Development of Highly Durable Thermal Barrier Coating by Suppression of Thermally Grown Oxide

2018 ◽  
Vol 140 (8) ◽  
Author(s):  
Masahiro Negami ◽  
Shinya Hibino ◽  
Akihito Kawano ◽  
Yoshimichi Nomura ◽  
Ryozo Tanaka ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Bond Coat ◽  
Ambient Air ◽  
Xrd Analysis ◽  
Thermally Grown Oxide ◽  
Thermal Barrier ◽  
Al2o3 Layer ◽  
Barrier Coating ◽  
Α Al2o3 ◽  
Metastable Alumina

Durability of thermal barrier coating (TBC) systems is important because of recent rising of turbine inlet temperature (TIT) for improved efficiency of industrial gas turbine engines. However, high-temperature environment accelerates the degradation of the TBC as well as causes spalling of the top coat. Spalling of the top coat may be attributed to several factors, but evidently the growth of thermally grown oxide (TGO) should be considered as an important factor. One method for reducing the growth rate of TGO is to provide a dense α-Al2O3 layer at the boundary of the bond coat and top coat. This α-Al2O3 layer will suppress the diffusion of oxygen to the bond coat and consumption of aluminum of the bond coat is suppressed. In this study, we focused on thermal pre-oxidation of the bond coat as a means for forming an α-Al2O3 barrier layer that would be effective at reducing the growth rate of TGO, and we studied the suitable pre-oxidation conditions. In the primary stage, we analyzed the oxidation behavior of the bond coat surface during pre-oxidation heat treatment by means of in situ synchrotron X-ray diffraction (XRD) analysis. As a result, we learned that during oxidation in ambient air environment, in the initial stage of oxidation metastable alumina is produced in addition to α-Al2O3, but if the thermal treatment is conducted under some specific low oxygen partial pressure condition, unlike in the ambient air environment, only α-Al2O3 is formed with suppressing formation of metastable alumina. We also conducted transmission electron microscope (TEM) and XRD analysis of oxide scale formed after pre-oxidation heat treatment of the bond coat. As a result, we learned that if pre-oxidation is performed under specific oxygen partial pressure conditions, a monolithic α-Al2O3 layer is formed on the bond coat. We performed a durability evaluation test of TBC with the monolithic α-Al2O3 layer formed by pre-oxidation of the bond coat. An isothermal oxidation test confirmed that the growth of TGO in the TBC that had undergone pre-oxidation was suppressed more thoroughly than that in the TBC that had not undergone pre-oxidation. Cyclic thermal shock test by hydrogen burner rig was also carried out. TBC with the monolithic α-Al2O3 layer has resistance to >2000 cycle thermal shock at a load equivalent to that of actual gas turbine.

Development of Highly Durable Thermal Barrier Coating by Suppression of Thermally Grown Oxide

2017 ◽  
Author(s):  
Masahiro Negami ◽  
Shinya Hibino ◽  
Akihito Kawano ◽  
Yoshimichi Nomura ◽  
Ryozo Tanaka ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Bond Coat ◽  
Ambient Air ◽  
Xrd Analysis ◽  
Thermally Grown Oxide ◽  
Thermal Barrier ◽  
Al2o3 Layer ◽  
Barrier Coating ◽  
Α Al2o3 ◽  
Metastable Alumina

Durability of thermal barrier coating (TBC) systems is important because of recent rising of TIT (Turbine inlet temperature) for improved efficiency of industrial gas turbine engines. However, high-temperature environment accelerates the degradation of the TBC as well as causes spalling of the top coat. Spalling of the top coat may be attributed to several factors, but evidently the growth of thermally grown oxide (TGO) should be considered as an important factor. One method for reducing the growth rate of TGO is to provide a dense α-Al2O3 layer at the boundary of the bond coat and top coat. This α-Al2O3 layer will protect the bond coat against oxidation and prevent outward diffusion of aluminum of the bond coat which causes further oxidation. In this study, we focused on thermal pre-oxidation of the bond coat as a means for forming an α-Al2O3 barrier layer that would be effective at reducing the growth rate of TGO and we studied the suitable pre-oxidation conditions. In the primary stage we analyzed the oxidation behavior of the bond coat surface during pre-oxidation heat treatment by means of in-situ synchrotron X-ray diffraction (XRD) analysis. As a result, we learned that during oxidation in ambient air environment, in the initial stage of oxidation metastable alumina is produced in addition to α-Al2O3, but if the thermal treatment is conducted under some specific low oxygen partial pressure condition, unlike in the ambient air environment, only α-Al2O3 is formed with suppressing formation of metastable alumina. We also conducted TEM and XRD analysis of oxide scale formed after pre-oxidation heat treatment of the bond coat. As a result, we learned that if pre-oxidation is performed under specific oxygen partial pressure conditions, a monolithic α-Al2O3 layer is formed on the bond coat. We performed a durability evaluation test of TBC with the monolithic α-Al2O3 layer formed by pre-oxidation of the bond coat. An isothermal oxidation test confirmed that the growth of TGO in the TBC that had undergone pre-oxidation was suppressed more thoroughly than that in the TBC that had not undergone pre-oxidation. Cyclic thermal shock test by hydrogen burner rig was also carried out. TBC with the monolithic α-Al2O3 layer has resistance to >2000 cycle thermal shock at a load equivalent to that of actual gas turbine.

Delamination toughness of electron beam physical vapor deposition (EB-PVD) Y2O3–ZrO2 thermal barrier coatings by the pushout method: Effect of thermal cycling temperature

2008 ◽  
Vol 23 (9) ◽  
pp. 2382-2392 ◽  
Author(s):  
M. Tanaka ◽  
Y.F. Liu ◽  
S.S. Kim ◽  
Y. Kagawa
Keyword(s):  
Electron Beam ◽  
Thermal Cycling ◽  
Bond Coat ◽  
Physical Vapor Deposition ◽  
Thermally Grown Oxide ◽  
Test Method ◽  
Thermal Barrier ◽  
Barrier Coating ◽  
Delamination Toughness ◽  
Cycling Temperature

A pushout test method was used to quantify effect of thermal cycling temperatures on the delamination toughness of an electron beam physical vapor deposited thermal barrier coating (EB-PVD TBC). The delamination toughness, Γi, was related to the maximum thermal cycling temperature, Th, equal to 1000, 1025, 1050, and 1100 °C. The measured delamination toughness varied from 9 to 95 J/m2. At Th = 1000 °C, Γi attained a maximum value, larger than that of the as-deposited sample and decreasing with increased Th. During the thermal cycling tests, the thermally grown oxide (TGO) was formed between the TBC and the bond coat deposited onto the superalloy substrate. Inside the TGO layer, mixture of Al2O3 and ZrO2 oxides was observed close to the TBC side with nearly pure Al2O3 phases close to the bond-coat side. During the pushout test, delamination occurred at the interface of the mixture and pure Al2O3 layer with an exception for Th = 1100 °C specimens where delamination also occurred at the interface between the TGO and bond-coat layers. The effect of thermal cycling temperatures on the delamination toughness is discussed in terms of the microstructural change and delamination behavior.

On the Change in Stress State Associated with Bond Coat Oxidation during Heat Treatment of a Thermal Barrier Coating System

1997 ◽  
Author(s):  
Y.C. Tsui ◽  
T.W. Clyne ◽  
R.C. Reed
Keyword(s):  
Heat Treatment ◽  
Stress State ◽  
Oxide Layer ◽  
Thermal Barrier Coating ◽  
Bond Coat ◽  
Driving Forces ◽  
Lateral Strain ◽  
Thermal Barrier ◽  
Residual Stress State ◽  
Barrier Coating

Abstract Thermal barrier coating systems have been heat treated in order to study the oxidation kinetics of the bond coat. All the surfaces of Ni superalloy substrates were sprayed with ~100 μm of a NiCrAlY bond coat, with or without ~250 μm of a ZrO2 top coat. Thermogravimetric analysis (TGA) was used to monitor continuously the mass change as a result of oxidation of the bond coat during heating at 1000°C for 100 hours in flowing air. In addition, some specimens were heated to 1000°C in static air, cooled to room temperature, weighed and re-heated cyclically. The total exposure time was 1000 hours. Rates of weight gain were found to be higher for the cycled specimens, despite the absence of air flow. This is attributed to damage to the oxide film, which was predominantly α-Al2O3, as a consequence of differential thermal contraction stresses. The changing residual stress state during heat treatment was predicted using a previously-developed numerical model. A thin (1 mm) substrate with ~100 μm bond coat and ~250 μm ZrO2 top coat was used in these simulations, which incorporated creep of the bond coat and the lateral strain associated with oxidation. It is concluded from these computations that, while high stresses develop in the oxide layer, the associated driving forces for interfacial debonding remain relatively low, as do specimen curvature changes. It seems likely that coating spallation after extensive oxide layer formation arises because the interface is strongly embrittled as the layer thickens.

TGO Formation with NiCoCrAlYTa Bond Coat Deposition Using APS and HVOF Method

2015 ◽  
Vol 1125 ◽  
pp. 18-22 ◽  
Author(s):  
S. Mohd Zulkifli ◽  
Muhammad Azizi Mat Yajid ◽  
Mohd Hasbullah Idris ◽  
M. Daroonparvar ◽  
Halimaton Hamdan
Keyword(s):  
Bond Coat ◽  
Oxidation Process ◽  
Thermally Grown Oxide ◽  
Inconel 625 ◽  
Thermal Barrier ◽  
Air Plasma Spray ◽  
Air Plasma ◽  
Continuous Layer ◽  
Barrier Coating ◽  
Coating Failure

Formation of thin and continuous layer of thermally grown oxide (TGO) in thermal barrier coating (TBC) are essential in order to avoid coating failure for high temperature applications. As-sprayed high velocity oxy-fuel (HVOF) bond coat can provide more uniform TGO layer in TBC system and much less oxide compare to air plasma spray (APS). In this paper, both APS and HVOF method are used to deposit NiCoCrAlYTa bond coat on Inconel 625 substrate followed by topcoat, YSZ deposition. Pre-oxidation process was done in normal oxygen furnace at 1000°C for 12 to 24 hours to study the characteristic of TGO formation via these two different methods. From the result obtained, it shows that HVOF method provide better TGO formation as compared to APS.

R&D Status and Needs for Improved EB-PVD Thermal Barrier Coating Performance

2000 ◽  
Vol 645 ◽  
Author(s):  
C. Leyens ◽  
U. Schulz ◽  
M. Bartsch ◽  
M. Peters
Keyword(s):  
Thermal Barrier Coating ◽  
Bond Coat ◽  
Gas Turbines ◽  
Systems Approach ◽  
Thermally Grown Oxide ◽  
Thermal Barrier ◽  
Factors Affecting ◽  
Performance Improvements ◽  
Barrier Coating ◽  
Temperature Capability

ABSTRACTThe key issues for thermal barrier coating development are high temperature capability and durability under thermal cyclic conditions as experienced in the hot section of gas turbines. Due to the complexity of the system and the interaction of the constituents, performance improvements require a systems approach. However, there are issues closely related to the ceramic top coating and the bond coat, respectively. Reduced thermal conductivity, sintering, and stresses within the ceramic coating are addressed in the paper as well as factors affecting failure of the TBC by spallation. The latter is primarily governed by the formation and growth of the thermally grown oxide scale and therefore related to the bond coat. A strategy for lifetime assessment of TBCs is discussed.

Development of a Thermal Barrier Coating Life Model

2003 ◽  
Author(s):  
K. Chan ◽  
S. Cheruvu ◽  
R. Viswanathan
Keyword(s):  
Gas Turbine ◽  
Bond Coat ◽  
Thermally Grown Oxide ◽  
Experimental Program ◽  
Thermal Barrier ◽  
Barrier Coating ◽  
Life Model ◽  
Useful Life ◽  
Plasma Sprayed ◽  
Kinetics Of

Thermal barrier coatings (TBCs) are widely used on the first stage turbine buckets and vanes of land-based (F and G class) gas turbine machines. These coatings normally fail by spallation due to delamination of the ceramic layer along the vicinity of the thermally grown oxide (TGO)/TBC interface. The failure processes involve several mechanisms including oxidation of the bond coat, thermomechanical fatigue, sintering, and spallation of the TBC. This paper describes the development of an analytical tool for predicting the useful life of TBCs for land-based gas turbine applications. The analytical model, called TBCLIFE, has been developed to treat bond coat oxidation, sintering and spallation of the TBC, as well as effects of coating thickness and substrate curvature on TBC spallation. In addition, a parallel experimental program has also been initiated to evaluate the durability of a plasma-sprayed TBC under isothermal and thermal cycling exposures. These results will be used to determine the kinetics of TGO scale growth and the material constants for the TBC life model. The TBC life model will be applied to predicting TBC life as a function of cycle time and the results will be presented as coating life diagrams. The utility of a coating life diagram for estimating the remaining life of TBC will be illustrated and discussed.

Effect of Temperature-Dependent Properties on Cyclic Plasticity of Bond Coat in Thermal Barrier Systems

2013 ◽  
Vol 535-536 ◽  
pp. 193-196
Author(s):  
Luo Chuan Su ◽  
Jian Guo Li ◽  
Wei Xu Zhang ◽  
Tie Jun Wang
Keyword(s):  
Bond Coat ◽  
Thermally Grown Oxide ◽  
Cyclic Plasticity ◽  
Effect Of Temperature ◽  
Thermal Barrier ◽  
Temperature Dependent ◽  
Barrier Coating ◽  
Thermal Growth ◽  
Key Factor ◽  
Temperature Dependent Properties

The accumulation of cyclic plasticity in bond coat (BC) is a key factor controlling the displacement instability of the thermally grown oxide (TGO) in thermal barrier systems. The cyclic plasticity is affected by the component material properties, which vary observably with the service temperature. A numerical model with the behavior of creep and thermal growth in TGO under thermal cycling is used to explore the effect of temperature-dependent properties on cyclic plasticity in BC. The influence of temperature-dependent Young's modulus of thermal barrier coating (TBC), TGO, BC and substrate, thermal expansion coefficient of TBC, BC and substrate, and the yield strength of BC on cyclic plasticity in BC is discussed respectively.

Failure of a Thermal Barrier System Due to a Cyclic Displacement Instability in the Thermally grown Oxide

2000 ◽  
Vol 645 ◽  
Author(s):  
Daniel R. Mumm ◽  
Anthony G. Evans
Keyword(s):  
Bond Coat ◽  
Large Scale ◽  
Thermal Exposure ◽  
Thermally Grown Oxide ◽  
Thermal Barrier ◽  
Oxide Interface ◽  
Barrier Coating ◽  
Out Of Plane ◽  
Plane Displacement ◽  
Thermally Grown

ABSTRACTThe mechanism controlling the cyclic failure of a commercial thermal barrier system has been investigated. The system comprises an electron-beam physical vapor deposited (EB-PVD) yttria-stabilized zirconia thermal barrier coating (TBC), deposited on a (Ni Pt) Al bond coating. The thermally grown oxide (TGO) layer that forms between the TBC and bond coat at high temperature is unstable with respect to out of plane displacement, provided initial perturbations are present. With cyclic thermal exposure, the TGO displaces into the bond coat at periodic interfacial sites. The out-of-plane displacements induce strains above the TGO, normal to the interface, that cause cracking. The cracks nucleate either within the TBC layer or at the TBC/TGO interface, and extend laterally until they coalesce with cracks from other sites and coating failure occurs by large scale buckling. The TGO displacements are accommodated by visco-plastic deformation of the underlying bond coat, and are driven by a lateral component of the growth strain in the TGO. The susceptibility of the TGO to out-of-plane displacement depends critically upon the initial morphology of the metal/oxide interface. The observed material responses are compared with predictions of a ‘ratcheting’ model.

Influence of Heat Treatment on Fracture Toughness and Wear Resistance of Nicral-Zro2 Multilayered Thermal Barrier Coating

2018 ◽  
Vol 37 (5) ◽  
pp. 463-475
Author(s):  
Zibo Ye ◽  
Guanghong Wang
Keyword(s):  
Heat Treatment ◽  
Fracture Toughness ◽  
Wear Resistance ◽  
Xrd Analysis ◽  
Thermal Barrier ◽  
Homogeneous Microstructure ◽  
Barrier Coating ◽  
Before And After ◽  
T Phase ◽  
The Relationship

AbstractThe chemical composition and fracture toughness of thermal barrier coatings (TBCs) before and after heat treatment were characterized, and the cracks around the interface between the coating and the substrate could be successfully eliminated and meanwhile the porosity of the coatings tended to reduce. The XRD analysis revealed the coatings were composed of non-transformable tetragonal t’ phase of ZrO2 and $\gamma $-(Ni, Cr) with minor Ni3Al ($\gamma ^' $) precipitates. Additionally, the relationship between the heat treatment and wear resistance was systematically studied. The results indicated that both the hardness and fracture toughness increased after quenching process. The oxidation wear became more prominent after heat treatment, which probably resulted from the better bonding strength of coatings. Dense and homogeneous microstructure introduced by vacuum oil-quenching improved stabilization of the weight gain during thermal cycle test.

The Effect of Vacuum Heat Treatment on the Oxidation Behavior of APS Thermal Barrier Coating

2011 ◽  
Vol 239-242 ◽  
pp. 3127-3130 ◽  
Author(s):  
Ya Jun Chen ◽  
Shi Qiang Liu ◽  
Xiao Ping Lin ◽  
Zhi Ping Wang ◽  
Li Jun Wang
Keyword(s):  
Heat Treatment ◽  
Thermal Barrier Coating ◽  
Oxidation Behavior ◽  
Thermally Grown Oxide ◽  
Nickel Base Superalloy ◽  
Thermal Barrier ◽  
Vacuum Heat Treatment ◽  
Air Plasma ◽  
Spinel Layer ◽  
Barrier Coating

Thermal barrier coating (TBC), which consisted of a NiCoCrAlY bond coat (BC) and a ZrO2-8 wt.%Y2O3 topcoat (TC), was fabricated on the nickel-base superalloy by air plasma spray (APS). The BC and TBC was treated by vacuum heat treatment (VHT). The oxidation of coating with and without VHT has been performed at 1050°C. Oxidation behavior of coatings and thermally grown oxide(TGO) scale were studied by SEM with EDS. As shown in the results, after treating by VHT, a continuous Al2O3 layer formed more rapidly on the VHT coating than that formed on the APS coating, which can act as a diffusion barrier to suppress the formation of other detrimental oxides. The pre-oxidation treatments reduced the growth rate and extend the steady-state growth stage. The TGO in VHT TBC was still a single layerAl2O3 oxide after 120h. However, after same oxidation time, the TGO in APS TBC produced a dual-layer oxide consisting of an inner Al2O3 layer and outer spinel layer. Therefore the VHT improves the oxidation resistance of APS coating.

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