (YSZ) coatings were deposited by supersonic and conventional atmospheric plasma spraying. During spraying, the surface temperature and velocity of in-flight particles were monitored by Spray Watch 2i on-line system. The phase composition of as-sprayed coatings was analyzed by X-ray diffractometry (XRD). Lattice parameters, tetragonality and the content of YO{sub 1.5} (mol%) of as-sprayed coatings were calculated according to the position of (0 0 4) and (4 0 0) diffraction peaks. It was found that the as-sprayed coatings were composed of metastable non-transformable tetragonal phase (t′). However, the amount of YO{sub 1.5} (mol%) in the as-sprayed coatings decreased with the increase of melting index of in-flight particles due to the partial evaporation of YO{sub 1.5} during spraying.

  11. Initial phase hot corrosion mechanism of gas tunnel type plasma sprayed thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Yugeswaran, S. [Joining and Welding Research Institute, Osaka University, Osaka 567-0047 (Japan); Kobayashi, A., E-mail: kobayasi@jwri.osaka-u.ac.jp [Joining and Welding Research Institute, Osaka University, Osaka 567-0047 (Japan); Ananthapadmanabhan, P.V. [L and PT Division, Bhabha Atomic Research Centre, Mumbai 400085 (India)

    2012-04-25

    Highlights: Black-Right-Pointing-Pointer Free standing TBC specimens were prepared by gas tunnel type plasma spraying with thickness of around 300-400 {mu}m. Black-Right-Pointing-Pointer 50%8YSZ + 50%La{sub 2}Zr{sub 2}O{sub 7} composite coating shows superior hot corrosion resistance. Black-Right-Pointing-Pointer Corrosive crystals structure and phase transformation was well controlled in this coating. - Abstract: The hot corrosion resistance of the top layer in TBC is one of the main constructive factors which determines the lifetime of the coatings under critical operating environments. In the present study, 8 wt% yttria stabilized zirconia (8YSZ), lanthanum zirconate (La{sub 2}Zr{sub 2}O{sub 7}) and equal weight percentage of its composite (50%8YSZ + 50% La{sub 2}Zr{sub 2}O{sub 7}) coatings were prepared by using gas tunnel type plasma spray torch at optimum spraying conditions. The hot corrosion performances of the above thermal barrier coatings were examined against 40 wt%V{sub 2}O{sub 5}-60 wt%Na{sub 2}SO{sub 4} corrosive ash at 1173 K for 5 h in open air atmosphere. After hot-corrosion testing, the coating surface was studied using a scanning electron microscope to observe the microstructure and X-ray diffraction techniques were used to identify the phase compositions. The results showed that LaVO{sub 4} and YVO{sub 4} are the main hot corrosion products along with the ZrO{sub 2} phase transformation from tetragonal to monoclinic phases in La{sub 2}Zr{sub 2}O{sub 7} and 8YSZ coatings respectively. The microstructure and phase formation mechanism of the hot corrosion products varied with each coating and among these, composition of 50%8YSZ + 50%La{sub 2}Zr{sub 2}O{sub 7} coating exhibited least degradation against V{sub 2}O{sub 5}-Na{sub 2}SO{sub 4} corrosive environment compared to the other coatings.

  12. Phosphor-Doped Thermal Barrier Coatings Deposited by Air Plasma Spray for In-Depth Temperature Sensing.

    Science.gov (United States)

    Peng, Di; Yang, Lixia; Cai, Tao; Liu, Yingzheng; Zhao, Xiaofeng; Yao, Zhiqi

    2016-09-28

    Yttria-stabilized zirconia (YSZ)-based thermal barrier coating (TBC) has been integrated with thermographic phosphors through air plasma spray (APS) for in-depth; non-contact temperature sensing. This coating consisted of a thin layer of Dy-doped YSZ (about 40 µm) on the bottom and a regular YSZ layer with a thickness up to 300 µm on top. A measurement system has been established; which included a portable; low-cost diode laser (405 nm); a photo-multiplier tube (PMT) and the related optics. Coating samples with different topcoat thickness were calibrated in a high-temperature furnace from room temperature to around 900 °C. The results convincingly showed that the current sensor and the measurement system was capable of in-depth temperature sensing over 800 °C with a YSZ top layer up to 300 µm. The topcoat thickness was found to have a strong effect on the luminescent signal level. Therefore; the measurement accuracy at high temperatures was reduced for samples with thick topcoats due to strong light attenuation. However; it seemed that the light transmissivity of YSZ topcoat increased with temperature; which would improve the sensor's performance at high temperatures. The current sensor and the measurement technology have shown great potential in on-line monitoring of TBC interface temperature.

  13. Phosphor-Doped Thermal Barrier Coatings Deposited by Air Plasma Spray for In-Depth Temperature Sensing

    Directory of Open Access Journals (Sweden)

    Di Peng

    2016-09-01

    Full Text Available Yttria-stabilized zirconia (YSZ-based thermal barrier coating (TBC has been integrated with thermographic phosphors through air plasma spray (APS for in-depth; non-contact temperature sensing. This coating consisted of a thin layer of Dy-doped YSZ (about 40 µm on the bottom and a regular YSZ layer with a thickness up to 300 µm on top. A measurement system has been established; which included a portable; low-cost diode laser (405 nm; a photo-multiplier tube (PMT and the related optics. Coating samples with different topcoat thickness were calibrated in a high-temperature furnace from room temperature to around 900 °C. The results convincingly showed that the current sensor and the measurement system was capable of in-depth temperature sensing over 800 °C with a YSZ top layer up to 300 µm. The topcoat thickness was found to have a strong effect on the luminescent signal level. Therefore; the measurement accuracy at high temperatures was reduced for samples with thick topcoats due to strong light attenuation. However; it seemed that the light transmissivity of YSZ topcoat increased with temperature; which would improve the sensor’s performance at high temperatures. The current sensor and the measurement technology have shown great potential in on-line monitoring of TBC interface temperature.

  14. Use of indentation technique to measure elastic modulus of plasma-sprayed zirconia thermal barrier coating

    Energy Technology Data Exchange (ETDEWEB)

    Singh, J.P.; Sutaria, M. [Argonne National Lab., IL (United States). Energy Technology Div.; Ferber, M. [Oak Ridge National Lab., TN (United States)

    1997-01-01

    Elastic modulus of an yttria partially stabilized zirconia (YSZ) thermal barrier coating (TBC) was evaluated with a Knoop indentation technique. The measured elastic modulus values for the coating ranged from 68.4 {+-} 22.6 GPa at an indentation load of 50 g to 35.7 {+-} 9.8 at an indentation load of 300 g. At higher loads, the elastic modulus values did not change significantly. This steady-state value of 35.7 GPa for ZrO{sub 2} TBC agreed well with literature values obtained by the Hertzian indentation method. Furthermore, the measured elastic modulus for the TBC is lower than that reported for bulk ZrO{sub 2} ({approx} 190 GPa). This difference is believed to be due to the presence of a significant amount of porosity and microcracks in the TBCs. Hardness was also measured.

  15. Parametric Studies Of Failure Mechanisms In Thermal Barrier Coatings During Thermal Cycling Using FEM

    Directory of Open Access Journals (Sweden)

    Srivathsa B.

    2015-12-01

    Full Text Available Thermal barrier coatings (TBCs are widely used on different hot components of gas turbine engines such as blades and vanes. Although, several mechanisms for the failure of the TBCs have been suggested, it is largely accepted that the durability of these coatings is primarily determined by the residual stresses that are developed during the thermal cycling. In the present study, the residual stress build-up in an electron beam physical vapour deposition (EB-PVD based TBCs on a coupon during thermal cycling has been studied by varying three parameters such as the cooling rate, TBC thickness and substrate thickness. A two-dimensional thermomechanical generalized plane strain finite element simulations have been performed for thousand cycles. It was observed that these variations change the stress profile significantly and the stress severity factor increases non-linearly. Overall, the predictions of the model agree with reported experimental results and help in predicting the failure mechanisms.

  16. Damage characterization of thermal barrier coatings by acoustic emission and thermography

    Energy Technology Data Exchange (ETDEWEB)

    Nies, Daniel; Rehmer, Birgit; Skrotzki, Birgit [BAM Federal Institute for Materials Research and Testing, Berlin (Germany); Vassen, Robert [Forschungszentrum Juelich, Juelich (Germany)

    2012-09-15

    Thermal barrier coatings allow increasing the operating temperature and efficiency of land-, sea-, or air-based turbines. As failure of the coating may result in serious damage of the turbine, reliable estimation of its lifetime is essential. To assess the lifetime, cyclic tests are conceived to combine thermal loading by heating the surface of the coating with laser irradiation and nondestructive methods for damage determination. Using laser irradiation allows a high reproducibility of the thermal load. The temperature of the sample surface during thermal loading is determined by an infrared-camera which also enables the possibility to detect damage in the coating via thermography. Additionally, four acoustic sensors, attached to the experimental setup, are used to detect damage in the sample and determine the source of acoustic events. Results of acoustic emission correlate well with thermographic images that visualize the formation and evolution of damage through delaminations in the samples. (Copyright copyright 2012 WILEY-VCH Verlag GmbH and Co. KGaA, Weinheim)

  17. Mechanism of spallation in platinum aluminide/electron beam physical vapor-deposited thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Gell, M.; Vaidyanathan, K.; Barber, B.; Cheng, J.; Jordan, E. [Univ. of Connecticut, Storrs, CT (United States)

    1999-02-01

    The spallation failure of a commercial thermal barrier coating (TBC), consisting of a single-crystal RENE N5 superalloy, a platinum aluminide (Pt-Al) bond coat, and an electron beam-deposited 7 wt pct yttria-stabilized zirconia ceramic layer (7YSZ), was studied following cyclic furnace testing. In the uncycled state and prior to deposition of the ceramic, the Pt-Al bond-coat surface contains a cellular network of ridges corresponding to the underlying bond-coat grain-boundary structure. With thermal cycling, the ridges and associated grain boundaries are the sites of preferential oxidation and cracking, which results in the formation of cavities that are partially filled with oxide. Using a fluorescent penetrant dye in conjunction with a direct-pull test, it is shown that, when specimens are cycled to about 80 pct of life, these grain-boundary regions show extensive debonding. The roles of oxidation and cyclic stress in localized grain boundary region spallation are discussed. The additional factors leading to large-scale TBC spallation are described.

  18. Thermal Barrier Coatings Made by the Solution Precursor Plasma Spray Process

    Science.gov (United States)

    Gell, Maurice; Jordan, Eric H.; Teicholz, Matthew; Cetegen, Baki M.; Padture, Nitin P.; Xie, Liangde; Chen, Dianying; Ma, Xinqing; Roth, Jeffrey

    2008-03-01

    The solution precursor plasma spray (SPPS) process is a relatively new and flexible thermal spray process that can produce a wide variety of novel materials, including some with superior properties. The SPPS process involves injecting atomized droplets of a precursor solution into the plasma. The properties of resultant deposits depend on the time-temperature history of the droplets in the plasma, ranging from ultra-fine splats to unmelted crystalline particles to unpyrolized particles. By controlling the volume fraction of these three different constituents, a variety of coatings can be produced, all with a nanograin size. In this article, we will be reviewing research related to thermal barrier coatings, emphasizing the processing conditions necessary to obtain a range of microstructures and associated properties. The SPPS process produces a unique strain-tolerant, low-thermal conductivity microstructure consisting of (i) three-dimensional micrometer and nanometer pores, (ii) through-coating thickness (vertical) cracks, (iii) ultra-fine splats, and (iv) inter-pass boundaries. Both thin (0.12 mm) and thick (4 mm) coatings have been fabricated. The volume fraction of porosity can be varied from 10% to 40% while retaining the characteristic microstructure of vertical cracks and ultra-fine splats. The mechanism of vertical crack formation will be described.

  19. Resistance of Nanostructured Environmental Barrier Coatings to the Movement of Molten Salts

    Science.gov (United States)

    Rao, S.; Frederick, L.; McDonald, A.

    2012-09-01

    Corrosion of components in a recovery boiler is a major problem faced by the pulp and paper industry. The superheater tubes become severely corroded due to the presence of sulfidic gases in the boiler and molten salts which are deposited on the surface of the tubes. As a result, the boiler must be decommissioned for expensive maintenance and repairs. Yttria-stabilized zirconia (YSZ) coatings have been shown to provide corrosion resistance when applied on gas turbines operating at high temperatures. Air plasma-sprayed YSZ environmental barrier coatings on Type 309 stainless steel were exposed to three different corrosive environments: Test A—600 °C, salt vapors, flue gases, 168 h; Test B—600 °C, molten salt, air, 168 h; and Test C—600 °C, molten salt, flue gases, 168 h. Two different types of YSZ coatings—conventional YSZ and nanostructured YSZ—were tested to study their resistance to corrosion and molten salt penetration. The performances of both types of coatings were evaluated, and a comparative study was conducted. It was found that the nanostructured YSZ samples protected the stainless steel substrate better than their conventional counterparts. This superior performance was attributed to the presence of semi-molten nano-agglomerates present in the coating microstructure, which acted as collection points for the penetrating molten salts.

  20. Thermal Conductivity in Suspension Sprayed Thermal Barrier Coatings: Modeling and Experiments

    Science.gov (United States)

    Ganvir, Ashish; Kumara, Chamara; Gupta, Mohit; Nylen, Per

    2016-12-01

    Axial suspension plasma spraying (ASPS) can generate microstructures with higher porosity and pores in the size range from submicron to nanometer. ASPS thermal barrier coatings (TBC) have already shown a great potential to produce low thermal conductivity coatings for gas turbine applications. It is important to understand the fundamental relationships between microstructural defects in ASPS coatings such as crystallite boundaries, porosity etc. and thermal conductivity. Object-oriented finite element (OOF) analysis has been shown as an effective tool for evaluating thermal conductivity of conventional TBCs as this method is capable of incorporating the inherent microstructure in the model. The objective of this work was to analyze the thermal conductivity of ASPS TBCs using experimental techniques and also to evaluate a procedure where OOF can be used to predict and analyze the thermal conductivity for these coatings. Verification of the model was done by comparing modeling results with the experimental thermal conductivity. The results showed that the varied scaled porosity has a significant influence on the thermal conductivity. Smaller crystallites and higher overall porosity content resulted in lower thermal conductivity. It was shown that OOF could be a powerful tool to predict and rank thermal conductivity of ASPS TBCs.

  1. Thermal Conductivity in Suspension Sprayed Thermal Barrier Coatings: Modeling and Experiments

    Science.gov (United States)

    Ganvir, Ashish; Kumara, Chamara; Gupta, Mohit; Nylen, Per

    2017-01-01

    Axial suspension plasma spraying (ASPS) can generate microstructures with higher porosity and pores in the size range from submicron to nanometer. ASPS thermal barrier coatings (TBC) have already shown a great potential to produce low thermal conductivity coatings for gas turbine applications. It is important to understand the fundamental relationships between microstructural defects in ASPS coatings such as crystallite boundaries, porosity etc. and thermal conductivity. Object-oriented finite element (OOF) analysis has been shown as an effective tool for evaluating thermal conductivity of conventional TBCs as this method is capable of incorporating the inherent microstructure in the model. The objective of this work was to analyze the thermal conductivity of ASPS TBCs using experimental techniques and also to evaluate a procedure where OOF can be used to predict and analyze the thermal conductivity for these coatings. Verification of the model was done by comparing modeling results with the experimental thermal conductivity. The results showed that the varied scaled porosity has a significant influence on the thermal conductivity. Smaller crystallites and higher overall porosity content resulted in lower thermal conductivity. It was shown that OOF could be a powerful tool to predict and rank thermal conductivity of ASPS TBCs.

  2. Effects of lamination and coating with drying oils on tensile and barrier properties of zein films.

    Science.gov (United States)

    Rakotonirainy, A M; Padua, G W

    2001-06-01

    Zein films plasticized with oleic acid have been considered potentially useful for biodegradable packaging applications. However, moisture was found to affect their tensile and gas barrier properties. We investigated the effects of two converting processes, fusion lamination and coating with drying oils, on tensile properties and gas permeability of zein films. Zein films were laminated to 4-ply sheets in a Carver press and coated with tung oil, linseed oil, or a mixture of tung and soybean oils. Tensile properties and permeability to water vapor, oxygen, and carbon dioxide were measured according to ASTM methods. Laminated films were clearer, tougher, and more flexible, and had a smoother finish than nontreated sheets. Lamination decreased O(2) and CO(2) permeability by filling in voids and pinholes in the film structure. Coating increased tensile strength and elongation and decreased water vapor permeability. Coatings acted as a composite layer preventing crack propagation and increasing film strength. They also formed a highly hydrophobic surface that prevented film wetting.

  3. Residual Stress Analysis of Ceramic Thermal Barrier Coating Based on Thermal Spray Process

    Science.gov (United States)

    Arai, Masayuki; Wada, Eiji; Kishimoto, Kikuo

    Residual stress is generated in ceramic thermal barrier coatings (TBCs), which were sprayed by a plasma spray technology, due to the difference in coefficients of thermal expansion between the coating and the substrate. Previous experimental results obtained by the X-ray diffraction method indicated that the residual stress at the ceramic coating surface is tensile and could lead to TBC failure such as cracking and spalling of the ceramic coating. In this study, a numerical model that can predict the residual stress exactly is proposed by taking into account a thermal spray process. This numerical model is a layer-buildup model based on a shear-lag theory, and the residual stress contribution comes from two kinds of the following stress components: (1) quenching stress, which was generated in molten spray particles impinged onto the substrate, and (2) thermal stress, which was generated due to differences in thermal expansion between the deposited particle and the underlying substrate. It is shown herein that residual stress predicted by the proposed numerical model coincided with the experimental one obtained by the strain gage technique, with a good level of accuracy.

  4. Advanced Environmental Barrier Coatings Developed for SiC/SiC Composite Vanes

    Science.gov (United States)

    Lee, Kang N.; Fox, Dennis S.; Eldridge, Jeffrey I.; Zhu, Dongming; Bansal, Narottam P.; Miller, Robert A.

    2003-01-01

    Ceramic components exhibit superior high-temperature strength and durability over conventional component materials in use today, signifying the potential to revolutionize gas turbine engine component technology. Silicon-carbide fiber-reinforced silicon carbide ceramic matrix composites (SiC/SiC CMCs) are prime candidates for the ceramic hotsection components of next-generation gas turbine engines. A key barrier to the realization of SiC/SiC CMC hot-section components is the environmental degradation of SiC/SiC CMCs in combustion environments. This is in the form of surface recession due to the volatilization of silica scale by water vapor. An external environmental barrier coating (EBC) is a logical approach to achieve protection and long-term durability.

  5. CrN-Ag nanocomposite coatings: Control of lubricant transport by diffusion barriers

    Energy Technology Data Exchange (ETDEWEB)

    Papi, P.A. [Department of Materials Science and Engineering, Rensselaer Polytechnic Institute, Troy, NY 12180 (United States); Mulligan, C.P. [Department of Materials Science and Engineering, Rensselaer Polytechnic Institute, Troy, NY 12180 (United States); U.S. Army Armament Research Development and Engineering Center, Benet Laboratories, Watervliet, NY 12189 (United States); Gall, D., E-mail: galld@rpi.edu [Department of Materials Science and Engineering, Rensselaer Polytechnic Institute, Troy, NY 12180 (United States)

    2012-12-01

    1-{mu}m-thick self-lubricating CrN-Ag composite coatings containing 16 at.% Ag were deposited on Si substrates by reactive co-sputtering at T{sub s} = 400 Degree-Sign C, and were covered with CrN cap layers with a columnar microstructure and a thickness d = 0-1000 nm. Vacuum annealing at T{sub a} = 500 and 600 Degree-Sign C for 1 h causes Ag transport to the sample surface and the formation of Ag surface grains. Quantitative scanning electron microscopy and energy dispersive spectroscopy analyses show that increasing d from 0 to 10 to 100 nm for T{sub a} = 500 Degree-Sign C leads to a decrease in the areal density of Ag surface grains from 0.86 to 0.45 to 0.04 {mu}m{sup -2}, while their lateral size remains constant at 360 {+-} 60 nm. However, increasing T{sub a} to 600 Degree-Sign C causes a doubling of the Ag grain size, and a 4-30 times larger overall Ag transport. These results are explained by kinetic barriers for Ag diffusion through the porous cap layer with a porosity that decreases with increasing d, resulting in an effective activation barrier for Ag transport that increases from 0.78 eV in the absence of a cap layer to 0.89 eV for d = 10 nm and 1.07 eV for d = 30 nm. Auger electron spectroscopy depth profile analyses of annealed layers reveal no detectable Ag within the CrN cap layer and a uniform depletion of the Ag reservoir throughout the composite coating thickness, indicating unhindered Ag transport within the composite. The overall results show that a CrN diffusion barrier cap layer is an effective approach to control Ag lubricant transport to the surface of CrN-Ag composite coatings. - Highlights: Black-Right-Pointing-Pointer CrN-Ag composite coatings are capped with CrN diffusion barriers. Black-Right-Pointing-Pointer Ag diffuses to the surface during annealing at 500 or 600 Degree-Sign C. Black-Right-Pointing-Pointer The Ag transport is controlled by the cap thickness d = 0-1000 nm. Black-Right-Pointing-Pointer The activation energy for Ag

  6. New Technique for Successful Thermal Barrier Coating Specimen Preparation for Transmission Electron Microscopy.

    Science.gov (United States)

    Brickey; Lee

    2000-05-01

    Reliability of thermal barrier coatings (TBC) hinges on the adhesion of a thermally grown oxide scale to an insulative ceramic topcoat and an underlying metallic bondcoat. The width of the scale and its interfaces makes transmission electron microscopy (TEM) an appropriate tool for its analysis. However, specimen preparation has proven to be a challenging obstacle leading to a dearth of TEM research on TBCs. A new approach to cross-section TBC TEM specimen preparation is described. The principal advantages of this technique are reproducibility, reduced specimen damage, and time savings resulting from decreased ion milling. This technique has been successfully applied to numerous TBC specimens with various thermal histories.

  7. SUBSURFACE BARRIER VALIDATION WITH THE SEAFACE SYSTEM

    Energy Technology Data Exchange (ETDEWEB)

    Sandra Dalvit Dunn

    1997-11-30

    The overall objective of the effort was to develop and demonstrate an integrated methodology and field system to evaluate the integrity of in situ, impermeable barriers constructed in the vadose zone. An autonomous, remotely accessible, automatic monitoring and analysis system was designed and fabricated. It was thoroughly tested under field conditions, and was able to function as designed throughout the test period. Data inversion software was developed with enhanced capabilities over the previous prototype version, and integrated with the monitoring system for real time operation. Analytical simulations were performed to determine the inversion code's sensitivity to model parameters. Numerical simulations were performed to better understand how typical field conditions differ from the ideal model(s) which are used (or have been developed for use) in the inversion code and to further validate the flux limited forward model developed for use with the system. Results from the analytical and numerical assessment of the inversion code showed that the SEAtrace{trademark} approach could locate leaks within 0.4 to 1.2 m. Leak size determination was less accurate, but produced results within a factor of 3 to 8 for leaks in the 2.5 to 10 cm diameter range. The smallest engineered leak in the test 1.1 cm diameter, could be located but its size estimate was high by a factor of 30. Data analysis was performed automatically after each gas scan was completed, yielding results in less than thirty minutes, although the bulk of the results reported required post test data analysis to remove effects of high background concentrations. The field test of the integrated system was problematic, primarily due to unanticipated, unintentional leaks formed in the impermeable liner. The test facility constructed to proof the system was ambitious, initially having 11 engineered leaks of various dimensions that could be independently operated. While a great deal of care went into the

  8. Properties of Whey-Protein-Coated Films and Laminates as Novel Recyclable Food Packaging Materials with Excellent Barrier Properties

    Directory of Open Access Journals (Sweden)

    Markus Schmid

    2012-01-01

    Full Text Available In case of food packaging applications, high oxygen and water vapour barriers are the prerequisite conditions for preserving the quality of the products throughout their whole lifecycle. Currently available polymers and/or biopolymer films are mostly used in combination with barrier materials derived from oil based plastics or aluminium to enhance their low barrier properties. In order to replace these non-renewable materials, current research efforts are focused on the development of sustainable coatings, while maintaining the functional properties of the resulting packaging materials. This article provides an introduction to food packaging requirements, highlights prior art on the use of whey-based coatings for their barriers properties, and describes the key properties of an innovative packaging multilayer material that includes a whey-based layer. The developed whey protein formulations had excellent barrier properties almost comparable to the ethylene vinyl alcohol copolymers (EVOH barrier layer conventionally used in food packaging composites, with an oxygen barrier (OTR of <2 [cm³(STP/(m²d bar] when normalized to a thickness of 100 μm. Further requirements of the barrier layer are good adhesion to the substrate and sufficient flexibility to withstand mechanical load while preventing delamination and/or brittle fracture. Whey-protein-based coatings have successfully met these functional and mechanical requirements.

  9. The effect of thermal aging on the thermal conductivity of plasma sprayed and EB-PVD thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Dinwiddie, R.B.; Beecher, S.C.; Porter, W.D. [Oak Ridge National Lab., TN (United States); Nagaraj, B.A. [General Electric Co., Cincinnati, OH (United States). Aircraft Engine Group

    1996-05-01

    Thermal barrier coatings (TBCs) applied to the hot gas components of turbine engines lead to enhanced fuel efficiency and component reliability. Understanding the mechanisms which control the thermal transport behavior of the TBCs is of primary importance. Electron beam-physical vapor deposition (EV-PVD) and air plasma spraying (APS) are the two most commonly used coating techniques. These techniques produce coatings with unique microstructures which control their performance and stability. The density of the APS coatings was controlled by varying the spray parameters. The low density APS yttria-partially stabilized zirconia (yttria-PSZ) coatings yielded a thermal conductivity that is lower than both the high density APS coatings and the EB-PVD coatings. The thermal aging of both fully and partially stabilized zirconia are compared. The thermal conductivity of the coatings permanently increases upon exposure to high temperatures. These increases are attributed to microstructural changes within the coatings. This increase in thermal conductivity can be modeled using a relationship which depends on both the temperature and time of exposure. Although the EB-PVD coatings are less susceptible to thermal aging effects, results suggest that they typically have a higher thermal conductivity than APS coatings before thermal aging. The increases in thermal conductivity due to thermal aging for plasma sprayed partially stabilized zirconia have been found to be less than for plasma sprayed fully stabilized zirconia coatings.

  10. Environmental barrier coating (EBC) durability modeling using a progressive failure analysis approach

    Science.gov (United States)

    Abdul-Aziz, Ali; Abumeri, Galib; Troha, William; Bhatt, Ramakrishna T.; Grady, Joseph E.; Zhu, D.

    2012-04-01

    Ceramic matrix composites (CMCs) are getting the attention of most engine manufacturers and aerospace firms for turbine engine and other related applications. This is because of their potential weight advantage and performance benefits. As a protecting guard for these materials, a highly specialized form of environmental barrier coating (EBC) is being developed and explored for high temperature applications that are greater than 1100 °C1,2. The EBCs are typically a multilayer of coatings and are on the order of hundreds of microns thick. CMCs are generally porous materials and this feature is somewhat beneficial since it allows some desirable infiltration of the EBC. Their degradation usually includes coating interface oxidation as opposed to moisture induced matrix degradation which is generally seen at a higher temperature. A variety of factors such as residual stresses, coating process related flaws, and casting conditions may influence the strength of degradation. The cause of such defects which cause cracking and other damage is that not much energy is absorbed during fracture of these materials. Therefore, an understanding of the issues that control crack deflection and propagation along interfaces is needed to maximize the energy dissipation capabilities of layered ceramics. Thus, evaluating components and subcomponents made out of CMCs under gas turbine engine conditions is suggested to demonstrate that these material will perform as expected and required under these aggressive environmental circumstances. Progressive failure analysis (PFA) is applied to assess the damage growth of the coating under combined thermal and mechanical loading conditions. The PFA evaluation is carried out using a full-scale finite element model to account for the average material failure at the microscopic or macroscopic levels. The PFA life prediction evaluation identified the root cause for damage initiation and propagation. It indicated that delamination type damage

  11. Low-Thermal-Conductivity Pyrochlore Oxide Materials Developed for Advanced Thermal Barrier Coatings

    Science.gov (United States)

    Bansal, Narottam P.; Zhu, Dong-Ming

    2005-01-01

    When turbine engines operate at higher temperatures, they consume less fuel, have higher efficiencies, and have lower emissions. The upper-use temperatures of the base materials (superalloys, silicon-based ceramics, etc.) used for the hot-section components of turbine engines are limited by the physical, mechanical, and corrosion characteristics of these materials. Thermal barrier coatings (TBCs) are applied as thin layers on the surfaces of these materials to further increase the operating temperatures. The current state-of-the-art TBC material in commercial use is partially yttria-stabilized zirconia (YSZ), which is applied on engine components by plasma spraying or by electron-beam physical vapor deposition. At temperatures higher than 1000 C, YSZ layers are prone to sintering, which increases thermal conductivity and makes them less effective. The sintered and densified coatings can also reduce thermal stress and strain tolerance, which can reduce the coating s durability significantly. Alternate TBC materials with lower thermal conductivity and better sintering resistance are needed to further increase the operating temperature of turbine engines.

  12. Highly Segmented Thermal Barrier Coatings Deposited by Suspension Plasma Spray: Effects of Spray Process on Microstructure

    Science.gov (United States)

    Chen, Xiaolong; Honda, Hiroshi; Kuroda, Seiji; Araki, Hiroshi; Murakami, Hideyuki; Watanabe, Makoto; Sakka, Yoshio

    2016-12-01

    Effects of the ceramic powder size used for suspension as well as several processing parameters in suspension plasma spraying of YSZ were investigated experimentally, aiming to fabricate highly segmented microstructures for thermal barrier coating (TBC) applications. Particle image velocimetry (PIV) was used to observe the atomization process and the velocity distribution of atomized droplets and ceramic particles travelling toward the substrates. The tested parameters included the secondary plasma gas (He versus H2), suspension injection flow rate, and substrate surface roughness. Results indicated that a plasma jet with a relatively higher content of He or H2 as the secondary plasma gas was critical to produce highly segmented YSZ TBCs with a crack density up to 12 cracks/mm. The optimized suspension flow rate played an important role to realize coatings with a reduced porosity level and improved adhesion. An increased powder size and higher operation power level were beneficial for the formation of highly segmented coatings onto substrates with a wider range of surface roughness.

  13. Durability Modeling of Environmental Barrier Coating (EBC Using Finite Element Based Progressive Failure Analysis

    Directory of Open Access Journals (Sweden)

    Ali Abdul-Aziz

    2014-01-01

    Full Text Available The necessity for a protecting guard for the popular ceramic matrix composites (CMCs is getting a lot of attention from engine manufacturers and aerospace companies. The CMC has a weight advantage over standard metallic materials and more performance benefits. However, these materials undergo degradation that typically includes coating interface oxidation as opposed to moisture induced matrix which is generally seen at a higher temperature. Additionally, other factors such as residual stresses, coating process related flaws, and casting conditions may influence the degradation of their mechanical properties. These durability considerations are being addressed by introducing highly specialized form of environmental barrier coating (EBC that is being developed and explored in particular for high temperature applications greater than 1100°C. As a result, a novel computational simulation approach is presented to predict life for EBC/CMC specimen using the finite element method augmented with progressive failure analysis (PFA that included durability, damage tracking, and material degradation model. The life assessment is carried out using both micromechanics and macromechanics properties. The macromechanics properties yielded a more conservative life for the CMC specimen as compared to that obtained from the micromechanics with fiber and matrix properties as input.

  14. New backing layer for transdermal drug delivery systems: coatings based on fatty acid and beeswax on chitosan films

    OpenAIRE

    Rullier-Birat, Bénédicte; Cazalbou, Sophie; Nassar, Maria Alejandra; Sandrine, Cavalie; Tourrette, Audrey

    2015-01-01

    International audience; Fatty acids and beeswax are known to improve barrier properties of biodegradable materials. Thanks to their hydrophobic character, they can act as a barrier against water giving to the material more occlusive properties. This work was aimed at preparing fatty acid and beeswax coatings for a transdermal drug delivery system. In order to study occlusive properties of these coatings, water vapor permeability and contact angle measurements were carried out. The most homoge...

  15. A computer program for full-coverage film-cooled blading analysis including the effects of a thermal barrier coating

    Science.gov (United States)

    1978-01-01

    The program input, coolant flow and heat transfer model, and the program output are discussed. As an example, sections of the suction and pressure sides of a high temperature, high pressure turbine vane are analyzed to show the effects of a thermal barrier coating. Compared to the uncoated design, the coating halves the required coolant flow, while simultaneously reducing metal outer temperatures by over 111 K.

  16. Dual function of novel pollen coat (surface proteins: IgE-binding capacity and proteolytic activity disrupting the airway epithelial barrier.

    Directory of Open Access Journals (Sweden)

    Mohamed Elfatih H Bashir

    Full Text Available BACKGROUND: The pollen coat is the first structure of the pollen to encounter the mucosal immune system upon inhalation. Prior characterizations of pollen allergens have focused on water-soluble, cytoplasmic proteins, but have overlooked much of the extracellular pollen coat. Due to washing with organic solvents when prepared, these pollen coat proteins are typically absent from commercial standardized allergenic extracts (i.e., "de-fatted", and, as a result, their involvement in allergy has not been explored. METHODOLOGY/PRINCIPAL FINDINGS: Using a unique approach to search for pollen allergenic proteins residing in the pollen coat, we employed transmission electron microscopy (TEM to assess the impact of organic solvents on the structural integrity of the pollen coat. TEM results indicated that de-fatting of Cynodon dactylon (Bermuda grass pollen (BGP by use of organic solvents altered the structural integrity of the pollen coat. The novel IgE-binding proteins of the BGP coat include a cysteine protease (CP and endoxylanase (EXY. The full-length cDNA that encodes the novel IgE-reactive CP was cloned from floral RNA. The EXY and CP were purified to homogeneity and tested for IgE reactivity. The CP from the BGP coat increased the permeability of human airway epithelial cells, caused a clear concentration-dependent detachment of cells, and damaged their barrier integrity. CONCLUSIONS/SIGNIFICANCE: Using an immunoproteomics approach, novel allergenic proteins of the BGP coat were identified. These proteins represent a class of novel dual-function proteins residing on the coat of the pollen grain that have IgE-binding capacity and proteolytic activity, which disrupts the integrity of the airway epithelial barrier. The identification of pollen coat allergens might explain the IgE-negative response to available skin-prick-testing proteins in patients who have positive symptoms. Further study of the role of these pollen coat proteins in allergic

  17. Mathematical analysis of thermoelastic characteristics in plasma-sprayed thermal barrier coatings.

    Science.gov (United States)

    Go, Jaegwi; Jungo, Yeon-Gil; Kim, Seokchan; Ali, Md Afsar; Paik, Ungyu

    2012-02-01

    The thermoelastic characteristics of plasma-sprayed thermal barrier coatings (TBCs) have been analyzed using mathematical modeling. Two types of TBC model, cylinder and circular disk which are commercial plasma-sprayed TBCs, subjecting to symmetric temperature distribution to the radial and longitudinal directions, respectively, were taken into consideration. Based on the thermoelastic theories, a second order ordinary differential equation was derived for the cylinder model and a pair of partial differential equations were set up for the circular disk model. The analytic solution was obtained from the ordinary differential equation, while a finite volume method was developed for numerical solutions to the pair of partial differential equations due to the complexity of governing equations. The thermoelastic characteristics of TBC models, such as temperature distributions, displacements, and stresses, were displayed according to the obtained solutions. The rate of heat conduction in the section of the top coat is relatively slow in comparison with the substrate, and no profound difference appears in the temperature distribution between two TBC models. The highest longitudinal tensile stress is expressed at the bond coat of both models, and the substrate is under the compressive stresses to the circumferential direction. While the cylinder expands to the positive longitudinal direction only, the expansion in the circular disk occurs to both the positive and negative longitudinal directions. Relatively large displacement and stresses exhibit in the cylinder as compared with the circular disk. In the circular disk, the stresses to the radial direction undulate at each section, and the displacement profile displays that the width of the circular disk is slightly narrowed. The results demonstrate that the mechanical and thermal properties of the top and bond coats are the crucial factors to be considered in controlling the thermoelastic characteristics of plasma

  18. Microstructural evolution and growth kinetics of thermally grown oxides in plasma sprayed thermal barrier coatings

    Directory of Open Access Journals (Sweden)

    Xiaoju Liu

    2016-02-01

    Full Text Available The formation of thermally grown oxide (TGO during high temperature is a key factor to the degradation of thermal barrier coatings (TBCs applied on hot section components. In the present study both the CoNiCrAlY bond coat and ZrO2-8 wt.% Y2O3 (8YSZ ceramic coat of TBCs were prepared by air plasma spraying (APS. The composition and microstructure of TGO in TBCs were investigated using scanning electron microscopy (SEM, energy dispersive spectroscopy (EDS and X-ray diffraction (XRD analysis. The growth rate of TGO for TBC and pure BC were gained after isothermal oxidation at 1100 °C for various times. The results showed that as-sprayed bond coat consisted of β and γ/γ′phases, β phase reducesd as the oxidation time increased. The TGO comprised α-Al2O3 formed in the first 2 h. CoO, NiO, Cr2O3 and spinel oxides appeared after 20 h of oxidation. Contents of CoO and NiO reduced while that of Cr2O3 and spinel oxides increased in the later oxidation stage. The TGO eventually consisted of a sub-Al2O3 layer with columnar microstructure and the upper porous CS clusters. The TGO growth kinetics for two kinds of samples followed parabolic laws, with oxidation rate constant of 0.344 μm/h0.5 for TBCs and 0.354 μm/h0.5 for pure BCs.

  19. Microstructural evolution and growth kinetics of thermally grown oxides in plasma sprayed thermal barrier coatings

    Institute of Scientific and Technical Information of China (English)

    Xiaoju Liu; Teng Wang; Caicai Li; Zhenhuan Zheng; Qiang Li

    2016-01-01

    The formation of thermally grown oxide (TGO) during high temperature is a key factor to the degradation of thermal barrier coatings (TBCs) applied on hot section components. In the present study both the CoNiCrAlY bond coat and ZrO2-8 wt.% Y2O3 (8YSZ) ceramic coat of TBCs were prepared by air plasma spraying (APS). The composition and microstructure of TGO in TBCs were investigated using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD) analysis. The growth rate of TGO for TBC and pure BC were gained after isothermal oxidation at 1100 °C for various times. The results showed that as-sprayed bond coat consisted of β and γ/γ'phases,β phase reducesd as the oxidation time increased. The TGO comprised α-Al2O3 formed in the first 2 h. CoO, NiO, Cr2O3 and spinel oxides appeared after 20 h of oxidation. Contents of CoO and NiO reduced while that of Cr2O3 and spinel oxides increased in the later oxidation stage. The TGO eventually consisted of a sub-Al2O3 layer with columnar microstructure and the upper porous CS clusters. The TGO growth kinetics for two kinds of samples followed parabolic laws, with oxidation rate constant of 0.344 μm/h0.5 for TBCs and 0.354 μm/h0.5 for pure BCs.

  20. Thermal Conductivity and Erosion Durability of Composite Two-Phase Air Plasma Sprayed Thermal Barrier Coatings

    Science.gov (United States)

    Schmitt, Michael P.; Rai, Amarendra K.; Zhu, Dongming; Dorfman, Mitchell R.; Wolfe, Douglas E.

    2015-01-01

    To enhance efficiency of gas turbines, new thermal barrier coatings (TBCs) must be designed which improve upon the thermal stability limit of 7 wt% yttria stabilized zirconia (7YSZ), approximately 1200 C. This tenant has led to the development of new TBC materials and microstructures capable of improved high temperature performance. This study focused on increasing the erosion durability of cubic zirconia based TBCs, traditionally less durable than the metastable t' zirconia based TBCs. Composite TBC microstructures composed of a low thermal conductivity/high temperature stable cubic Low-k matrix phase and a durable t' Low-k secondary phase were deposited via APS. Monolithic coatings composed of cubic Low-k and t' Low-k were also deposited, in addition to a 7YSZ benchmark. The thermal conductivity and erosion durability were then measured and it was found that both of the Low-k materials have significantly reduced thermal conductivities, with monolithic t' Low-k and cubic Low-k improving upon 7YSZ by approximately 13 and approximately 25%, respectively. The 40 wt% t' Low-k composite (40 wt% t' Low-k - 60 wt% cubic Low-k) showed a approximately 22% reduction in thermal conductivity over 7YSZ, indicating even at high levels, the t' Low-k secondary phase had a minimal impact on thermal in the composite coating. It was observed that a mere 20 wt% t' Low-k phase addition can reduce the erosion of a cubic Low-k matrix phase composite coating by over 37%. Various mixing rules were then investigated to assess this non-linear composite behavior and suggestions were made to further improve erosion durability.

  1. Energy Dependence of the Fusion Barrier for Heavy Nuclear Systems

    Institute of Scientific and Technical Information of China (English)

    LIZhu-xia; WUXi-zhen; TIANJun-long; WANGNing

    2003-01-01

    The dynamical behavior of the fusion potential barrier for heavy nuclear systems is studied by means of the improved quantum molecular dynamics model. It is found that the fusion potential barrier experienced in a realistic fusion process (the dynamic fusion potential barrier) reduces with decrease of incident energies.

  2. ENGINEERED BARRIER SYSTEM: PHYSICAL AND CHEMICAL ENVIRONMENT

    Energy Technology Data Exchange (ETDEWEB)

    R. Jarek

    2005-08-29

    The purpose of this model report is to describe the evolution of the physical and chemical environmental conditions within the waste emplacement drifts of the repository, including the drip shield and waste package surfaces. The resulting seepage evaporation and gas abstraction models are used in the total system performance assessment for the license application (TSPA-LA) to assess the performance of the engineered barrier system and the waste form. This report develops and documents a set of abstraction-level models that describe the engineered barrier system physical and chemical environment. Where possible, these models use information directly from other reports as input, which promotes integration among process models used for TSPA-LA. Specific tasks and activities of modeling the physical and chemical environment are included in ''Technical Work Plan for: Near-Field Environment and Transport In-Drift Geochemistry Model Report Integration'' (BSC 2005 [DIRS 173782], Section 1.2.2). As described in the technical work plan, the development of this report is coordinated with the development of other engineered barrier system reports. To be consistent with other project documents that address features, events, and processes (FEPs), Table 6.14.1 of the current report includes updates to FEP numbers and FEP subjects for two FEPs identified in the technical work plan (TWP) governing this report (BSC 2005 [DIRS 173782]). FEP 2.1.09.06.0A (Reduction-oxidation potential in EBS), as listed in Table 2 of the TWP (BSC 2005 [DIRS 173782]), has been updated in the current report to FEP 2.1.09.06.0B (Reduction-oxidation potential in Drifts; see Table 6.14-1). FEP 2.1.09.07.0A (Reaction kinetics in EBS), as listed in Table 2 of the TWP (BSC 2005 [DIRS 173782]), has been updated in the current report to FEP 2.1.09.07.0B (Reaction kinetics in Drifts; see Table 6.14-1). These deviations from the TWP are justified because they improve integration with FEPs

  3. Research Progress of A2 Zr2 O7-type Rare-earth Zirconate Thermal Barrier Coatings%A2 Zr2 O7型稀土锆酸盐热障涂层研究进展

    Institute of Scientific and Technical Information of China (English)

    张红松; 杨树森; 温倩

    2014-01-01

    Searching for new ceramic materials is the most feasible method in order to resolve the defects of current thermal barrier coatings. The A2 Zr2 O7-type rare earth zirconates are regarded as the most potential candidate ceramic materials for thermal barrier coatings because of their low thermal conductivities, high thermal expansion coefficients and excellent phase stability at high temperatures. Rare-earth zirconate coatings are one of the key-research directions in thermal barrier coating field. In the current paper, the research progress at home and abroad, such as coating preparing technology, coating structure, coating properties inclu-ding thermophysical properties, mechanics and thermal erosion, were systemically summarized. The development deficiencies of rare-earth zirconate thermal barrier coatings were investigated. In the future, the preparing and post-treatment technology of rare-earth zirconate coatings should be improved. The bonding strength, working lifetime, corrosion and sintering resistance of new ther-mal barrier coatings should also be enhanced. In order to study coating properties of nano-structure thermal barrier coatings, new preparing technology must be developed. The thermal insulation, working temperature and lifetime of new thermal barrier coatings should also be improved.%综述了国内外稀土锆酸盐热障涂层在制备技术,纳米涂层,涂层结构及涂层的热物理性能、力学性能及热腐蚀性能等方面的研究成果,讨论了稀土锆酸盐热障涂层在每个方面研究存在的不足。指出未来应该进一步改善稀土锆酸盐涂层的制备工艺及后处理工艺,提高涂层的结合强度,延长涂层的服役寿命,改善涂层耐腐蚀、抗烧结等性能;开发新的涂层制备工艺,重点研究各类纳米稀土锆酸盐涂层的性能;进一步提高涂层的隔热效果、服役温度及工作寿命。

  4. Accuracy of Young's Modulus of Thermal Barrier Coating Layer Determined by Bending Resonance of a Multilayered Specimen

    Science.gov (United States)

    Waki, Hiroyuki; Takizawa, Kensuke; Kato, Masahiko; Takahashi, Satoru

    2016-04-01

    The Young's modulus of individual layer in thermal barrier coating (TBC) system is an important mechanical property because it allows determining the parameters of materials mechanics in the TBC system. In this study, we investigated the accuracy of the evaluation method for the Young's modulus of a TBC layer according to the first bending resonance of a multilayered specimen comprising a substrate, bond coating, and TBC. First, we derived a closed-form solution for the Young's modulus of the TBC layer using the equation of motion for the bending vibration of a composite beam. The solution for the three-layered model provided the Young's modulus of the TBC layer according to the measured resonance frequency and the known values for the dimensions, mass, and Young's moduli of all the other layers. Next, we analyzed the sensitivity of these input errors to the evaluated Young's modulus and revealed the important inputs for accurate evaluation. Finally, we experimentally confirmed that the Young's modulus of the TBC layer was obtained accurately by the developed method.

  5. Mechanisms Underpinning Degradation of Protective Oxides and Thermal Barrier Coatings in High Hydrogen Content (HHC) - Fueled Turbines

    Energy Technology Data Exchange (ETDEWEB)

    Mumm, Daniel

    2013-08-31

    The overarching goal of this research program has been to evaluate the potential impacts of coal-derived syngas and high-hydrogen content fuels on the degradation of turbine hot-section components through attack of protective oxides and thermal barrier coatings. The primary focus of this research program has been to explore mechanisms underpinning the observed degradation processes, and connections to the combustion environments and characteristic non-combustible constituents. Based on the mechanistic understanding of how these emerging fuel streams affect materials degradation, the ultimate goal of the program is to advance the goals of the Advanced Turbine Program by developing materials design protocols leading to turbine hot-section components with improved resistance to service lifetime degradation under advanced fuels exposures. This research program has been focused on studying how: (1) differing combustion environments – relative to traditional natural gas fired systems – affect both the growth rate of thermally grown oxide (TGO) layers and the stability of these oxides and of protective thermal barrier coatings (TBCs); and (2) how low levels of fuel impurities and characteristic non-combustibles interact with surface oxides, for instance through the development of molten deposits that lead to hot corrosion of protective TBC coatings. The overall program has been comprised of six inter-related themes, each comprising a research thrust over the program period, including: (i) evaluating the role of syngas and high hydrogen content (HHC) combustion environments in modifying component surface temperatures, heat transfer to the TBC coatings, and thermal gradients within these coatings; (ii) understanding the instability of TBC coatings in the syngas and high hydrogen environment with regards to decomposition, phase changes and sintering; (iii) characterizing ash deposition, molten phase development and infiltration, and associated corrosive

  6. Silica-sol-based spin-coating barrier layer against phosphorous diffusion for crystalline silicon solar cells.

    Science.gov (United States)

    Uzum, Abdullah; Fukatsu, Ken; Kanda, Hiroyuki; Kimura, Yutaka; Tanimoto, Kenji; Yoshinaga, Seiya; Jiang, Yunjian; Ishikawa, Yasuaki; Uraoka, Yukiharu; Ito, Seigo

    2014-01-01

    The phosphorus barrier layers at the doping procedure of silicon wafers were fabricated using a spin-coating method with a mixture of silica-sol and tetramethylammonium hydroxide, which can be formed at the rear surface prior to the front phosphorus spin-on-demand (SOD) diffusion and directly annealed simultaneously with the front phosphorus layer. The optimization of coating thickness was obtained by changing the applied spin-coating speed; from 2,000 to 8,000 rpm. The CZ-Si p-type silicon solar cells were fabricated with/without using the rear silica-sol layer after taking the sheet resistance measurements, SIMS analysis, and SEM measurements of the silica-sol material evaluations into consideration. For the fabrication of solar cells, a spin-coating phosphorus source was used to form the n(+) emitter and was then diffused at 930°C for 35 min. The out-gas diffusion of phosphorus could be completely prevented by spin-coated silica-sol film placed on the rear side of the wafers coated prior to the diffusion process. A roughly 2% improvement in the conversion efficiency was observed when silica-sol was utilized during the phosphorus diffusion step. These results can suggest that the silica-sol material can be an attractive candidate for low-cost and easily applicable spin-coating barrier for any masking purpose involving phosphorus diffusion.

  7. Calcium-magnesium Aluminosilicate (CMAS) Interactions with Advanced Environmental Barrier Coating Material

    Science.gov (United States)

    Wiesner, Valerie L.; Bansal, Narottam P.

    2015-01-01

    Particulates, like sand and volcanic ash, threaten the development of robust environmental barrier coatings (EBCs) that protect next-generation silicon-based ceramic matrix composite (CMC) turbine engine components from harsh combustion environments during service. The siliceous particulates transform into molten glassy deposits of calcium-magnesium aluminosilicate (CMAS) when ingested by an aircraft engine operating at temperatures above 1200C. In this study, a sample of desert sand was melted into CMAS glass to evaluate high-temperature interactions between the sand glass and an advanced EBC material. Desert sand glass was added to the surface of hot-pressed EBC substrates, which were then heated in air at temperatures ranging from 1200C to 1500C. Scanning electron microscopy and X-ray energy-dispersive spectroscopy were used to evaluate microstructure and phase compositions of specimens and the CMASEBC interface after heat treatments.

  8. Designing a highly sensitive Eddy current sensor for evaluating damage on thermal barrier coating

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Jong Min; Kim, Hak Joon; Song, Sung Jin; Seok, Chang Seong; Lee, Yeong Ze [Dept. of Mechanical Engineering, Sungkyunkwan University, Suwon (Korea, Republic of); Lee, Seul Gi [LG Electronics, Seoul (Korea, Republic of)

    2016-06-15

    A thermal barrier coating (TBC) has been widely applied to machine components working under high temperature as a thermal insulator owing to its critical financial and safety benefits to the industry. However, the nondestructive evaluation of TBC damage is not easy since sensing of the microscopic change that occurs on the TBC is required during an evaluation. We designed an eddy current probe for evaluating damage on a TBC based on the finite element method (FEM) and validated its performance through an experiment. An FEM analysis predicted the sensitivity of the probe, showing that impedance change increases as the TBC thermally degrades. In addition, the effect of the magnetic shield concentrating magnetic flux density was also observed. Finally, experimental validation showed good agreement with the simulation result.

  9. Luminescence-Based Diagnostics of Thermal Barrier Coating Health and Performance

    Science.gov (United States)

    Eldridge, Jeffrey I.

    2013-01-01

    Thermal barrier coatings (TBCs) are typically composed of translucent ceramic oxides that provide thermal protection for metallic components exposed to high-temperature environments in both air- and land-based turbine engines. For advanced turbine engines designed for higher temperature operation, a diagnostic capability for the health and performance of TBCs will be essential to indicate when a mitigating action needs to be taken before premature TBC failure threatens engine performance or safety. In particular, it is shown that rare-earth-doped luminescent sublayers can be integrated into the TBC structure to produce luminescence emission that can be monitored to assess TBC erosion and delamination progression, and to map surface and subsurface temperatures as a measure of TBC performance. The design and implementation of these TBCs with integrated luminescent sublayers are presented.

  10. Residual stress evolution regularity in thermal barrier coatings under thermal shock loading

    Directory of Open Access Journals (Sweden)

    Ximin Chen

    2014-01-01

    Full Text Available Residual stress evolution regularity in thermal barrier ceramic coatings (TBCs under different cycles of thermal shock loading of 1100°C was investigated by the microscopic digital image correlation (DIC and micro-Raman spectroscopy, respectively. The obtained results showed that, as the cycle number of the thermal shock loading increases, the evolution of the residual stress undergoes three distinct stages: a sharp increase, a gradual change, and a reduction. The extension stress near the TBC surface is fast transformed to compressive one through just one thermal cycle. After different thermal shock cycles with peak temperature of 1100°C, phase transformation in TBC does not happen, whereas the generation, development, evolution of the thermally grown oxide (TGO layer and micro-cracks are the main reasons causing the evolution regularity of the residual stress.

  11. Effects of Thermal Barrier Coatings on Approaches to Turbine Blade Cooling

    Science.gov (United States)

    Boyle, Robert J.

    2007-01-01

    Reliance on Thermal Barrier Coatings (TBC) to reduce the amount of air used for turbine vane cooling is beneficial both from the standpoint of reduced NOx production, and as a means of improving cycle efficiency through improved component efficiency. It is shown that reducing vane cooling from 10 to 5 percent of mainstream air can lead to NOx reductions of nearly 25 percent while maintaining the same rotor inlet temperature. An analysis is given which shows that, when a TBC is relied upon in the vane thermal design process, significantly less coolant is required using internal cooling alone compared to film cooling. This is especially true for small turbines where internal cooling without film cooling permits the surface boundary layer to remain laminar over a significant fraction of the vane surface.

  12. Failure mechanism of EB-PVD thermal barrier coatings on NiAl substrate

    Institute of Scientific and Technical Information of China (English)

    2007-01-01

    Yttria stabilized zirconia(YSZ) was deposited on the line cut β-NiAl substrate by electron-beam physical vapour deposition(EB-PVD), and the cyclic oxidation behaviors of thermal barrier coatings on β-NiAl substrate were investigated in 1 h thermal cycles at 1 200 ℃ in air. The results show that the samples fail after 80-100 cycles. Sub-interface cavitations in the substrate develop due to depletion of Al in forming thermally grown oxides(TGOs). The collapse and closing up of cavities result in the ragged YSZ/TGO/substrate interface. Since the specific crack trajectories are quite sensitive to local geometry, cracks along the YSZ/TGO/substrate interfaces ultimately lead to YSZ spallation.

  13. Degradation Of Environmental Barrier Coatings (EBC) Due To Chemical and Thermal Expansion Incompatibility

    Science.gov (United States)

    Lee, Kang N.; King, Deboran (Technical Monitor)

    2001-01-01

    Current environmental barrier coatings (EBCs) consist of multiple layers, with each layer having unique properties to meet the various requirements for successful EBCs. As a result, chemical and thermal expansion compatibility between layers becomes an important issue to maintaining durability. Key constituents in current EBCs are mullite (3Al2O3-2SiO2), BSAS (BaO(1-x)-SrO(x)-Al2O3-2SiO2), and YSZ (ZrO2-8 wt.% Y2O3). The mullite-BSAS combination appears benign although significant diffusion occurs. Mullite-YSZ and BSAS-YSZ combinations do not react up to 1500 C. Thermally grown SiO2- BSAS and mullite-BSAS-YSZ combinations are most detrimental, forming low melting glasses. Thermal expansion mismatch between YSZ and mullite or BSAS causes severe cracking and delamination.

  14. Residual stress inspection by Eu3+ photoluminescence piezo-spectroscopy: An application in thermal barrier coatings

    Science.gov (United States)

    Zhao, Yu; Ma, Chunli; Huang, Fengxian; Wang, Chunjie; Zhao, Sumei; Cui, Qiliang; Cao, Xueqiang; Li, Fangfei

    2013-08-01

    A non-destructive inspection technique was developed to measure the residual stresses in thermal barrier coatings (TBCs) by using Eu3+ photoluminescence piezo-spectroscopy. The new approach is based on the relationship between stress and the position of the main peak of 5D0→7F2 transition, which is built by the high-pressure techniques. The Eu3+ luminescent sublayer was applied in the current method to ensure that the detected position in TBCs can be well controlled. The laser used to detect Eu3+ luminescence gives a proper penetration depth and spatial resolution, which make this method suitable to detect the stresses concentrated near the interfaces between different layers. This method was successfully applied in detecting residual stress in plasma sprayed TBCs with a 8YSZ:Eu (1 mol. %) sublayer.

  15. Strain response of thermal barrier coatings captured under extreme engine environments through synchrotron X-ray diffraction.

    Science.gov (United States)

    Knipe, Kevin; Manero, Albert; Siddiqui, Sanna F; Meid, Carla; Wischek, Janine; Okasinski, John; Almer, Jonathan; Karlsson, Anette M; Bartsch, Marion; Raghavan, Seetha

    2014-07-31

    The mechanical behaviour of thermal barrier coatings in operation holds the key to understanding durability of jet engine turbine blades. Here we report the results from experiments that monitor strains in the layers of a coating subjected to thermal gradients and mechanical loads representing extreme engine environments. Hollow cylindrical specimens, with electron beam physical vapour deposited coatings, were tested with internal cooling and external heating under various controlled conditions. High-energy synchrotron X-ray measurements captured the in situ strain response through the depth of each layer, revealing the link between these conditions and the evolution of local strains. Results of this study demonstrate that variations in these conditions create corresponding trends in depth-resolved strains with the largest effects displayed at or near the interface with the bond coat. With larger temperature drops across the coating, significant strain gradients are seen, which can contribute to failure modes occurring within the layer adjacent to the interface.

  16. Strain response of thermal barrier coatings captured under extreme engine environments through synchrotron X-ray diffraction

    Science.gov (United States)

    Knipe, Kevin; Manero, Albert; Siddiqui, Sanna F.; Meid, Carla; Wischek, Janine; Okasinski, John; Almer, Jonathan; Karlsson, Anette M.; Bartsch, Marion; Raghavan, Seetha

    2014-07-01

    The mechanical behaviour of thermal barrier coatings in operation holds the key to understanding durability of jet engine turbine blades. Here we report the results from experiments that monitor strains in the layers of a coating subjected to thermal gradients and mechanical loads representing extreme engine environments. Hollow cylindrical specimens, with electron beam physical vapour deposited coatings, were tested with internal cooling and external heating under various controlled conditions. High-energy synchrotron X-ray measurements captured the in situ strain response through the depth of each layer, revealing the link between these conditions and the evolution of local strains. Results of this study demonstrate that variations in these conditions create corresponding trends in depth-resolved strains with the largest effects displayed at or near the interface with the bond coat. With larger temperature drops across the coating, significant strain gradients are seen, which can contribute to failure modes occurring within the layer adjacent to the interface.

  17. Optics and multilayer coatings for EUVL systems

    Energy Technology Data Exchange (ETDEWEB)

    Soufli, R; Bajt, S; Hudyma, R M; Taylor, J S

    2008-03-21

    EUV lithography (EUVL) employs illumination wavelengths around 13.5 nm, and in many aspects it is considered an extension of optical lithography, which is used for the high-volume manufacturing (HVM) of today's microprocessors. The EUV wavelength of illumination dictates the use of reflective optical elements (mirrors) as opposed to the refractive lenses used in conventional lithographic systems. Thus, EUVL tools are based on all-reflective concepts: they use multilayer (ML) coated optics for their illumination and projection systems, and they have a ML-coated reflective mask.

  18. Oxidation resistance of Al2O3-nanostructured/CSZ composite compared to conventional CSZ and YSZ thermal barrier coatings

    Science.gov (United States)

    Keyvani, A.; Bahamirian, M.

    2016-10-01

    Thermal barrier coatings are widely used in combustion sections of turbine engines, however, their main disadvantage is the spallation from the bond coat, occurring due to oxidation and formation of thermally grown oxide (TGO). In this paper, the oxidation resistance of yttria stabilized zirconia (YSZ), ceria stabilized zirconia (CSZ), and Al2O3-nanostructured/CSZ composite coatings have been studied and compared with each other. Samples were heated in air at 1100 °C using an electrical furnace. Three types of the top coats were applied by thermal spray technique on IN738LC base metal. Scanning electron microscopy was used to study the microstructure of the coatings before and after the oxidation. The experimental results showed that Al2O3-nanostructured/CSZ composite coating exhibits considerably better oxidation resistance compared to conventional YSZ and CSZ coatings. The microstructural analysis indicated a smaller growth of TGO in the Al2O3-nanostructured/CSZ composite coating, improving the oxidation resistance of the coating.

  19. Anisotropic Mechanical Properties of Plasma-Sprayed Thermal Barrier Coatings at High Temperature Determined by Ultrasonic Method

    Science.gov (United States)

    Wei, Qin; Zhu, Jianguo; Chen, Wei

    2016-02-01

    The mechanical properties of plasma-sprayed thermal barrier coatings (TBC) are of great scientific and technological significance for the design and fabrication of TBC systems. The ultrasonic method combined with a sing-around method for mechanical properties measurement of TBC is deduced and the elastic modulus can be determined in the spray, or longitudinal, direction, and the transverse direction. Tested specimens of plasma-sprayed TBC are detached from the substrate and treated with thermal exposure at 1400 °C. The elastic moduli along the longitudinal and transverse directions of the TBCs are measured by different types of ultrasonic waves combined with a sing-around method, while the Poisson's ratio is also obtained simultaneously. The experimental results indicate that the magnitude of longitudinal elastic modulus is larger than that of the transverse one, and thus the plasma-sprayed TBC has an anisotropic mechanical property. Moreover, the elastic moduli along both longitudinal and transverse directions change with high-temperature exposure time, which consists of a rapid increasing stage followed by a slow decreasing stage. In addition, the magnitude of Poisson's ratio increases slightly from 0.05 to 0.2 with the high-temperature exposure time. Generally, the microstructures in the plasma-sprayed coatings and their evolution in a high-temperature environment are the main causes of the varying anisotropic mechanical properties.

  20. Interface delamination of the thermal barrier coating subjected to local heating

    Institute of Scientific and Technical Information of China (English)

    2010-01-01

    To investigate the possible failure modes of the thermal barrier coating (TBC) used to protect the scramjet combustion chamber, the local heating via laser beam irradiation was utilized to simulate the service condition of high thermal flux and high temperature gradient. Firstly, the experimental method and process were described and the typical fracture morphology of the TBC under test were provided. Then, the theoretical and finite element modeling were carried out to study the temperature, deformation and stresses of the specimen when the top ceramic coat was subjected to local heating, and to demonstrate the mechanism on the failure of the TBC. It is revealed that the interface delamination shall appear and ultimately lead to the failure of the TBC under such thermal loading of local quick heating. According to the outcome of this study, the driving force of the interface delamination is influenced greatly by the key structural parameters and performance matching. Moreover, by utilizing the rules of the effects of these parameters on the fracture driving force, there is some possibility for the designer to optimize the performances of the TBC.

  1. Effects of supersonic fine particle bombarding on thermal cyclic failure lifetime of thermal barrier coating

    Institute of Scientific and Technical Information of China (English)

    CHEN Ya-jun; LIN Xiao-ping; WANG Zhi-ping; WANG Li-jun; JI Zhao-hui; DONG Yun

    2010-01-01

    Thermal barrier coating(TBC)consisting of a NiCoCrAlY bond coat(BC)and a ZrO2-8 wt.%Y2O3 topcoat(TC)was fabricated on the nickel-base supcralloy by air plasma spray(APS).The BC was trea-ted by supersonic fine particle bombarding(SFPB).Thermal cyclic failure and residual stress in thermally grown oxide(TGO)scale were studied by SEM with EDS and ruby fluorescence spectroscopy(RFS).As shown in the results,after treated by SFPB,thickening of TGO was relatively slow,which reduced the level of growth stress.The TBC with SFPB treatment was still remained well undergoing 350 times of thermal cycle.However,after thermal cycle with the same times,the separation of TC was observed in TBC without SFPB treatment.The residual stress analysis by RFS showed that the residual stress of SFPB-treated TBC increased with the increasing number of thermal cycle.The residual stress of conventional TBC reached a value of 650MPa at 350 times of cycle and that of SFPB-treated TBC only reached 532 MPa at 400 times of cycle.The BC with SFPB treatment after 400 times of cycle was analyzed by RFS,the high stress value was not observed in local thickened region of TGO.Thermal cycling resistance of TBC can be improved by the SFPB technology.

  2. Conjugate heat transfer investigation on the cooling performance of air cooled turbine blade with thermal barrier coating

    Science.gov (United States)

    Ji, Yongbin; Ma, Chao; Ge, Bing; Zang, Shusheng

    2016-08-01

    A hot wind tunnel of annular cascade test rig is established for measuring temperature distribution on a real gas turbine blade surface with infrared camera. Besides, conjugate heat transfer numerical simulation is performed to obtain cooling efficiency distribution on both blade substrate surface and coating surface for comparison. The effect of thermal barrier coating on the overall cooling performance for blades is compared under varied mass flow rate of coolant, and spatial difference is also discussed. Results indicate that the cooling efficiency in the leading edge and trailing edge areas of the blade is the lowest. The cooling performance is not only influenced by the internal cooling structures layout inside the blade but also by the flow condition of the mainstream in the external cascade path. Thermal barrier effects of the coating vary at different regions of the blade surface, where higher internal cooling performance exists, more effective the thermal barrier will be, which means the thermal protection effect of coatings is remarkable in these regions. At the designed mass flow ratio condition, the cooling efficiency on the pressure side varies by 0.13 for the coating surface and substrate surface, while this value is 0.09 on the suction side.

  3. Thermal Properties of Oxides With Magnetoplumbite Structure for Advanced Thermal Barrier Coatings

    Science.gov (United States)

    Bansal, Narottam P.; Zhu, Dongming; Eslamloo-Grami, Maryam

    2007-01-01

    Oxides having magnetoplumbite structure are promising candidate materials for applications as high temperature thermal barrier coatings because of their high thermal stability, high thermal expansion, and low thermal conductivity. In this study, powders of LaMgAl11O19, GdMgAl11O19, SmMgAl11O19, and Gd0.7Yb0.3MgAl11O19 magnetoplumbite oxides were synthesized by citric acid sol-gel method and hot pressed into disk specimens. The thermal expansion coefficients (CTE) of these oxide materials were measured from room temperature to 1500 C. The average CTE value was found to be approx.9.6x10(exp -6)/C. Thermal conductivity of these magnetoplumbite-based oxide materials was also evaluated using steady-state laser heat flux test method. The effects of doping on thermal properties were also examined. Thermal conductivity of the doped Gd0.7Yb0.3MgAl11O19 composition was found to be lower than that of the undoped GdMgAl11O19. In contrast, thermal expansion coefficient was found to be independent of the oxide composition and appears to be controlled by the magnetoplumbite crystal structure. Thermal conductivity testing of LaMgAl11O19 and LaMnAl11O19 magnetoplumbite oxide coatings plasma sprayed on NiCrAlY/Rene N5 superalloy substrates indicated resistance of these coatings to sintering even at temperatures as high as 1600 C.

  4. International Collaboration Activities on Engineered Barrier Systems

    Energy Technology Data Exchange (ETDEWEB)

    Jove-Colon, Carlos F. [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

    2016-08-31

    The Used Fuel Disposition Campaign (UFDC) within the DOE Fuel Cycle Technologies (FCT) program has been engaging in international collaborations between repository R&D programs for high-level waste (HLW) disposal to leverage on gathered knowledge and laboratory/field data of near- and far-field processes from experiments at underground research laboratories (URL). Heater test experiments at URLs provide a unique opportunity to mimetically study the thermal effects of heat-generating nuclear waste in subsurface repository environments. Various configurations of these experiments have been carried out at various URLs according to the disposal design concepts of the hosting country repository program. The FEBEX (Full-scale Engineered Barrier Experiment in Crystalline Host Rock) project is a large-scale heater test experiment originated by the Spanish radioactive waste management agency (Empresa Nacional de Residuos Radiactivos S.A. – ENRESA) at the Grimsel Test Site (GTS) URL in Switzerland. The project was subsequently managed by CIEMAT. FEBEX-DP is a concerted effort of various international partners working on the evaluation of sensor data and characterization of samples obtained during the course of this field test and subsequent dismantling. The main purpose of these field-scale experiments is to evaluate feasibility for creation of an engineered barrier system (EBS) with a horizontal configuration according to the Spanish concept of deep geological disposal of high-level radioactive waste in crystalline rock. Another key aspect of this project is to improve the knowledge of coupled processes such as thermal-hydro-mechanical (THM) and thermal-hydro-chemical (THC) operating in the near-field environment. The focus of these is on model development and validation of predictions through model implementation in computational tools to simulate coupled THM and THC processes.

  5. ETV Program Report: Coatings for Wastewater Collection Systems - Standard Cement Materials, Epoxy Coating 4553

    Science.gov (United States)

    The Standard Cement Materials, Inc. Standard Epoxy Coating 4553™ (SEC 4553) epoxy coating used for wastewater collection system rehabilitation was evaluated by EPA’s Environmental Technology Verification Program under laboratory conditions at the Center for Innovative Grouting Ma...

  6. Deployment Efficiency and Barrier Effectiveness Testing of a Temporary Anti-Personnel (TAP) Barrier System.

    Energy Technology Data Exchange (ETDEWEB)

    Allen, David James [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States); Hedrick, Charles D. [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States); Martinez, Ruben [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

    2017-02-01

    This report documents tests conducted by Sandia National Laboratories (SNL) on behalf of the U.S. Department of State to evaluate a temporary anti-personnel (TAP) barrier system developed by Mitigation Technologies. For this, the SNL Denial and Structural Assessment department developed a test protocol for the evaluation of the TAP barrier system on the basis of deployment efficiency and barrier effectiveness against a riotous/mob attack threat. The test protocol was then executed by SNL personnel and the results of the testing are documented.

  7. Surface geometry and strain energy effects in the failure of a (Ni, Pt)Al/EB-PVD thermal barrier coating

    Energy Technology Data Exchange (ETDEWEB)

    Vaidyanathan, Krishnakumar; Jordan, Eric H.; Gell, Maurice

    2004-03-08

    Thermal cycling tests were conducted on a commercial yttria-stabilized zirconia electron beam-physical vapor deposited thermal barrier coating (TBC) on a platinum aluminide ({beta}-(Ni, Pt)Al) bond coat. Surprisingly, the longest life sample lasted 10 times longer than the shortest life sample. Two distinct mechanisms have been found responsible for the observed damage initiation and progression at the thermally grown oxide (TGO)/bond coat interface. The first mechanism leads to localized debonding at the TGO/bond coat interface due to increasing out-of-plane tensile stresses at ridges that form along bond coat grain boundaries. The second mechanism is driven by cyclic plasticity of the bond coat that leads to cavity formation at the TGO/bond coat interface. The primary finding of this work is that the first mechanism, involving tensile stress at ridge tops, is life limiting. Based on this mechanism, it is demonstrated that the variation in bond coat ridge aspect ratio can explain the unusual 10x variation in observed sample life. It is proposed that ridge top spallation leads to debonds of sufficient size to result in unstable fracture driven by the strain energy stored in the TGO. The criticality of the flaw created by local debonding is supported by experimental determination of the strain energy available in the TGO through measurement of TGO stress and thickness combined with published fracture mechanics solutions of the relevant flaw geometry.

  8. MnCo{sub 2}O{sub 4} spinel chromium barrier coatings for SOFC interconnect by HVOF

    Energy Technology Data Exchange (ETDEWEB)

    Lagerbom, J.; Varis, T.; Pihlatie, M.; Himanen, O.; Saarinen, V.; Kiviaho, J.; Turunen, E. [VTT Technical Research Centre of Finland, Espoo (Finland); Puranen, J. [Tampere Univ. of Technology (Finland). Inst. of Materials Science

    2010-07-01

    Chromia released from steel parts used for interconnect plates by evaporation and condensation can quickly degrade the cell (cathode) performance in solid oxide fuel cell SOFC. Coatings on top of the IC plate can work as a chromium evaporation barrier. The coating material should have good electrical conductivity, high temperature stability and nearly the same coefficient of thermal expansion as the cell materials. One candidate for the coating material is MnCo{sub 2}O{sub 4} spinel because of its suitable properties. High velocity oxy fuel (HVOF) spraying was used for the coating application on Crofer 22 APU steel samples. Using commercial and self made spray dried powders together with an HV2000 spray gun it was possible to successfully manufacture, well adhering, dense and reasonably uniform coatings. The samples were tested in oxidation exposure tests in air followed by post analysis in SEM. Powders and coatings microstructures are presented here, both before and after exposure. It was found out that together with spraying parameters the powder characteristics used influence clearly to the coating quality. Especially as very thin coatings was aimed with dense structure fine powders was found to be essential. (orig.)

  9. Relationship Between Lamellar Structure and Elastic Modulus of Thermally Sprayed Thermal Barrier Coatings with Intra-splat Cracks

    Science.gov (United States)

    Li, Guang-Rong; Lv, Bo-Wen; Yang, Guan-Jun; Zhang, Wei-Xu; Li, Cheng-Xin; Li, Chang-Jiu

    2015-12-01

    The elastic modulus of plasma-sprayed top coating plays an important role in thermal cyclic lifetime of thermally sprayed thermal barrier coatings (TBCs), since the thermal stress is determined by the substrate/coating thermal mismatch and the elastic modulus of top coating. Consequently, much attention had been paid to understanding the relationship between elastic modulus and lamellar structure of top coating. However, neglecting the intra-splat cracks connected with inter-splat pores often leads to poor prediction in in-plane modulus. In this study, a modified model taking account of intra-splat cracks and other main structural characteristics of plasma-sprayed yttria-stabilized zirconia coating was proposed. Based on establishing the relationship between elastic modulus and structural parameters of basic unit, effects of structural parameters on the elastic modulus of coatings were discussed. The predicted results are well consistent with experimental data on coating elastic modulus in both out-plane direction and in-plane direction. This study would benefit the further comprehensive understanding of failure mechanism of TBCs in thermal cyclic condition.

  10. Fluctuating Potential Barrier System with Correlated Spatial Noises

    Institute of Scientific and Technical Information of China (English)

    LI Jing-Hui

    2004-01-01

    In this paper, we study a fluctuating potential barrier system with correlated spatial noises. Study shows that for this system, there is the resonant activation over the fluctuating potential barrier, and that the correlation between the different spatial noises can enhance (or weaken) the resonant activation.

  11. Porous-Al2O3 thermal barrier coatings with dispersed Pt particles prepared by cathode plasma electrolytic deposition

    Institute of Scientific and Technical Information of China (English)

    Jin Zhang

    2016-01-01

    Porousa-Al2O3 thermal barrier coatings (TBCs) containing dispersed Pt particles were prepared by cathode plasma electrolytic deposition (CPED). The influence of the Pt particles on the microstructure of the coatings and the CPED process were studied. The prepared coatings were mainly composed ofα-Al2O3. The average thickness of the coatings was approximately 100μm. Such single-layer TBCs ex-hibited not only excellent high-temperature cyclic oxidation and spallation resistance, but also good thermal insulation properties. Porousa-Al2O3 TBCs inhibit further oxidation of alloy substrates because of their extremely low oxygen diffusion rate, provide good thermal insu-lation because of their porous structure, and exhibit excellent mechanical properties because of the toughening effect of the Pt particles and because of stress relaxation induced by deformation of the porous structure.

  12. Roll-to-roll DBD plasma pretreated polyethylene web for enhancement of Al coating adhesion and barrier property

    Science.gov (United States)

    Zhang, Haibao; Li, Hua; Fang, Ming; Wang, Zhengduo; Sang, Lijun; Yang, Lizhen; Chen, Qiang

    2016-12-01

    In this paper the roll-to-roll atmospheric dielectric barrier discharge (DBD) was used to pre-treat polyethylene (PE) web surface before the conventional thermal evaporation aluminum (Al) was performed as a barrier layer. We emphasized the plasma environment effect based on the inlet three kinds of reactive monomers. The cross hatch test was employed to assess the Al coating adhesion; and the oxygen transmission rate (OTR) was used to evaluate gas barrier property. The results showed that after roll-to-roll DBD plasma treatment all Al coatings adhered strongly on PE films and were free from pinhole defects with mirror morphology. The OTR was reduced from 2673 cm3/m2 day for Al-coated original PE to 138 cm3/m2 day for Al-coated allyamine (C3H7N) modified PE. To well understand the mechanism the chemical compositions of the untreated and DBD plasma pretreated PE films were analyzed by X-ray photoelectron spectroscopy (XPS). The surface topography was characterized by atomic force microscopy (AFM). For the property of surface energy the water contact angle measurement was also carried out in the DBD plasma treated samples with deionized water.

  13. Monitoring Delamination of Plasma-Sprayed Thermal Barrier Coatings by Reflectance-Enhanced Luminescence

    Science.gov (United States)

    Eldridge, Jeffrey I.; Bencic, Timothy J.

    2006-01-01

    Highly scattering plasma-sprayed thermal barrier coatings (TBCs) present a challenge for optical diagnostic methods to monitor TBC delamination because scattering attenuates light transmitted through the TBC and usually degrades contrast between attached and delaminated regions of the TBC. This paper presents a new approach where reflectance-enhanced luminescence from a luminescent sublayer incorporated along the bottom of the TBC is used to identify regions of TBC delamination. Because of the higher survival rate of luminescence reflecting off the back surface of a delaminated TBC, the strong scattering exhibited by plasma-sprayed TBCs actually accentuates contrast between attached and delaminated regions by making it more likely that multiple reflections of luminescence off the back surface occur before exiting the top surface of the TBC. A freestanding coating containing sections designed to model an attached or delaminated TBC was prepared by depositing a luminescent Eu-doped or Er-doped yttria-stabilized zirconia (YSZ) luminescent layer below a plasma-sprayed undoped YSZ layer and utilizing a NiCr backing layer to represent an attached substrate. For specimens with a Eu-doped YSZ luminescent sublayer, luminescence intensity maps showed excellent contrast between unbacked and NiCr-backed sections even at a plasma-sprayed overlayer thickness of 300 m. Discernable contrast between unbacked and NiCr-backed sections was not observed for specimens with a Er-doped YSZ luminescent sublayer because luminescence from Er impurities in the undoped YSZ layer overwhelmed luminescence originating form the Er-doped YSZ sublayer.

  14. Erosion Performance of Gadolinium Zirconate-Based Thermal Barrier Coatings Processed by Suspension Plasma Spray

    Science.gov (United States)

    Mahade, Satyapal; Curry, Nicholas; Björklund, Stefan; Markocsan, Nicolaie; Nylén, Per; Vaßen, Robert

    2017-01-01

    7-8 wt.% Yttria-stabilized zirconia (YSZ) is the standard thermal barrier coating (TBC) material used by the gas turbines industry due to its excellent thermal and thermo-mechanical properties up to 1200 °C. The need for improvement in gas turbine efficiency has led to an increase in the turbine inlet gas temperature. However, above 1200 °C, YSZ has issues such as poor sintering resistance, poor phase stability and susceptibility to calcium magnesium alumino silicates (CMAS) degradation. Gadolinium zirconate (GZ) is considered as one of the promising top coat candidates for TBC applications at high temperatures (>1200 °C) due to its low thermal conductivity, good sintering resistance and CMAS attack resistance. Single-layer 8YSZ, double-layer GZ/YSZ and triple-layer GZdense/GZ/YSZ TBCs were deposited by suspension plasma spray (SPS) process. Microstructural analysis was carried out by scanning electron microscopy (SEM). A columnar microstructure was observed in the single-, double- and triple-layer TBCs. Phase analysis of the as-sprayed TBCs was carried out using XRD (x-ray diffraction) where a tetragonal prime phase of zirconia in the single-layer YSZ TBC and a cubic defect fluorite phase of GZ in the double and triple-layer TBCs was observed. Porosity measurements of the as-sprayed TBCs were made by water intrusion method and image analysis method. The as-sprayed GZ-based multi-layered TBCs were subjected to erosion test at room temperature, and their erosion resistance was compared with single-layer 8YSZ. It was shown that the erosion resistance of 8YSZ single-layer TBC was higher than GZ-based multi-layered TBCs. Among the multi-layered TBCs, triple-layer TBC was slightly better than double layer in terms of erosion resistance. The eroded TBCs were cold-mounted and analyzed by SEM.

  15. Comparison of coating processes in the development of aluminum-based barriers for blanket applications

    Energy Technology Data Exchange (ETDEWEB)

    Wulf, Sven-Erik, E-mail: sven-erik.wulf@kit.edu; Krauss, Wolfgang; Konys, Jürgen

    2014-10-15

    Highlights: •Electrochemical processes ECA and ECX are suitable for Al deposition on RAFM steels. •ECA and ECX are able to produce thin Al layers with adjustable thicknesses. •All aluminization processes need a subsequent heat treatment. •Scales made by ECA or ECX exhibit reduced thicknesses compared to HDA. •ECX provides higher flexibility compared to ECA to produce scales on RAFM steels. -- Abstract: Reduced activation ferritic-martensitic steels (RAFM), e.g. Eurofer 97, are envisaged in future fusion technology as structural material, which will be in direct contact with a flowing liquid lead–lithium melt serving as breeder material. Aluminum-based barrier layers had proven their ability to protect the structural material from corrosion attack in flowing Pb–15.7Li and to reduce tritium permeation into the coolant. Coming from scales produced by hot dipping aluminization (HDA), the development of processes based on electrochemical methods to produce defined aluminum-based scales on RAFM steels gained attention in research during the last years. Two different electrochemical processes are proposed: The first one, referred to as ECA process, is based on the electrodeposition of aluminum from volatile, metal-organic electrolytes. The other process called ECX is based on ionic liquids. All three processes exhibit specific characteristics, for example in the field of processability, control of coating thicknesses (low activation criteria) and heat treatment behavior. The aim of this article is to compare these different coating processes critically, whereby the focus is on the comparison of ECA and ECX processes. New results for ECX-process will be presented and occurring development needs for the future will be discussed.

  16. Thermal barrier coating by electron beam-physical vapor deposition of zirconia co-doped with yttria and niobia

    Directory of Open Access Journals (Sweden)

    Daniel Soares de Almeida

    2010-08-01

    Full Text Available The most usual ceramic material for coating turbine blades is yttria doped zirconia. Addition of niobia, as a co-dopant in the Y2O3-ZrO2 system, can reduce the thermal conductivity and improve mechanical properties of the coating. The purpose of this work was to evaluate the influence of the addition of niobia on the microstructure and thermal properties of the ceramic coatings. SEM on coatings fractured cross-section shows a columnar structure and the results of XRD show only zirconia tetragonal phase in the ceramic coating for the chemical composition range studied. As the difference NbO2,5-YO1,5 mol percent increases, the tetragonality increases. A significant reduction of the thermal conductivity, measured by laser flash technique in the zirconia coating co-doped with yttria and niobia when compared with zirconia-yttria coating was observed.

  17. Isothermal oxidation behaviour of thermal barrier coatings with CoCrAlY bond coat irradiated by high-current pulsed electron beam

    Energy Technology Data Exchange (ETDEWEB)

    Cai, Jie [School of Materials Science and Engineering, Jiangsu University, Zhenjiang 212013 (China); Guan, Qingfeng, E-mail: guanqf@mail.ujs.edu.cn [School of Materials Science and Engineering, Jiangsu University, Zhenjiang 212013 (China); Hou, Xiuli [School of Materials Science and Engineering, Jiangsu University, Zhenjiang 212013 (China); Wang, Zhiping; Su, Jingxin; Han, Zhiyong [College of Science, Civil Aviation University of China, Tianjin 300300 (China)

    2014-10-30

    Highlights: • The original coarse surface was re-melted by pulsed electron beam irradiation. • Very fine grains were homogeneously dispersed on the irradiated coat surface. • A compact Al{sub 2}O{sub 3} scale was formed in irradiated TBCs at the onset of oxidation. • The selective oxidation of Al element avoided the formation of other oxides. • The irradiated coating has a much higher oxidation resistance. - Abstract: Thermal sprayed CoCrAlY bond coat irradiated by high-current pulsed electron beam (HCPEB) and thermal barrier coatings (TBCs) prepared with the irradiated bond coat and the ceramic top coat were investigated. The high temperature oxidation resistance of these specimens was tested at 1050 °C in air. Microstructure observations revealed that the original coarse surface of the as-sprayed bond coat was significantly changed as the interconnected bulged nodules with a compact appearance after HCPEB irradiation. Abundant Y-rich alumina particulates and very fine grains were dispersed on the irradiated surface. After high temperature oxidation test, the thermally grown oxide (TGO) in the initial TBCs grew rapidly and was comprised of two distinct layers: a large percentage of mixed oxides in the outer layer and a relatively small portion of Al{sub 2}O{sub 3} in the inner layer. Severe local internal oxidation and extensive cracks in the TGO layer were discovered as well. Comparatively, the irradiated TBCs exhibited thinner TGO layer, slower TGO growth rate, and homogeneous TGO composition (primarily consisting of Al{sub 2}O{sub 3}). The results indicate that TBCs with the irradiated bond coat have a much higher oxidation resistance.

  18. COMPARISON OF THERMAL SHOCK BEHAVIOR OF 7YSZ, 15YSZ AND SYSZ THERMAL BARRIER COATINGS PRODUCED BY APS METHOD

    Directory of Open Access Journals (Sweden)

    H. Jamali

    2016-07-01

    Full Text Available Nanostructured scandia, yttria doped zirconia (SYSZ, 7wt. % yttria stabilized zirconia (7YSZ and 15YSZ thermal barrier coatings (TBCs were produced by plasma spraying on nickel-based superalloy substrates with NiCrAlY as the bond coat. The thermal shock behavior of the three as-sprayed TBCs at 1000 °C was investigated. The results indicated that the thermal cycling lifetime of SYSZ and 7YSZ TBCs was longer than the 15YSZ TBCs due to the lower thermal mismatch stress between the ceramic layer and the metallic layer at high temperature and higher amount of tetragonal phase.

  19. Phonon tunneling through a double barrier system

    Energy Technology Data Exchange (ETDEWEB)

    Villegas, Diosdado [Departamento de Física, Universidad Central “Marta Abreu” de Las Villas, CP 54830, Santa Clara, Villa Clara (Cuba); Instituto de Física, Universidad Autónoma de Puebla, 18 Sur y San Claudio, Edif. 110A, Ciudad Universitaria, 72570 Puebla (Mexico); León-Pérez, Fernando de [Centro Universitario de la Defensa de Zaragoza, Ctra. de Huesca s/n, E-50090 Zaragoza (Spain); Pérez-Álvarez, R. [Universidad Autónoma del Estado de Morelos, Av. Universidad 1001, CP 62209 Cuernavaca (Mexico); Arriaga, J., E-mail: arriaga@ifuap.buap.mx [Instituto de Física, Universidad Autónoma de Puebla, 18 Sur y San Claudio, Edif. 110A, Ciudad Universitaria, 72570 Puebla (Mexico)

    2015-04-15

    The tunneling of optical and acoustic phonons at normal incidence on a double-barrier is studied in this paper. Transmission coefficients and resonance conditions are derived theoretically under the assumption that the long-wavelength approximation is valid. It is shown that the behavior of the transmission coefficients for the symmetric double barrier has a Lorentzian form close to resonant frequencies and that Breit–Wigner's formula have a general validity in one-dimensional phonon tunneling. Authors also study the so-called generalized Hartman effect in the tunneling of long-wavelength phonons and show that this effect is a numerical artifact resulting from taking the opaque limit before exploring the variation with a finite barrier width. This study could be useful for the design of acoustic devices.

  20. Chemical and mechanical consequences of environmental barrier coating exposure to calcium-magnesium-aluminosilicate.

    Energy Technology Data Exchange (ETDEWEB)

    Harder, B.; Ramirez-Rico, J.; Almer, J. D.; Kang, L.; Faber, K. (X-Ray Science Division); (NASA Glenn Research Center); (Univ. of Seville); (Rolls-Royce Corp.); (Northwestern Univ.)

    2011-06-01

    The success of Si-based ceramics as high-temperature structural materials for gas turbine applications relies on the use of environmental barrier coatings (EBCs) with low silica activity, such as Ba{sub 1-x}Sr{sub x}Al{sub 2}Si{sub 2}O{sub 8} (BSAS), which protect the underlying components from oxidation and corrosion in combustion environments containing water vapor. One of the current challenges concerning EBC lifetime is the effect of sandy deposits of calcium-magnesium-aluminosilicate (CMAS) glass that melt during engine operation and react with the EBC, changing both its composition and stress state. In this work, we study the effect of CMAS exposure at 1300 C on the residual stress state and composition in BSAS-mullite-Si-SiC multilayers. Residual stresses were measured in BSAS multilayers exposed to CMAS for different times using high-energy X-ray diffraction. Their microstructure was studied using a combination of scanning electron microscopy and transmission electron microscopy techniques. Our results show that CMAS dissolves the BSAS topcoat preferentially through the grain boundaries, dislodging the grains and changing the residual stress state in the topcoat to a nonuniform and increasingly compressive stress state with increasing exposure time. The presence of CMAS accelerates the hexacelsian-to-celsian phase transformation kinetics in BSAS, which reacts with the glass by a solution-reprecipitation mechanism. Precipitates have crystallographic structures consistent with Ca-doped celsian and Ba-doped anorthite.

  1. Effects of Doping on Thermal Conductivity of Pyrochlore Oxides for Advanced Thermal Barrier Coatings

    Science.gov (United States)

    Bansal, Narottam P.; Zhu, Dongming; Eslamloo-Grami, Maryam

    2006-01-01

    Pyrochlore oxides of general composition, A2B2O7, where A is a 3(+) cation (La to Lu) and B is a 4(+) cation (Zr, Hf, Ti, etc.) have high melting point, relatively high coefficient of thermal expansion, and low thermal conductivity which make them suitable for applications as high-temperature thermal barrier coatings. The effect of doping at the A site on the thermal conductivity of a pyrochlore oxide La2Zr2O7, has been investigated. Oxide powders of various compositions La2Zr2O7, La(1.7)Gd(0.3)Zr2O7, La(1.7)Yb(0.3)Zr2O7 and La(1.7)Gd(0.15)Yb(0.15)Zr2O7 were synthesized by the citric acid sol-gel method. These powders were hot pressed into discs and used for thermal conductivity measurements using a steady-state laser heat flux test technique. The rare earth oxide doped pyrochlores La(1.7)Gd(0.3)Zr2O7, La(1.7)Yb(0.3)Zr2O7 and La(1.7)Gd(0.15)Yb(0.15)Zr2O7 had lower thermal conductivity than the un-doped La2Zr2O7. The Gd2O3 and Yb2O3 co-doped composition showed the lowest thermal conductivity.

  2. Current Issues with Environmental Barrier Coatings for Ceramics and Ceramic Composites

    Science.gov (United States)

    Lee, Kang N.

    2004-01-01

    The environmental barrier coating (EBC) for SiC/SiC ceramic matrix composites and Si3N4 ceramics is an emerging field as the application of silicon-based ceramics in the gas turbine engine hot section is on the horizon, both for aero and industrial gas turbines. EBC is an enabling technology for silicon-based ceramics because these materials without an EBC cannot be used in combustion environments due to rapid surface recession. Significant progress in EBC development has been made during the last decade through various government-sponsored programs. Current EBCs are based on silicon, mullite (3Al2O3-2SiO2) and BSAS (barium strontium aluminum silicate with celsian structure). Volatility of BSAS, BSAS-silica chemical reaction, and low melting point of silicon limit temperature capability of current EBCs to about 1350 C for long-term applications. There is a need for higher temperature EBCs as the temperature capability of silicon-based ceramics continue to increase. Therefore, research is underway to develop EBCs with improved temperature capability compared to current EBCs. The current status and issues with the advanced EBC development efforts will be discussed.

  3. ENGINEERED BARRIER SYSTEM FEATURES, EVENTS AND PROCESSES

    Energy Technology Data Exchange (ETDEWEB)

    Jaros, W.

    2005-08-30

    The purpose of this report is to evaluate and document the inclusion or exclusion of engineered barrier system (EBS) features, events, and processes (FEPs) with respect to models and analyses used to support the total system performance assessment for the license application (TSPA-LA). A screening decision, either Included or Excluded, is given for each FEP along with the technical basis for exclusion screening decisions. This information is required by the U.S. Nuclear Regulatory Commission (NRC) at 10 CFR 63.114 (d, e, and f) [DIRS 173273]. The FEPs addressed in this report deal with those features, events, and processes relevant to the EBS focusing mainly on those components and conditions exterior to the waste package and within the rock mass surrounding emplacement drifts. The components of the EBS are the drip shield, waste package, waste form, cladding, emplacement pallet, emplacement drift excavated opening (also referred to as drift opening in this report), and invert. FEPs specific to the waste package, cladding, and drip shield are addressed in separate FEP reports: for example, ''Screening of Features, Events, and Processes in Drip Shield and Waste Package Degradation'' (BSC 2005 [DIRS 174995]), ''Clad Degradation--FEPs Screening Arguments (BSC 2004 [DIRS 170019]), and Waste-Form Features, Events, and Processes'' (BSC 2004 [DIRS 170020]). For included FEPs, this report summarizes the implementation of the FEP in the TSPA-LA (i.e., how the FEP is included). For excluded FEPs, this analysis provides the technical basis for exclusion from TSPA-LA (i.e., why the FEP is excluded). This report also documents changes to the EBS FEPs list that have occurred since the previous versions of this report. These changes have resulted due to a reevaluation of the FEPs for TSPA-LA as identified in Section 1.2 of this report and described in more detail in Section 6.1.1. This revision addresses updates in Yucca Mountain Project

  4. Effects of a Mixed Zone on TGO Displacement Instabilities of Thermal Barrier Coatings at High Temperature in Gas-Cooled Fast Reactors

    Directory of Open Access Journals (Sweden)

    Jian Wang

    2016-01-01

    Full Text Available Thermally grown oxide (TGO, commonly pure α-Al2O3, formed on protective coatings acts as an insulation barrier shielding cooled reactors from high temperatures in nuclear energy systems. Mixed zone (MZ oxide often grows at the interface between the alumina layer and top coat in thermal barrier coatings (TBCs at high temperature dwell times accompanied by the formation of alumina. The newly formed MZ destroys interface integrity and significantly affects the displacement instabilities of TGO. In this work, a finite element model based on material property changes was constructed to investigate the effects of MZ on the displacement instabilities of TGO. MZ formation was simulated by gradually changing the metal material properties into MZ upon thermal cycling. Quantitative data show that MZ formation induces an enormous stress in TGO, resulting in a sharp change of displacement compared to the alumina layer. The displacement instability increases with an increase in the MZ growth rate, growth strain, and thickness. Thus, the formation of a MZ accelerates the failure of TBCs, which is in agreement with previous experimental observations. These results provide data for the understanding of TBC failure mechanisms associated with MZ formation and of how to prolong TBC working life.

  5. Residual Stress in TGO and Interfacial Damage in Thermal Barrier Coating after Thermal Exposure and Cyclic Indentation

    Science.gov (United States)

    Zhu, Shijie; Fukuda, Kunihisa; Osaki, Toru

    The local stress distributions in thermally grown oxide (TGO) layer of thermal barrier coating before and after thermal exposure were measured by photo-stimulated luminescence spectrum. The effect of isothermal oxidation on the residual stress in the TGO was investigated. It was found that the compressive stress in the TGO increased with an increase in thermal exposure time up to 100 hours and then decreased. The residual stresses in the TGO were also influenced by interfacial damage introduced by cyclic indentation.

  6. Characterization of functionally graded ZrO2 thermal barrier coatings sprayed by supersonic plasma spray with dual powder feed ports

    Institute of Scientific and Technical Information of China (English)

    HAN Zhi-hai; WANG Hai-jun; ZHOU Shi-kui; XU Bing-shi

    2005-01-01

    The functionally graded thermal barrier coatings (FG-TBCs) with 80 % ZrO2-13 % CeO2-7 % Y2 Os ( CYSZ)/NiCoCrAlY were prepared using a recently developed supersonic plasma spraying(S-PS) with dual powder feed ports system. The thermal shock experiment of FG-TBCs specimens was carried out by means of the automatic thermal cycle device, in which the samples were heated to 1 200 ℃ by oxygen-acetylene flame jet then waterquenched to ambient temperature. The temperature-time curves of specimens and photographs can be watched online and recorded by a computer during the test. The results show that the totally 1 mm-thick FG-TBCs have excellent thermal shock resistance due to the fact that the coatings have no any peeling-off after 200 thermal cycles. The microstructures and morphologies of FG-TBCs were characterized and analyzed by SEM.

  7. A Study on Corrosion Resistance of Coating System on Steel

    Energy Technology Data Exchange (ETDEWEB)

    Nah, Hwan Seon; Lee, Hyeon Ju; Kim, Kang Seok [Korea Electricity Power Research Institute, Daejeon (Korea, Republic of); Lee, Chul Woo [KEPCO E and Co., Yongin (Korea, Republic of)

    2007-04-15

    The design purpose of architectural finish on steel structures is to prevent corrosion in the respect of structural durability, function, beauty and economy. In particular, as structures located on shores is easily degraded due to damage from salt, it is necessary to evaluate the applied coating systems on steel structures. This study is focused on anti-corrosive tests of both steel surfaces and high strength bolts. Two kinds of tests were conducted on each specimen under the condition of outdoor exposure and salt spray comparatively during 760 hours. In case of coating systems on steel surfaces, three layered coating system showed the best function among the various coating systems. Regarding the coating systems on high strength bolts, the coating system composed of zinc dust on hot dip galvanized coating was found to be the best against corrosion.

  8. Experimental investigation of thermal barrier (8YSZ-TiO2-Al2O3 coated piston used in direct injection compression ignition engine

    Directory of Open Access Journals (Sweden)

    Muthusamy Jayaram

    2016-01-01

    Full Text Available Thermal barrier coatings are becoming increasingly important in providing protection from high temperature degradation for heat engine components and allow further increase in engine temperatures for higher efficiency. The main objective of this research work is to experimentally investigate the air plasma sprayed yttria stabilized zirconia with addition of titanium oxide and aluminum oxide thermal barrier coating on Al-13% Si piston material. The mechanical properties of the coated and uncoated samples were comparatively analyzed. The test revealed that hardness values of coated samples are ten times higher than the hardness values of uncoated samples. The microstructure and surface morphology of the coating were evaluated by scanning electron microscopy. The delamination behaviour of thermal barrier coating was evaluated by thermal cycle test. Finally, the performance test of the coated and uncoated engine was evaluated with the same engine operating conditions. The brake thermal efficiency is increased by 5.99%. The brake specific fuel consumption was decreased by 0.06 kg/kWh, in TBC engine with 8YSZ + Al2O3 + TiO2. The CO and HC was greatly decreased in thermal barrier coating engine. There was the greater reduction of NOx is observed due to coating because of nitrogen has absorbed by zirconia.

  9. Optimizing Compliance and Thermal Conductivity of Plasma Sprayed Thermal Barrier Coatings via Controlled Powders and Processing Strategies

    Science.gov (United States)

    Tan, Yang; Srinivasan, Vasudevan; Nakamura, Toshio; Sampath, Sanjay; Bertrand, Pierre; Bertrand, Ghislaine

    2012-09-01

    The properties and performance of plasma-sprayed thermal barrier coatings (TBCs) are strongly dependent on the microstructural defects, which are affected by starting powder morphology and processing conditions. Of particular interest is the use of hollow powders which not only allow for efficient melting of zirconia ceramics but also produce lower conductivity and more compliant coatings. Typical industrial hollow spray powders have an assortment of densities resulting in masking potential advantages of the hollow morphology. In this study, we have conducted process mapping strategies using a novel uniform shell thickness hollow powder to control the defect microstructure and properties. Correlations among coating properties, microstructure, and processing reveal feasibility to produce highly compliant and low conductivity TBC through a combination of optimized feedstock and processing conditions. The results are presented through the framework of process maps establishing correlations among process, microstructure, and properties and providing opportunities for optimization of TBCs.

  10. Advanced neutron and X-ray techniques for insights into the microstructure of EB-PVD thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Kulkarni, Anand [State University of New York, Stony Brook, NY 11794 (United States); Goland, Allen [State University of New York, Stony Brook, NY 11794 (United States); Herman, Herbert [State University of New York, Stony Brook, NY 11794 (United States)]. E-mail: hherman@ms.cc.sunysb.edu; Allen, Andrew J. [National Institute of Standards and Technology, Gaithersburg, MD 20899 (United States); Dobbins, Tabbetha [National Institute of Standards and Technology, Gaithersburg, MD 20899 (United States); DeCarlo, Francesco [Argonne National Laboratory, Argonne, IL 60439 (United States); Ilavsky, Jan [Argonne National Laboratory, Argonne, IL 60439 (United States); Long, Gabrielle G. [Argonne National Laboratory, Argonne, IL 60439 (United States); Fang, Stacy [Chromalloy Gas Turbine Corporation, Orangeburg, NY 10962 (United States); Lawton, Paul [Chromalloy Gas Turbine Corporation, Orangeburg, NY 10962 (United States)

    2006-06-25

    The ongoing quest to increase gas turbine efficiency and performance (increased thrust) provides a driving force for materials development. While improved engine design and usage of novel materials provide solutions for increased engine operating temperatures, and hence fuel efficiency, reliability issues remain. Thermal barrier coatings (TBCs), deposited onto turbine components using the electron-beam physical vapor deposition (EB-PVD) process, exhibit unique pore architectures capable of bridging the technological gap between insulation/life extension and prime reliance. This article explores the potential of advanced X-ray and neutron techniques for comprehension of an EB-PVD TBC coating microstructure. While conventional microscopy reveals a hierarchy of voids, complementary advanced techniques allow quantification of these voids in terms of component porosities, anisotropy, size and gradient through the coating thickness. In addition, the derived microstructural parameters obtained both further knowledge of the nature and architecture of the porosity, and help establish its influence on the resultant thermal and mechanical properties.

  11. Microstructural characterization of electron beam-physical vapor deposition thermal barrier coatings through high-resolution computed microtomography

    Science.gov (United States)

    Kulkarni, Anand; Herman, Herbert; Decarlo, Francesco; Subramanian, Ramesh

    2004-07-01

    Thermal barrier coatings (TBCs), deposited using the electron beam-physical vapor deposition (EB-PVD) process, comprise a unique architecture of porosity capable of bridging the technological gap between insulation/life extension and prime reliance. The TBC microstructures consist of columnar structure, nucleated via vapor condensation, along with a high degree of intercolumnar porosity, thus providing enhanced stress relief on thermomechanical loading and also accommodating misfit stresses resulting from CTE mismatch. In this article, we report the characterization of these coatings using high-resolution synchrotron-based X-ray computed microtomography (XMT) at 1.3- µm resolution. Experiments focused on quantitative characterization/visualization of imperfections in these coatings and on the relative changes in microstructural features upon isothermal annealing. The influence of time/temperature of exposure was investigated and the results were correlated with elastic modulus.

  12. High Temperature Thermal Properties of Columnar Yttria Stabilized Zirconia Thermal Barrier Coating Performed by Suspension Plasma Spraying

    Science.gov (United States)

    Bernard, B.; Schick, V.; Remy, B.; Quet, A.; Bianchi, L.

    2016-09-01

    Performance enhancement of gas turbines is a main issue for the aircraft industry. Over many years, a large part of the effort has been focused on the development of more insulating Thermal Barrier Coatings (TBCs). In this study, Yttria Stabilized Zirconia (YSZ) columnar structures are processed by Suspension Plasma Spraying (SPS). These structures have already demonstrated abilities to get improved thermal lifetime, similarly to standard YSZ TBCs performed by EB-PVD. Thermal diffusivity measurements coupled with differential scanning calorimetry analysis are performed from room temperature up to 1100 °C, first, on HastelloyX substrates and then, on bilayers including a SPS YSZ coating. Results show an effective thermal conductivity for YSZ performed by SPS lower than 1 W.m-1K-1 whereas EB- PVD YSZ coatings exhibit a value of 1.5 W.m-1K-1.

  13. Research on ZrO2 Thermal Barrier Coatings Modified by High-Intensity Pulsed Ion Beam

    Institute of Scientific and Technical Information of China (English)

    WV Di; LIU Chen; ZHU Xiao-Peng; LEI Ming-Kai

    2008-01-01

    @@ We report a modification method for ZrO2 thermal barrier coatings (TBCs) by high-intensity pulsed ion beam (HIPIB) irradiation. Based on the temporal and spatial distribution models of the ion beam density detected by Faraday cup in the chamber and the ions accelerating voltage, the energy deposition of the beam ions in ZrO2 is calculated by Monte Carlo method. Taking this time-dependent nonlinear deposited energy as the source term of two-dimensional thermal conduction equation, we obtain the temporal and spatial ablation process of ZrO2 thermal barrier coatings during a pulse time. The top-layer TBC material in thickness of about 0.2μm is ablated by vaporization and the coating in thickness of 1 μm is melted after one shot at the ion current density of 200 A/cm2. This calculation is in reasonable agreement with those measured by HIPIB irradiation experiments.The melted top coat becoming a dense modification layer due to HIPIB irradiation seals the gaps among ZrO2crystal clusters, and hence barrels the direct tunnel of oxygen.

  14. Overlay metallic-cermet alloy coating systems

    Science.gov (United States)

    Gedwill, M. A.; Levine, S. R.; Glasgow, T. K. (Inventor)

    1984-01-01

    A substrate, such as a turbine blade, vane, or the like, which is subjected to high temperature use is coated with a base coating of an oxide dispersed, metallic alloy (cermet). A top coating of an oxidation, hot corrosion, erosion resistant alloy of nickel, cobalt, or iron is then deposited on the base coating. A heat treatment is used to improve the bonding. The base coating serves as an inhibitor to interdiffusion between the protective top coating and the substrate. Otherwise, the protective top coating would rapidly interact detrimentally with the substrate and degrade by spalling of the protective oxides formed on the outer surface at elevated temperatures.

  15. John H. Chafee Coastal Barrier Resources System Approximate Polygons

    Data.gov (United States)

    US Fish and Wildlife Service, Department of the Interior — This Coastal Barrier Resources System (CBRS) data set, produced by the U.S. Fish and Wildlife Service (Service), contains areas designated as undeveloped coastal...

  16. Sol-gel coatings as active barriers to protect ceramic reinforcement in aluminum matrix composites

    Energy Technology Data Exchange (ETDEWEB)

    Rams, J.; Urena, A.; Campo, M. [Departamento de Tecnologia Quimica, Ambiental y de los Materiales, ESCET, Universidad Rey Juan Carlos C/ Tulipan s/nMostoles 28933 Madrid (Spain)

    2004-02-01

    Silica obtained through a sol-gel process is used as a coating for ceramic reinforcements (SiC) in aluminium matrix composite materials. The interaction between molten aluminium and the coated particles during material casting can be controlled by means of the thermal treatment given to the coating. Wettability is increased because the coating reacts with molten aluminium, and the formation of the degrading aluminium carbide is inhibited. (Abstract Copyright [2004], Wiley Periodicals, Inc.)

  17. A synchrotron X-ray diffraction deconvolution method for the measurement of residual stress in thermal barrier coatings as a function of depth.

    Science.gov (United States)

    Li, C; Jacques, S D M; Chen, Y; Daisenberger, D; Xiao, P; Markocsan, N; Nylen, P; Cernik, R J

    2016-12-01

    The average residual stress distribution as a function of depth in an air plasma-sprayed yttria stabilized zirconia top coat used in thermal barrier coating (TBC) systems was measured using synchrotron radiation X-ray diffraction in reflection geometry on station I15 at Diamond Light Source, UK, employing a series of incidence angles. The stress values were calculated from data deconvoluted from diffraction patterns collected at increasing depths. The stress was found to be compressive through the thickness of the TBC and a fluctuation in the trend of the stress profile was indicated in some samples. Typically this fluctuation was observed to increase from the surface to the middle of the coating, decrease a little and then increase again towards the interface. The stress at the interface region was observed to be around 300 MPa, which agrees well with the reported values. The trend of the observed residual stress was found to be related to the crack distribution in the samples, in particular a large crack propagating from the middle of the coating. The method shows promise for the development of a nondestructive test for as-manufactured samples.

  18. Combined Experimental and Numerical Simulations of Thermal Barrier Coated Turbine Blades Erosion

    Science.gov (United States)

    Hamed, Awate; Tabakoff, Widen; Swar, Rohan; Shin, Dongyun; Woggon, Nthanial; Miller, Robert

    2013-01-01

    A combined experimental and computational study was conducted to investigate the erosion of thermal barrier coated (TBC) blade surfaces by alumina particles ingestion in a single stage turbine. In the experimental investigation, tests of particle surface interactions were performed in specially designed tunnels to determine the erosion rates and particle restitution characteristics under different impact conditions. The experimental results show that the erosion rates increase with increased impingement angle, impact velocity and temperature. In the computational simulations, an Euler-Lagrangian two stage approach is used in obtaining numerical solutions to the three-dimensional compressible Reynolds Averaged Navier-Stokes equations and the particles equations of motion in each blade passage reference frame. User defined functions (UDF) were developed to represent experimentally-based correlations for particle surface interaction models which were employed in the three-dimensional particle trajectory simulations to determine the particle rebound characteristics after each surface impact. The experimentally based erosion UDF model was used to predict the TBC erosion rates on the turbine blade surfaces based on the computed statistical data of the particles impact locations, velocities and angles relative to the blade surface. Computational results are presented for the predicted TBC blade erosion in a single stage commercial APU turbine, for a NASA designed automotive turbine, and for the NASA turbine scaled for modern rotorcraft operating conditions. The erosion patterns in the turbines are discussed for uniform particle ingestion and for particle ingestion concentrated in the inner and outer 5 percent of the stator blade span representing the flow cooling the combustor liner.

  19. Analyses on the U-Mo/Al Chemical Interaction and the Effects of Diffusion Barrier Coatings

    Energy Technology Data Exchange (ETDEWEB)

    Ryu, Ho Jin; Kim, Woo Jeong; Cho, Woo Hyung; Jeong, Yong Jin; Lee, Yoon Sang; Park, Jong Man; Kim, Chang Kyu [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of)

    2012-05-15

    While many HEU-fueled research reactors have been converted by adopting LEU U{sub 3}Si{sub 2} fuel in harmony with the Reduced Enrichment for Research and Test Reactors (RERTR) program, some high performance research reactors still need the development of advanced fuels with higher uranium densities. Currently, gamma-phase U-Mo alloys are considered promising candidates to be used as high uranium density fuel for the high performance reactors. For the production of UMo alloy powder, the centrifugal atomization technology developed by KAERI has been considered the most promising way because of high yield production and excellent powder quality when compared with other possible methods such as grinding, machining or hydriding-dehydriding. However, severe pore formation associated with an extensive interaction between the U-Mo and Al matrix, although the irradiation performance of U-Mo itself showed most stable, delay the fuel qualification of UMo fuel for high performance research reactors. Because the reaction products, i.e. uranium aluminides (UAlx), is less dense than the mixed reactants, the volume of the fuel meat increases after formation of interaction layer(IL). In addition to the impact on the swelling performance, the reaction layers between the U-Mo and Al matrix induces a degradation of the thermal conductivities of the U-Mo/Al dispersion fuels. The chemical interaction between the U-Mo and Al matrix are analyzed in this study to find remedies to reduce the growth of the interaction layers during irradiation. In addition, various coating technologies for the formation of diffusion barriers on U-Mo particles are proposed as a result of the analyses

  20. Influence of deposition conditions on the microstructure of Al-based coatings for applications as corrosion and anti-permeation barrier

    Energy Technology Data Exchange (ETDEWEB)

    Wulf, Sven-Erik, E-mail: sven-erik.wulf@kit.edu; Holstein, Nils; Krauss, Wolfgang; Konys, Jürgen

    2013-10-15

    Highlights: • Electrochemical Al deposition is industrially relevant for barrier formation. • Al coatings have to be converted into protective layers by heat treatments. • Morphology of Al coatings made by ECX process depends on deposition parameters. • Heat treatment behavior depends on the morphology of the coating produced by ECX. • ECX is proven to produce layer sequences on Eurofer similar to HDA and ECA process. -- Abstract: Previous research revealed that the application of aluminum-based barriers is suitable to minimize corrosion rates of Eurofer steel in Pb–15.7Li and tritium-permeation from the liquid breeder into the cooling system (HCLL) in an envisaged future fusion reactor. Besides the former developed hot-dip-aluminization process (HDA), electrodeposition techniques based on water-free electrolytes, such as toluene-based electrolytes (ECA) and ionic liquids (ECX), showed promising results for the production of suitable aluminum layers. These processes allow electrodeposition of Al-layers on Eurofer steel with adjustable layer thicknesses, but a heat treatment procedure is needed afterwards to form the desired Fe–Al/Alumina scale. To investigate the deposition and treatment process in more detail, a new series of aluminum electroplating was performed by using the ECX process. The variation of deposition parameters (direct and pulsed current) showed clear impact on the morphology of deposited Al-layers. Heat treatments revealed that the formation of Fe–Al barriers is significantly influenced by the morphology of deposits, beyond other parameters like layer thickness. Presented metallographic and SEM/EDX analyses underline the occurred dependencies between deposition conditions and morphology and on the other hand Al-layer morphology and heat treatment behavior.

  1. Tritium permeation characterization of Al2O3/FeAl coatings as tritium permeation barriers on 321 type stainless steel containers

    Science.gov (United States)

    Yang, Feilong; Xiang, Xin; Lu, Guangda; Zhang, Guikai; Tang, Tao; Shi, Yan; Wang, Xiaolin

    2016-09-01

    Accurate tritium transport properties of prospective tritium permeation barriers (TPBs) are essential to tritium systems in fusion reactors. By passing a temperature and rate-controlled sweeping gas over specimen surfaces to carry the permeated tritium to an ion chamber, the gas-driven permeation of tritium has been performed on 321 type stainless steel containers with Al2O3/FeAl barriers, to determine the T-permeation resistant performance and mechanism of the barrier. The tritium permeability of the Al2O3/FeAl coated container was reduced by 3 orders of magnitude at 500-700 °C by contrast with that of the bare one, which meets the requirement of the tritium permeation reduction factor (PRF) of TPBs for tritium operating components in the CN-HCCB TBM. The Al2O3/FeAl barrier resists the tritium permeation by the diffusion in the bulk substrate at a limited number of defect sites with an effective area and thickness, suggesting that the TPB quality is a very important factor for efficient T-permeation resistance.

  2. Detection of segmentation cracks in top coat of thermal barrier coatings during plasma spraying by non-contact acoustic emission method.

    Science.gov (United States)

    Ito, Kaita; Kuriki, Hitoshi; Araki, Hiroshi; Kuroda, Seiji; Enoki, Manabu

    2014-06-01

    Numerous cracks can be observed in the top coat of thermal barrier coatings (TBCs) deposited by the atmospheric plasma spraying (APS) method. These cracks can be classified into vertical and horizontal ones and they have opposite impact on the properties of TBCs. Vertical cracks reduce the residual stress in the top coat and provide strain tolerance. On the contrary, horizontal cracks trigger delamination of the top coat. However, monitoring methods of cracks generation during APS are rare even though they are strongly desired. Therefore, an in situ, non-contact and non-destructive evaluation method for this objective was developed in this study with the laser acoustic emission (AE) technique by using laser interferometers as a sensor. More AE events could be detected by introducing an improved noise reduction filter and AE event detection procedures with multiple thresholds. Generation of vertical cracks was successfully separated from horizontal cracks by a newly introduced scanning pattern of a plasma torch. Thus, generation of vertical cracks was detected with certainty by this monitoring method because AE events were detected only during spraying and a positive correlation was observed between the development degree of vertical cracks and the total AE energy in one experiment.

  3. The Improvement of Oxidation Resistance of a Re-Based Diffusion Barrier/Ni–Al Coating on the Single-Crystal Ni-Based TMS-82+ Superalloy

    NARCIS (Netherlands)

    Wu, Y.; Wang, Y.M.; Song, G.M.; Li, X.W.

    2011-01-01

    Oxidation behavior of a Re-based diffusion barrier/Ni–Al coated single-crystal (SC) Ni-based TMS-82+ superalloy was studied to compare with those of the base and Ni–Al coated superalloys under cyclic air at 1150 °C for 200 h. The base superalloy showed a negative mass gain due to extensive oxide spa

  4. Hot Corrosion Behavior of Double-ceramic-layer LaTi2Al9O19/YSZ Thermal Barrier Coatings

    Institute of Scientific and Technical Information of China (English)

    XIE Xiaoyun; GUO Hongbo; GONG Shengkai; XU Huibin

    2012-01-01

    LaTi2Al9O19 (LTA) exhibits promising potential as a new kind of thermal barrier coating (TBC) material,due to its excellent high-temperature capability and low thermal conductivity.In this paper,LTA/yttria stabilized zirconia (YSZ) TBCs are produccd by atmospheric plasma spraying.Hot corrosion behavior and the related failure mechanism of the coating are investigated.Decomposition of LTA does not occur even after 1 458 hot corrosion cycles at 1 373 K,revealing good chemical stability in molten salt of Na2SO4 and NaCl.However,the molten salt infiltrates to the bond coat,causing dissolving of the thermally grown oxide (TGO) in the molten salt and hot corrosion of the bond coat.As a result,cracking of the TBC occurs within the oxide layer.In conclusion,the ceranic materials LTA and YSZ reveal good chemical stability in molten salts of Na2SO4 and NaCl,and the bond coat plays a significant role in providing protection for the component against hot corrosion in the LTA/YSZ TBCs.LTA exhibits very promising potential as a novel TBC material.

  5. Experimental Study on the Machining of Inclined Holes for Thermal Barrier-Coated Nickel Superalloys by EDM

    Science.gov (United States)

    Zhang, Guowei; Guo, Yongfeng; Wang, Li

    2016-10-01

    Thermal barrier coatings (TBCs) are used to thermally insulate superalloy components from the hot gas streams in gas turbine engines. In this work, electrical discharge machining (EDM) was used to machine different inclined holes in TBC-coated nickel superalloys by integrating the inner-jet-liquid rotating electrode method and the assisting electrode method. The influences of the inclination angle (i.e., from 0° to 60°) and EDM parameters (i.e., peak current, pulse duration, duty factor and flushing pressure) on the machining time and electrode wear were investigated. The surface morphologies and elemental distribution were analyzed using a scanning electron microscope and an energy dispersive spectroscope. The results of the analysis showed that the 8YSZ ceramic coating is more prone to brittle fracture and cracking than the IN718 substrate and NiCoAlY bond coating, and pits and cracks become more pronounced as the inclination angle increases. The damage on the trailing edge is primarily caused by the thermal stress fracture, and the damage on the leading edge is mainly caused by thermal erosion. Using high-energy parameters, a delamination with dimensions of 28 μm (W) × 200 μm (L) occurs on the trailing edges of the coating/substrate interface.

  6. Furnace Cyclic Behavior of Plasma-Sprayed Zirconia-Yttria and Multi-Component Rare Earth Oxide Doped Thermal Barrier Coatings

    Science.gov (United States)

    Zhu, Dongming; Nesbitt, James A.; McCue, Terry R.; Barrett, Charles A.; Miller, Robert A.

    2002-01-01

    Ceramic thermal barrier coatings will play an increasingly important role in advanced gas turbine engines because of their ability to enable further increases in engine temperatures. However, the coating performance and durability become a major concern under the increasingly harsh thermal cycling conditions. Advanced zirconia- and hafnia-based cluster oxide thermal barrier coatings with lower thermal conductivity and improved thermal stability are being developed using a high-heat-flux laser-rig based test approach. Although the new composition coatings were not yet optimized for cyclic durability, an initial durability screening of numerous candidate coating materials was carried out using conventional furnace cyclic tests. In this paper, furnace thermal cyclic behavior of the advanced plasma-sprayed zirconia-yttria-based thermal barrier coatings that were co-doped with multi-component rare earth oxides was investigated at 1163 C using 45 min hot cycles. The ceramic coating failure mechanisms were studied by using scanning electron microscopy combined with X-ray diffraction phase analysis after the furnace tests. The coating cyclic lifetime will be discussed in relation to coating phase structures, total dopant concentrations, and other properties.

  7. Degradation of thermal barrier coatings on an Integrated Gasification Combined Cycle (IGCC) simulated film-cooled turbine vane pressure surface due to particulate fly ash deposition

    Science.gov (United States)

    Luo, Kevin

    Coal synthesis gas (syngas) can introduce contaminants into the flow of an Integrated Gasification Combined Cycle (IGCC) industrial gas turbine which can form molten deposits onto components of the first stage of a turbine. Research is being conducted at West Virginia University (WVU) to study the effects of particulate deposition on thermal barrier coatings (TBC) employed on the airfoils of an IGCC turbine hot section. WVU had been working with U.S. Department of Energy, National Energy Technology Laboratory (NETL) to simulate deposition on the pressure side of an IGCC turbine first stage vane to study the effects on film cooling. To simulate the particulate deposition, TBC coated, angled film-cooled test articles were subjected to accelerated deposition injected into the flow of a combustor facility with a pressure of approximately 4 atm and a gas temperature of 1560 K. The particle characteristics between engine conditions and laboratory are matched using the Stokes number and particulate loading. To investigate the degradation on the TBC from the particulate deposition, non-destructive evaluations were performed using a load-based multiple-partial unloading micro-indentation technique and were followed by scanning electron microscopy (SEM) evaluation and energy dispersive X-ray spectroscopy (EDS) examinations. The micro-indentation technique used in the study was developed by Kang et al. and can quantitatively evaluate the mechanical properties of materials. The indentation results found that the Young's Modulus of the ceramic top coat is higher in areas with deposition formation due to the penetration of the fly ash. The increase in the modulus of elasticity has been shown to result in a reduction of strain tolerance of the 7% yttria-stabilized zirconia (7YSZ) TBC coatings. The increase in the Young's modulus of the ceramic top coat is due to the stiffening of the YSZ columnar microstructure from the cooled particulate fly ash. SEM evaluation was used to

  8. The role of plants on isolation barrier systems

    Energy Technology Data Exchange (ETDEWEB)

    Link, S.O.; Downs, J.L. [Pacific Northwest Lab., Richland, WA (United States); Waugh, W.J. [UNC Chem-Nuclear Geotech, Grand Junction, CO (United States)

    1994-11-01

    Surface barriers are used to isolate buried wastes from the environment. Most have been built for short-term isolation. The need to isolate radioactive wastes from the environment requires that the functional integrity of a barrier be maintained for thousands of years. Barrier function strongly depends on vegetation. Plants reduce wind and water erosion and minimize drainage, but may transport contaminants if roots extend into buried wastes. Our review of the function of plants on surface barriers focuses on the role of plants across mesic to arid environments and gives special consideration to studies done at Hanford. The Hanford Barrier Development Program was created to design and test an earthen cover system to inhibit water infiltration, plant and animal intrusion, and wind and water erosion, while isolating buried wastes for at least 1000 years. Studies at the Hanford have shown that plants will significantly interact with the barrier. Plants transpire soil water back into the atmosphere. Deep-rooted perennials best recycle water; soil water may drain through the root zone of shallow-rooted annuals. Lysimeter studies indicate that a surface layer of fine soil with deep-rooted plants precludes drainage even with three times normal precipitation. The presence of vegetation greatly reduces water and wind erosion, but deep-rooted plants pose a threat of biointrusion and contaminant transport. The Hanford barrier includes a buried rock layer and asphalt layer to prevent biointrusion.

  9. Influence of Annealing on the Grain Growth and Thermal Diffusivity of Nanostructured YSZ Thermal Barrier Coating

    Institute of Scientific and Technical Information of China (English)

    Na WANG; Chungen ZHOU; Shengkai GONG; Huibin XU

    2006-01-01

    The nanostructured zirconia coatings were deposited by atmospherically plasma spraying. Scanning electron microscopy (SEM), transmission electron microscopy (TEM) and X-ray diffraction were used to investigate the microstructure of the zirconia coatings. Thermal diffusivity values at normal temperatures have been evaluated by laser flash technique. Effect of annealing on the microstructure evolution of the zirconia coating has been performed. The grains and thermal diffusivity are increased with increasing annealing time and temperature.The grain growth is according to the GRIGC (the grain rotation induced grain coalescence) mechanism. The increase in thermal diffusivity is attributed to the grain growth and the decrease in porosity of nanostructured zirconia coatings.

  10. A graphene-oxide-based thin coating on the separator: an efficient barrier towards high-stable lithium-sulfur batteries

    Science.gov (United States)

    Zhang, Yunbo; Miao, Lixiao; Ning, Jing; Xiao, Zhichang; Hao, Long; Wang, Bin; Zhi, Linjie

    2015-06-01

    The electrochemical performance of lithium-sulfur (Li-S) batteries can be significantly improved by simply coating a thin barrier layer on the separator. The spray-coating of a mixture of graphene oxides (GO) and oxidized carbon nanotubes (o-CNT) can achieve a barrier coating of only 0.3 mg cm-2, which is much less than conventional interlayers and has no negative impact on the energy density but significantly enhances the electrochemical performances of the whole battery device. Due to the binding forces induced by functional groups on GO and the interconnected nanoscale channels provided by o-CNT, the thus fabricated Li-S batteries show dramatically improved specific discharge capacities of up to 750 mAh g-1 at 1 C even after 100 cycles, more than twice those of batteries without barrier coatings.

  11. Thermal cycling damage evolution of a thermal barrier coating and the influence of substrate creep, interface roughness and pre-oxidation

    Energy Technology Data Exchange (ETDEWEB)

    Schweda, Mario; Beck, Tilmann; Singheiser, Lorenz [Forschungszentrum Juelich GmbH (DE). Inst. fuer Energie- und Klimaforschung (IEK), Werkstoffstruktur und Eigenschaften (IEK-2)

    2012-01-15

    The influence of roughness profile shape, roughness depth, bond coat creep strength and pre-oxidation on the thermal cycling damage evolution and lifetime of a plasma-sprayed ZrO{sub 2} thermal barrier coating system was investigated. A simplified model system was used where FeCrAlY substrates simulated the bond coat. Substrate creep was varied by using the oxide dispersoid strengthened alloy MA956 and the conventional material Fecralloy. Stochastic 3- and periodic 2-dimensional roughness profiles were produced by sand blasting and high speed turning. Damage evolution is significantly influenced by substrate creep with a trend to higher lifetimes for the fast creeping substrate. Pre-oxidation has no influence. Lifetimes of the periodically profiled samples are up to 100 times lower than these of stochastically profiled samples. In the case of periodically profiled samples, the highest lifetime was reached for the highest roughness depth combined with local undercuttings in the roughness profile. For stochastically profiled samples the influence of roughness depth could not be determined due to the wide lifetime scatter. (orig.)

  12. Degradation and Failure Characteristics of NPP Containment Protective Coating Systems

    Energy Technology Data Exchange (ETDEWEB)

    Sindelar, R.L.

    2001-02-22

    A research program to investigate the performance and potential for debris formation of Service Level I coating systems used in nuclear power plant containment is being performed at the Savannah River Technology Center. The research activities are aligned to address phenomena important to cause coating disbondment as identified by the Industry Coatings Expert Panel. The period of interest for performance covers the time from application of the coating through 40 years of service, followed by a medium-to-large break loss-of-coolant accident scenario, which is a design basis accident (DBA) scenario. The interactive program elements are described in this report and the application of these elements to evaluate the performance of the specific coating system of Phenoline 305 epoxy-phenolic topcoat over Carbozinc 11 primer on a steel substrate. This system is one of the predominant coating systems present on steel substrates in NPP containment.

  13. Subsurface barrier validation with the SEAtrace{trademark} system

    Energy Technology Data Exchange (ETDEWEB)

    Sandra Dalvit Dunn; William Lowry; Veraun Chipman

    1999-09-01

    Under contract to the Department of Energy, Science and Engineering Associates has completed development and testing of a subsurface barrier verification and monitoring system. This system, called SEAtrace{trademark}, is able to locate and size leaks with a high degree of accuracy in subsurface barriers that are emplaced in an unsaturated medium. It uses gaseous tracer injection, in-field real-time monitoring, and real time data analysis to evaluate barrier integrity. The approach is: Conservative as it measures vapor leaks in a containment system whose greatest risk is posed by liquid leaks; Applicable to any impermeable type of barrier emplacement technology in the unsaturated zone; Inexpensive as it uses readily available, non-toxic, nonhazardous gaseous tracers, does not require an inordinately large number of sampling points, and injection and sampling points can be emplaced by direct push techniques; Capable of assessing not only a barrier's initial integrity, but can also provide long-term monitoring. To date, six demonstrations of the system have been completed. Results from two of the demonstrations are detailed in this report. They include the final developmental demonstration of the SEAtrace system and a comparison demonstration of two tracer based verification technologies. The final developmental demonstration of SEAtrace was completed at a naval facility in Brunswick, Maine. The demonstration was funded solely by the DOE and was performed in cooperation with the US Navy, the Environmental Protection Agency, and the Maine Department of Environmental Protection.

  14. Low Thermal Conductivity Yttria-Stabilized Zirconia Thermal Barrier Coatings Using the Solution Precursor Plasma Spray Process

    Science.gov (United States)

    Jordan, Eric H.; Jiang, Chen; Roth, Jeffrey; Gell, Maurice

    2014-06-01

    The primary function of thermal barrier coatings (TBCs) is to insulate the underlying metal from high temperature gases in gas turbine engines. As a consequence, low thermal conductivity and high durability are the primary properties of interest. In this work, the solution precursor plasma spray (SPPS) process was used to create layered porosity, called inter-pass boundaries, in yttria-stabilized zirconia (YSZ) TBCs. IPBs have been shown to be effective in reducing thermal conductivity. Optimization of the IPB microstructure by the SPPS process produced YSZ TBCs with a thermal conductivity of 0.6 W/mK, an approximately 50% reduction compared to standard air plasma sprayed (APS) coatings. In preliminary tests, SPPS YSZ with IPBs exhibited equal or greater furnace thermal cycles and erosion resistance compared to regular SPPS and commercially made APS YSZ TBCs.

  15. Thin film deposition at atmospheric pressure using dielectric barrier discharges: Advances on three-dimensional porous substrates and functional coatings

    Science.gov (United States)

    Fanelli, Fiorenza; Bosso, Piera; Mastrangelo, Anna Maria; Fracassi, Francesco

    2016-07-01

    Surface processing of materials by atmospheric pressure dielectric barrier discharges (DBDs) has experienced significant growth in recent years. Considerable research efforts have been directed for instance to develop a large variety of processes which exploit different DBD electrode geometries for the direct and remote deposition of thin films from precursors in gas, vapor and aerosol form. This article briefly reviews our recent progress in thin film deposition by DBDs with particular focus on process optimization. The following examples are provided: (i) the plasma-enhanced chemical vapor deposition of thin films on an open-cell foam accomplished by igniting the DBD throughout the entire three-dimensional (3D) porous structure of the substrate, (ii) the preparation of hybrid organic/inorganic nanocomposite coatings using an aerosol-assisted process, (iii) the DBD jet deposition of coatings containing carboxylic acid groups and the improvement of their chemical and morphological stability upon immersion in water.

  16. Revestimentos cerâmicos utilizados como barreira térmica Ceramic coatings used as thermal barrier

    Directory of Open Access Journals (Sweden)

    J. P. Oliveira

    2013-03-01

    Full Text Available Neste trabalho procurou-se fazer uma introdução aos revestimentos de barreira térmica cerâmicos, em especial à utilização deste tipo de materiais na camada top coat, apresentando as suas propriedades fundamentais. Posteriormente apresentam-se os novos materiais que podem vir a substituir a zircónia parcialmente estabilizada com ítria, sendo este o material mais utilizado para desempenhar esta função. Neste trabalho, também se faz uma descrição sumária dos métodos de processamento de cada material que foram abordados neste trabalho. E por fim apresenta-se uma tabela com algumas das propriedades termo-físicas mais importantes para os materiais analisados.In this work we started by doing a introduction to the ceramic thermal barrier coatings, especially in the utilization of this kind of material as top coat by presenting its fundamental properties. After we present new materials that may replace zirconia partially stabilized with yttria (PSZ, being this last material the most used as top coat. In this work, we also make a brief description of the processing methods for each material analyzed in this article. Last we present a table when some of the most important thermal-physical properties of the materials studied.

  17. Reactive coating of soybean oil-based polymer on nanofibrillated cellulose film for water vapor barrier packaging.

    Science.gov (United States)

    Lu, Peng; Xiao, Huining; Zhang, Weiwei; Gong, Glen

    2014-10-13

    Nanofibrillated cellulose (NFC) easily forms a high strength film but is unable to withstand the influence of water vapor when used in high moisture situations. The water vapor transmission rate (WVTR) of a NFC film was as high as 5088 g/m(2)24h (38 °C, 90% RH). The addition of beeswax latex in a NFC casting film (NFX) lowered the WVTR to 3918 g/m(2)24h. To further reduce the WVTR, a coating agent comprised of acrylated epoxidized soybean oil (AESO) and 3-aminopropyltriethoxysilane (APTS) was applied onto the NFX film using a rod coater. A combination of the suitable AESO/APTS ratio, initiator dosing, curing time and temperature could reduce the WVTR to 188 g/m(2) 24h when the coat weight was 5 g/m(2). Moreover, the coated NFX film was highly hydrophobic along with the improved transparency and thermal stability. This biodegradable polymer-coated NFC film can be used as potential packaging barrier in certain areas.

  18. Thermal Cycling Behavior of Thermal Barrier Coatings with MCrAlY Bond Coat Irradiated by High-Current Pulsed Electron Beam.

    Science.gov (United States)

    Cai, Jie; Lv, Peng; Guan, Qingfeng; Xu, Xiaojing; Lu, Jinzhong; Wang, Zhiping; Han, Zhiyong

    2016-11-30

    Microstructural modifications of a thermally sprayed MCrAlY bond coat subjected to high-current pulsed electron beam (HCPEB) and their relationships with thermal cycling behavior of thermal barrier coatings (TBCs) were investigated. Microstructural observations revealed that the rough surface of air plasma spraying (APS) samples was significantly remelted and replaced by many interconnected bulged nodules after HCPEB irradiation. Meanwhile, the parallel columnar grains with growth direction perpendicular to the coating surface were observed inside these bulged nodules. Substantial Y-rich Al2O3 bubbles and varieties of nanocrystallines were distributed evenly on the top of the modified layer. A physical model was proposed to describe the evaporation-condensation mechanism taking place at the irradiated surface for generating such surface morphologies. The results of thermal cycling test showed that HCPEB-TBCs presented higher thermal cycling resistance, the spalling area of which after 200 cycles accounted for only 1% of its total area, while it was about 34% for APS-TBCs. The resulting failure mode, i.e., in particular, a mixed delamination crack path, was shown and discussed. The irradiated effects including compact remelted surface, abundant nanoparticles, refined columnar grains, Y-rich alumina bubbles, and deformation structures contributed to the formation of a stable, continuous, slow-growing, and uniform thermally grown oxide with strong adherent ability. It appeared to be responsible for releasing stress and changing the cracking paths, and ultimately greatly improving the thermal cycling behavior of HCPEB-TBCs.

  19. Investigation on the preparation of Si/mullite/Yb_2Si_2O_7 environmental barrier coatings onto silicon carbide

    Institute of Scientific and Technical Information of China (English)

    许越; 闫钊通

    2010-01-01

    With the development of aero-engine,gas import temperatures of hot section structural materials are increasingly higher.Metal alloy materials due to the rapidly decreased mechanical properties at relative high temperature are gradually replaced with silicon-based non-oxide silicon carbide ceramics.However,silicon carbide ceramic materials tend to spall and deform in engine combustion environment,need environmental barrier coatings for the protection of the matrix.The preparation of Si/mullite/Yb2Si2O7 envir...

  20. Microstructural Evolution and interfacial motion in systems with diffusion barriers

    Energy Technology Data Exchange (ETDEWEB)

    Perry H. Leo

    2009-03-05

    This research program was designed to model and simulate phase transformations in systems containing diffusion barriers. The modeling work included mass flow, phase formation, and microstructural evolution in interdiffusing systems. Simulation work was done by developing Cahn-Hilliard and phase field equations governing both the temporal and spatial evolution of the composition and deformation fields and other important phase variables.

  1. The Effects of Thermal Barrier Coatings on Diesel Engine Performance and Emission

    Science.gov (United States)

    Das, D.; Majumdar, G.; Sen, R. S.; Ghosh, B. B.

    2014-01-01

    The purpose of this paper is to determine the effect of coating thickness on performance and emission of a diesel engine including comparisons with results from an uncoated piston diesel engine. Primarily three piston crowns were coated with Al2O3 (bond coat) of 100 μm thickness each by using Plasma spray coating technique. Then these piston crowns were coated with partially stabilized zirconia with a thickness of 250, 350, 450 μm respectively by using the same technique over the bond coat. These pistons inserted into the cylinder of a diesel engine one by one to collect the combustion and emission data. Then these data were compared with standard diesel engine. It was observed that the thermal efficiency increased with increasing load levels, whereas specific fuel consumption reduced with increasing load. However, it was observed that harmful gases and particulates like CO, smoke and HC were reduced in case of all types of coated piston engine with the increase of load. Increased amount of NOX emission was reported during the experimentation.

  2. Application of thermal barrier coating for improving the suitability of Annona biodiesel in a diesel engine

    Directory of Open Access Journals (Sweden)

    Ramalingam Senthil

    2016-01-01

    Full Text Available The Annona biodiesel was produced from Annona oil through transesterification process. The aim of the present study is to analyze the performance and emission characteristics of a single cylinder, direct injection, compression ignition engine using a annona methyl ester as a fuel. They are blended together with the Neat diesel fuel such as 20%, 40%, 60%, 80%, and Neat biodiesel. The performance, emission and combustion characteristics are evaluated by operating the engine at different loads. The performance parameters such as brake thermal efficiency, brake specific fuel consumption. The emission constituents such as carbon monoxide, unburned hydrocarbons, oxides of nitrogen, and smoke were recorded. Then the piston and both exhaust and intake valves of the test engine were coated with 100 µm of NiCrAl as lining layer. Later the same parts were coated with 400 µm material of coating that was the mixture of 88% of ZrO2, 4% of MgO, and 8% of Al2O3. After the engine coating process, the same fuels is tested in the engine at the same engine operation. The same performance and emission parameters were evaluated. Finally, these parameters are compared with uncoated engine in order to find out the changes in the performance and emission parameters of the coated engine. It is concluded that the coating engine resulting in better performance, especially in considerably lower brake specific fuel consumption values. The engine emissions are lowered both through coating and annona methyl ester biodiesel expect the nitrogen oxides emission.

  3. Advances in PSII Deposited Diamond-Like Carbon Coatings for Use as a Barrier to Corrosion

    Energy Technology Data Exchange (ETDEWEB)

    Lillard, R.S.; Butt, D.P.; Baker, N.P.; Walter, K.C.; Nastasi, M.

    1998-10-01

    Plasma source ion implantation (PSII) is a non line of sight process for implanting complex shaped targets without the need for complex fixturing. The breakdown initiation of materials coated with diamond-like carbon (DLC) produced by PSII occurs at defects in the DLC which expose the underlying material. To summarize these findings, a galvanic couple is established between the coating and exposed material at the base of the defect. Pitting and oxidation of the base and metal leads to the development of mechanical stress in the coating and eventually spallation of the coating. This paper presents our current progress in attempting to mitigate the breakdown of these coatings by implanting the parent material prior to coating with DLC. Ideally one would like to implant the parent material with chromium or molybdenum which are known to improve corrosion resistance, however, the necessary organometallics needed to implant these materials with PSII are not yet available. Here we report on the effects of carbon, nitrogen, and boron implantation on the susceptibility of PSII-DLC coated mild steel to breakdown.

  4. Application of a production line phosphorescence sensor coating system on a jet engine for surface temperature detection

    Science.gov (United States)

    Sollazzo, P. Y.; Feist, J. P.; Berthier, S.; Charnley, B.; Wells, J.; Heyes, A. L.

    2013-09-01

    Thermal Barrier Coatings (TBC) are used to reduce the working temperature of the high pressure turbine blade metal surface and hence permit engines to operate at higher temperatures/ efficiencies. A sensor TBC is an adaptation of existing TBCs to enhance their functionality, such that they become sensors and allow measurement of component temperatures. The sensing capability is introduced by embedding optically active materials into the TBC and by illuminating these coatings with excitation light phosphorescence can be observed. The phosphorescence carries temperature and structural information about the coating. This paper describes the first ever implementation of a sensor coating system on a full-scale jet engine. The system consists of three main components: industrially manufactured coatings, advanced remote detection optics with large stand-off distances and tailored control and readout software. The majority of coatings were based on yttrium stabilized zirconia doped with Dy and Eu, although other coatings were manufactured, too. Coatings were produced on a production line using atmospheric plasma spraying. An advanced optical system was designed, manufactured and operated permitting scanning of coated components using a wide acceptance angle. Successful measurements were taken from the nozzle guide vanes at the inlet to the turbine section and are reported in the paper.

  5. Effects of heat treatment on the corrosion resistance of carbon steel coated with LaMgAl11O19 thermal barrier coatings

    Institute of Scientific and Technical Information of China (English)

    Liang-liang Huang; Hui-min Meng; Li-kang Liang; Sen Li; Jin-hui Shi

    2015-01-01

    LaMgAl11O19 thermal barrier coatings (TBCs) were applied to carbon steels with a NiCoCrAlY bond coat by plasma spraying. The effects of heat treatment on the corrosion resistance of carbon steel coated with LaMgAl11O19 TBCs were investigated in 3.5wt% NaCl solution using polarization curves, electrochemical impedance spectroscopy (EIS), scanning electron microscopy (SEM), and X-ray diffrac-tion (XRD). The results show that a large number of cracks are found in the LaMgAl11O19 TBCs after the samples are heat-treated, including some through-thickness cracks. The corrosion forms of the as-sprayed and heat-treated TBCs are uniform corrosion and pitting corrosion, respectively. The as-sprayed TBCs exhibit three EIS time constants after being immersed for less than 7 d, and then a new time constant ap-pears because of steel substrate corrosion. When the immersion time is increased to 56 d, a Warburg impedance (W) component appears in the EIS data. The EIS data for the heat-treated TBCs exhibit only two time constants after the samples are immersed for less than 14 d, and a new time constant appears when the immersion time is increased further. The heat treatment reduces the corrosion resistance of carbon steel coated with LaMgAl11O19 TBCs. The corrosion products are primarilyγ-FeOOH and Fe3O4.

  6. Progress in Long Life Thermal Barrier Coatings Technologies%长寿命热障涂层技术研究进展

    Institute of Scientific and Technical Information of China (English)

    王世兴; 刘新基; 汪瑞军

    2012-01-01

    随着高性能航空发动机对长寿命热障涂层需求的增加,提高热障涂层寿命已成为研究重点。本文从粘结层成分及结构设计和陶瓷层制备技术方面介绍了长寿命热障涂层研究进展,最后展望了未来低成本、长寿命热障涂层制备技术的研究方向及研究重点。%With high performance gas turbine engine increased demand for long life thermal barrier coatings, the research interest was focused on improvement thermal barrier coatings life. In this paper, the development and research statues of bond coat composition,structure design and top coat deposition technology for long life thermal barrier coatings was introduced. The research direction and focus of long life thermal barrier coatings deposited by low cost technologies was also anticipated.

  7. Diffusion Coatings for Corrosion-Resistant Components in Coal Gasification Systems

    Energy Technology Data Exchange (ETDEWEB)

    Gopala N. Krishnan; Ripudaman Malhotra; Esperanza Alvarez; Kai-Hung Lau; Jordi Perez-Mariano; Angel Sanjurjo

    2006-06-30

    Heat-exchangers, particle filters, turbines, and other components in integrated coal gasification combined cycle system must withstand the highly sulfiding conditions of the high-temperature coal gas over an extended period of time. The performance of components degrades significantly with time unless expensive high alloy materials are used. Deposition of a suitable coating on a low-cost alloy may improve its resistance to such sulfidation attack, and decrease capital and operating costs. The alloys used in the gasifier service include austenitic and ferritic stainless steels, nickel-chromium-iron alloys, and expensive nickel-cobalt alloys. During this period, we analyzed several coated and exposed samples of 409 steel by scanning electron microscopy (SEM) and energy-dispersive X-ray (EDX). We report here on findings of this analysis: (1) A SS409 coupon that was coated with multilayered combined nitrides of Ti, Al, and Si showed adherent coatings on the surface; (2) A similarly coated coupon, after exposure to simulated coal gas at 900 C for 300 h, revealed that the coating has cracked during the exposure; (3) An SS409 coupon that was coated with nitrides of Ti and Si with a barrier layer of tungsten in between to improve the adhesion of the coating and to prevent outward diffusion of iron to the surface. (4) A porous coupon was coated with nitrides of Ti and Al and examination of the coupon revealed deposition of Ti at the interior surfaces. A similarly prepared coupon was exposed to simulated coal gas at 370 C for 300 h, and it showed no corrosion.

  8. Assessment of NDE methods for detecting cracks and damage in environmental barrier coated CMC tested under tension

    Science.gov (United States)

    Abdul-Aziz, Ali; Wroblewski, Adam C.; Bhatt, Ramakrishna T.; Jaskowiak, Martha H.; Gorican, Daniel; Rauser, Richard W.

    2015-03-01

    For validating physics based analytical models predicting spallation life of environmental barrier coating (EBC) on fiber reinforced ceramic matrix composites, the fracture strength of EBC and kinetics of crack growth in EBC layers need to be experimentally determined under engine operating conditions. In this study, a multi layered barium strontium aluminum silicate (BSAS) based EBC-coated, melt infiltrated silicon carbide fiber reinforced silicon carbide matrix composite (MI SiC/SiC) specimen was tensile tested at room temperature. Multiple tests were performed on a single specimen with increasing predetermined stress levels until final failure. During loading, the damage occurring in the EBC was monitored by digital image correlation (DIC). After unloading from the predetermined stress levels, the specimen was examined by optical microscopy and computed tomography (CT). Results indicate both optical microscopy and CT could not resolve the primary or secondary cracks developed during tensile loading until failure. On the other hand, DIC did show formation of a primary crack at ~ 50% of the ultimate tensile strength and this crack grew with increasing stress and eventually led to final failure of the specimen. Although some secondary cracks were seen in the DIC strain plots prior to final failure, the existence of these cracks were not confirmed by other methods. By using a higher resolution camera, it is possible to improve the capability of DIC in resolving secondary cracks and damage in coated specimen tested at room temperature, but use of DIC at high temperature requires significant development. Based on the current data, it appears that both optical microscopy and CT do not offer any hope for detecting crack initiation or determining crack growth in EBC coated CMC tested at room or high temperatures after the specimen has been unloaded. Other methods such as, thermography and optical/SEM of the polished cross section of EBC coated CMC specimens stressed to

  9. Engineered Barrier System performance requirements systems study report. Revision 02

    Energy Technology Data Exchange (ETDEWEB)

    Balady, M.A.

    1997-01-14

    This study evaluates the current design concept for the Engineered Barrier System (EBS), in concert with the current understanding of the geologic setting to assess whether enhancements to the required performance of the EBS are necessary. The performance assessment calculations are performed by coupling the EBS with the geologic setting based on the models (some of which were updated for this study) and assumptions used for the 1995 Total System Performance Assessment (TSPA). The need for enhancements is determined by comparing the performance assessment results against the EBS related performance requirements. Subsystem quantitative performance requirements related to the EBS include the requirement to allow no more than 1% of the waste packages (WPs) to fail before 1,000 years after permanent closure of the repository, as well as a requirement to control the release rate of radionuclides from the EBS. The EBS performance enhancements considered included additional engineered components as well as evaluating additional performance available from existing design features but for which no performance credit is currently being taken.

  10. 环境障碍涂层研究综述%Overview on the Development of Environment Barrier Coating

    Institute of Scientific and Technical Information of China (English)

    陈旭; 洪智亮; 鲁琳静; 成来飞

    2011-01-01

    环境障碍涂层(Environment barrier coating,EBC)能够解决构件在燃气环境中长时间腐蚀的问题,从而成为航空发动机材料研究的热点.从材料体系、制备工艺、性能考核和表征方法4个方面综述了目前EBC的研究成果.通过对目前国内外研究成果的总结和分析,提出了EBC当前研究存在的问题,并展望了EBC进一步研究的方向.%Environment barrier coating (EBC) which can protect ceramic matrix composite components from corrosion for a long time in combustion environment, become the focus in the field of aviation engine materials. The research results of EBC are reviewed fully according to the following point as: materials, processes, tests and evaluation methods. Based on the summary and analysis on the achievement of EBC at home and abroad, some issues and the tendency on the development of EBC are proposed finally.

  11. Performance and emission characteristics of the thermal barrier coated SI engine by adding argon inert gas to intake mixture

    Directory of Open Access Journals (Sweden)

    T. Karthikeya Sharma

    2015-11-01

    Full Text Available Dilution of the intake air of the SI engine with the inert gases is one of the emission control techniques like exhaust gas recirculation, water injection into combustion chamber and cyclic variability, without scarifying power output and/or thermal efficiency (TE. This paper investigates the effects of using argon (Ar gas to mitigate the spark ignition engine intake air to enhance the performance and cut down the emissions mainly nitrogen oxides. The input variables of this study include the compression ratio, stroke length, and engine speed and argon concentration. Output parameters like TE, volumetric efficiency, heat release rates, brake power, exhaust gas temperature and emissions of NOx, CO2 and CO were studied in a thermal barrier coated SI engine, under variable argon concentrations. Results of this study showed that the inclusion of Argon to the input air of the thermal barrier coated SI engine has significantly improved the emission characteristics and engine’s performance within the range studied.

  12. Depth-Penetrating Measurements Developed for Thermal Barrier Coatings Incorporating Thermographic Phosphors

    Science.gov (United States)

    Eldridge, Jeffrey I.; Bencic, Timothy J.

    2004-01-01

    The insulating properties of thermal barrier coatings (TBCs) provide highly beneficial thermal protection to turbine engine components by reducing the temperature sustained by those components. Therefore, measuring the temperature beneath the TBC is critical for determining whether the TBC is performing its insulating function. Currently, noncontact temperature measurements are performed by infrared pyrometry, which unfortunately measures the TBC surface temperature rather than the temperature of the underlying component. To remedy this problem, the NASA Glenn Research Center, under the Information Rich Test Instrumentation Project, developed a technique to measure the temperature beneath the TBC by incorporating a thin phosphor layer beneath the TBC. By performing fluorescence decay-time measurements on light emission from this phosphor layer, Glenn successfully measured temperatures from the phosphor layer up to 1100 C. This is the first successful demonstration of temperature measurements that penetrate beneath the TBC. Thermographic phosphors have a history of providing noncontact surface temperature measurements. Conventionally, a thermographic phosphor is applied to the material surface and temperature measurements are performed by exciting the phosphor with ultraviolet light and then measuring the temperature-dependent decay time of the phosphor emission at a longer wavelength. The innovative feature of the new approach is to take advantage of the relative transparency of the TBC (composed of yttria-stabilized zirconia) in order to excite and measure the phosphor emission beneath the TBC. The primary obstacle to achieving depth-penetrating temperature measurements is that the TBCs are completely opaque to the ultraviolet light usually employed to excite the phosphor. The strategy that Glenn pursued was to select a thermographic phosphor that could be excited and emit at wavelengths that could be transmitted through the TBC. The phosphor that was selected was

  13. Transparent gas barrier coatings on polymeric substrates, as substitute of pollutant metallic aluminum, in the packaging industry; Recubrimientos barrera transparentes sobre polimeros, como sustitutos del aluminio metalico contaminante, en la industria del embalaje

    Energy Technology Data Exchange (ETDEWEB)

    Garcia, G.; Sanchez, O. [Universidad Autonoma de Madrid (Spain); Vazquez, L.; Martinez, J.M. [Instituto de Ciencia de Materiales de Madrid CSIC (Spain)

    1997-12-31

    Transparent gas barrier coatings based on silicon and aluminium oxides and deposited on flexible polymers have been studied. These coatings have high interest in the packaging industry for replacing the actual aluminium films that are opaque and pollutant. in this paper we show an study of the coating morphology and its influence in the barrier properties, that is, in the coating permeability. In addition, it has been shown how scanning Electron Microscopy (SEM) and Atomic Force Microscopy (AFM) can be used for studying transparent barrier coatings on polymeric substrates. (Author) 26 refs.

  14. Low temperature monitoring system for subsurface barriers

    Science.gov (United States)

    Vinegar, Harold J.; McKinzie, II. Billy John

    2009-08-18

    A system for monitoring temperature of a subsurface low temperature zone is described. The system includes a plurality of freeze wells configured to form the low temperature zone, one or more lasers, and a fiber optic cable coupled to at least one laser. A portion of the fiber optic cable is positioned in at least one freeze well. At least one laser is configured to transmit light pulses into a first end of the fiber optic cable. An analyzer is coupled to the fiber optic cable. The analyzer is configured to receive return signals from the light pulses.

  15. Applications of coatings in coal-fired energy systems

    Energy Technology Data Exchange (ETDEWEB)

    Natesan, K.

    1992-03-01

    Corrosion and erosion of metallic structural materials at elevated temperatures in complex multicomponent gas environments that include particulates are potential problems in many fossil energy systems, especially those using coal as a feedstock. The use of appropriate corrosion-resistant coatings on metallic components offers an avenue to minimize material degradation and extend component life. The purpose of this paper is to review the current status of coating performance in environments typical of pulverized-coal-fired boilers, coal gasification, fluidized-bed combustion, and gas turbines. The paper discusses the complexity of environments in different systems and the coating requirements for acceptable performance. Examples illustrate the morphology and corrosion/erosion performance of coating/structural alloy combinations exposed in some of these systems. La addition, future research and development needs are discussed for coating applications in several coal-fired systems.

  16. Galvanic Liquid Applied Coating System For Protection of Embedded Steel Surfaces from Corrosion

    Science.gov (United States)

    Curran, Joseph; Curran, Jerome; Voska, N. (Technical Monitor)

    2002-01-01

    Corrosion of reinforcing steel in concrete is an insidious problem facing Kennedy Space Center (KSC), other Government Agencies, and the general public. These problems include KSC launch support structures, highway bridge infrastructure, and building structures such as condominium balconies. Due to these problems, the development of a Galvanic Liquid Applied Coating System would be a breakthrough technology having great commercial value for the following industries: Transportation, Infrastructure, Marine Infrastructure, Civil Engineering, and the Construction Industry. This sacrificial coating system consists of a paint matrix that may include metallic components, conducting agents, and moisture attractors. Similar systems have been used in the past with varying degrees of success. These systems have no proven history of effectiveness over the long term. In addition, these types of systems have had limited success overcoming the initial resistance between the concrete/coating interface. The coating developed at KSC incorporates methods proven to overcome the barriers that previous systems could not achieve. Successful development and continued optimization of this breakthrough system would produce great interest in NASA/KSC for corrosion engineering technology and problem solutions. Commercial patents on this technology would enhance KSC's ability to attract industry partners for similar corrosion control applications.

  17. Origin of Small Barriers in Jahn–Teller Systems

    DEFF Research Database (Denmark)

    Barriuso, M. T.; Ortiz-Sevilla, B.; Aramburu, J. A.

    2013-01-01

    Despite its relevance, the microscopic origin of the energy barrier, B, between the compressed and elongated geometries of Jahn–Teller (JT) systems is not well understood yet because of a lack of quantitative data about its various contributions. Seeking to clear up this matter, we have carried o...

  18. Experimental Study on Spiral Patterns in Dielectric Barrier Discharge System

    Institute of Scientific and Technical Information of China (English)

    LIU Shu-Hua; DONG Li-Fang; LIU Fu-Cheng; LI Shu-Feng; LI Xue-Chen; WANG Hong-Fang

    2006-01-01

    Spiral patterns are obtained in a dielectric barrier discharge system with water electrodes. The dynamics of spiral formation and transition is investigated. Wavelength characteristic of spiral patterns is also studied. Correlation measurements indicate that the wavelength of spiral pattern increases with the increasing gas gap width and oscillates with the increasing drive frequency.

  19. Damage evolution in an electron beam physical vapor deposited thermal barrier coating as a function of cycle temperature and time

    Energy Technology Data Exchange (ETDEWEB)

    Sridharan, Swetha [Department of Metallurgy and Materials Engineering, University of Connecticut, Storrs, CT 06269 (United States); Xie, Liangde [Department of Metallurgy and Materials Engineering, University of Connecticut, Storrs, CT 06269 (United States); Jordan, Eric H. [Department of Mechanical Engineering, University of Connecticut, 191 Auditorium Road, Storrs, CT 06269 (United States)]. E-mail: jordan@engr.uconn.edu; Gell, Maurice [Department of Metallurgy and Materials Engineering, University of Connecticut, Storrs, CT 06269 (United States); Murphy, K.S. [Howmet Research Corporation, Howmet Castings, Whitehall, MI 49461 (United States)

    2005-02-25

    Failure of thermal barrier coatings (TBCs) deposited on a single-crystal superalloy with a grit-blasted platinum modified nickel aluminide [{beta}-(Ni, Pt) Al] bond coat has been studied as a function of thermal cycling temperature and time. One-hour cyclic furnace tests were conducted at 1100 deg. C, 1121 deg. C and 1151 deg. C, and 24-h tests were run at 1121 deg. C. It was found that all the samples tested in the 1-h cycle failed in the TBC, near the TBC/TGO interface, due to progressive cracking beginning at {approx}20% life fraction. In contrast, the 24-h cyclic test samples failed at the TGO/bond coat interface. Thus, a life prediction for this TBC will ultimately require the use of two independent damage mechanisms and failure will be predicted on the basis of whichever occurs first during the TBC cyclic life. A single-valued relation was found between the rumpling amplitudes and the oxide thickness, independent of temperature and cycle time, consistent with oxidation being rate controlling.

  20. Monitoring Delamination of Thermal Barrier Coating During Interrupted High-Heat Flux Laser Testing Using Upconversion Luminescence Imaging

    Science.gov (United States)

    Eldridge, Jeffrey I.; Zhu, Dongming; Wolfe, Douglas E.

    2011-01-01

    Upconversion luminescence imaging of thermal barrier coatings (TBCs) has been shown to successfully monitor TBC delamination progression during interrupted furnace cycling. However, furnace cycling does not adequately model engine conditions where TBC-coated components are subjected to significant heat fluxes that produce through-thickness temperature gradients that may alter both the rate and path of delamination progression. Therefore, new measurements are presented based on luminescence imaging of TBC-coated specimens subjected to interrupted high-heat-flux laser cycling exposures that much better simulate the thermal gradients present in engine conditions. The TBCs tested were deposited by electron-beam physical vapor deposition (EB-PVD) and were composed of 7wt% yttria-stabilized zirconia (7YSZ) with an integrated delamination sensing layer composed of 7YSZ co-doped with erbium and ytterbium (7YSZ:Er,Yb). The high-heat-flux exposures that produce the desired through-thickness thermal gradients were performed using a high power CO2 laser operating at a wavelength of 10.6 microns. Upconversion luminescence images revealed the debond progression produced by the cyclic high-heat-flux exposures and these results were compared to that observed for furnace cycling.

  1. Process engineering of ceramic composite coatings for fuel cell systems

    Energy Technology Data Exchange (ETDEWEB)

    Li, G.; Kim, H.; Chen, M.; Yang, Q.; Troczynski, T. [British Columbia Univ., Vancouver, BC (Canada). Dept. of Metals and Materials Engineering

    2003-07-01

    Researchers at UBCeram at the Department of Metals and Materials Engineering at the University of British Columbia have developed a technology to chemically bond composite sol-gel (CB-CSG) coating onto metallic surfaces of complex or concave shapes. The process has been optimized for electrically resistive coatings and corrosion-resistant coatings. The CSG is sprayed onto metallic surfaces and is heat-treated at 300 degrees C to partially dehydrate the hydroxides. The CSG film is then chemically bonded through reaction of active alumina with metal phosphates, such as aluminium phosphate. A new chromate-free process is being developed to address the issue of coatings porosity. The electrodeposition technique involves polymer particles mixed with suspended fine alumina particles which are co-deposited by electrophoretic means or by electrocoagulation. The composite e-coatings have excellent mechanical properties and are being considered as a protective coating for various components of fuel cell systems. 9 refs., 7 figs.

  2. Water Repellence and Oxygen and Water Vapor Barrier of PVOH-Coated Substrates before and after Surface Esterification

    Directory of Open Access Journals (Sweden)

    Markus Schmid

    2014-11-01

    Full Text Available This study investigates chemical grafting with fatty acid chlorides as a method for the surface modification of hydrophilic web materials. The resulting changes in the water repellence and barrier properties were studied. For this purpose, different grades of polyvinyl alcohol (PVOH were coated on regenerated cellulose films (“cellophane” and paper and then grafted with fatty acid chlorides. The PVOH grades varied in their degree of hydrolysis and average molecular weight. The surface was esterified with two fatty acid chlorides, palmitoyl (C16 and stearoyl chloride (C18, by chemical grafting. The chemical grafting resulted in water-repellent surfaces and reduced water vapor transmission rates by a factor of almost 19. The impact of the surface modification was greater for a higher degree of hydrolysis of the polyvinyl alcohol and for shorter fatty acid chains. Although the water vapor barrier for palmitoyl-grafted PVOH was higher than for stearoyl-grafted PVOH, the contact angle with water was lower. Additionally, it was shown that a higher degree of hydrolysis led to higher water vapor barrier improvement factors after grafting. Furthermore, the oxygen permeability decreased after grafting significantly, due to the fact that the grafting protects the PVOH against humidity when the humidity is applied on the grafted side. It can be concluded that the carbon chain length of the fatty acid chlorides is the limiting factor for water vapor adsorption, but the grafting density is the bottleneck for water diffusing in the polymer.

  3. Enhanced water vapor barrier properties for biopolymer films by polyelectrolyte multilayer and atomic layer deposited Al{sub 2}O{sub 3} double-coating

    Energy Technology Data Exchange (ETDEWEB)

    Hirvikorpi, Terhi [VTT Technical Research Centre of Finland, Biologinkuja 7, Espoo, P.O. Box 1000, FI-02044 VTT (Finland); Vaehae-Nissi, Mika, E-mail: mika.vaha-nissi@vtt.fi [VTT Technical Research Centre of Finland, Biologinkuja 7, Espoo, P.O. Box 1000, FI-02044 VTT (Finland); Harlin, Ali [VTT Technical Research Centre of Finland, Biologinkuja 7, Espoo, P.O. Box 1000, FI-02044 VTT (Finland); Salomaeki, Mikko [University of Turku, Department of Chemistry, Laboratory of Materials Chemistry and Chemical Analysis, Vatselankatu 2, FI-20014 (Finland); Areva, Sami [Tampere University of Technology, Department of Biomedical Engineering, Biokatu 6, P.O. Box 692, FI-33101 Tampere (Finland); Korhonen, Juuso T. [Aalto University School of Science, Department of Applied Physics, P.O. Box 15100 FI-00076 AALTO, Espoo (Finland); Karppinen, Maarit [Aalto University School of Chemical Technology, Laboratory of Inorganic Chemistry, P.O. Box 16100, FI-00076 AALTO, Espoo (Finland)

    2011-09-01

    Commercial polylactide (PLA) films are coated with a thin (20 nm) non-toxic polyelectrolyte multilayer (PEM) film made from sodium alginate and chitosan and additionally with a 25-nm thick atomic layer deposited (ALD) Al{sub 2}O{sub 3} layer. The double-coating of PEM + Al{sub 2}O{sub 3} is found to significantly enhance the water vapor barrier properties of the PLA film. The improvement is essentially larger compared with the case the PLA film being just coated with an ALD-grown Al{sub 2}O{sub 3} layer. The enhanced water vapor barrier characteristics of the PEM + Al{sub 2}O{sub 3} double-coated PLA films are attributed to the increased hydrophobicity of the surface of these films.

  4. Modelling water vapour permeability through atomic layer deposition coated photovoltaic barrier defects

    Energy Technology Data Exchange (ETDEWEB)

    Elrawemi, Mohamed, E-mail: Mohamed.elrawemi@hud.ac.uk [EPSRC Centre for Innovative Manufacturing in Advanced Metrology, School of Computing and Engineering, University of Huddersfield, Huddersfield (United Kingdom); Blunt, Liam; Fleming, Leigh [EPSRC Centre for Innovative Manufacturing in Advanced Metrology, School of Computing and Engineering, University of Huddersfield, Huddersfield (United Kingdom); Bird, David, E-mail: David.Bird@uk-cpi.com [Centre for Process Innovation Limited, Sedgefield, County Durham (United Kingdom); Robbins, David [Centre for Process Innovation Limited, Sedgefield, County Durham (United Kingdom); Sweeney, Francis [EPSRC Centre for Innovative Manufacturing in Advanced Metrology, School of Computing and Engineering, University of Huddersfield, Huddersfield (United Kingdom)

    2014-11-03

    Transparent barrier films such as Al{sub 2}O{sub 3} used for prevention of oxygen and/or water vapour permeation are the subject of increasing research interest when used for the encapsulation of flexible photovoltaic modules. However, the existence of micro-scale defects in the barrier surface topography has been shown to have the potential to facilitate water vapour ingress, thereby reducing cell efficiency and causing internal electrical shorts. Previous work has shown that small defects (≤ 3 μm lateral dimension) were less significant in determining water vapour ingress. In contrast, larger defects (≥ 3 μm lateral dimension) seem to be more detrimental to the barrier functionality. Experimental results based on surface topography segmentation analysis and a model presented in this paper will be used to test the hypothesis that the major contributing defects to water vapour transmission rate are small numbers of large defects. The model highlighted in this study has the potential to be used for gaining a better understanding of photovoltaic module efficiency and performance. - Highlights: • A model of water vapour permeation through barrier defects is presented. • The effect of the defects on the water vapour permeability is investigated. • Defect density correlates with water vapour permeability. • Large defects may dominate the permeation properties of the barrier film.

  5. Effect of Processing Conditions on the Anelastic Behavior of Plasma Sprayed Thermal Barrier Coatings

    Science.gov (United States)

    Viswanathan, Vaishak

    2011-12-01

    Plasma sprayed ceramic materials contain an assortment of micro-structural defects, including pores, cracks, and interfaces arising from the droplet based assemblage of the spray deposition technique. The defective architecture of the deposits introduces a novel "anelastic" response in the coatings comprising of their non-linear and hysteretic stress-strain relationship under mechanical loading. It has been established that this anelasticity can be attributed to the relative movement of the embedded defects under varying stresses. While the non-linear response of the coatings arises from the opening/closure of defects, hysteresis is produced by the frictional sliding among defect surfaces. Recent studies have indicated