Improved Oxidation Life of Segmented Plasma Sprayed 8YSZ Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Smialek, James L.

2004-03-01

Unconventional plasma sprayed thermal barrier coating (TBC) systems were produced and evaluated by interrupted or cyclic furnace oxidation life testing. First, approximately 250 µm thick 8YSZ coatings were directly sprayed onto grit blasted surfaces of PWA 1484, without a bond coat, to take advantage of the excellent oxidation resistance of this superalloy. For nominal sulfur (S) contents of 1 ppmw, total coating separation took place at relatively short times (200 h at 1100°C). Reductions in the S content, by melt desulfurization commercially (0.3 ppmw) or by hydrogen (H2) annealing in the laboratory (0.01 ppmw), improved scale adhesion and extended life appreciably, by factors of 5-10. However, edge-initiated failure persisted, producing massive delamination as one sheet of coating. Secondly, surfaces of melt desulfurized PWA 1484 were machined with a grid of grooves or ribs (˜250 µm wide and high), resulting in a segmented TBC surface macrostructure, for the purpose of subverting this failure mechanism. In this case, failure occurred only as independent, single-segment events. For grooved samples, 1100 °C segment life was extended to ˜1000h for 5 mm wide segments, with no failure observed out to 2000 h for segments ≤2.5 mm wide. Ribbed samples were even more durable, and segments ≤6 mm remained intact for 2000 h. Larger segments failed by buckling at times inversely related to the segment width and decreased by oxidation effects at higher temperatures. This critical buckling size was consistent with that predicted for elastic buckling of a TBC plate subject to thermal expansion mismatch stresses. Thus, low S substrates demonstrate appreciable coating lives without a bond coat, while rib segmenting extends life considerably.

Thermal barrier coatings with (Al2O3-Y2O3)/(Pt or Pt-Au) composite bond coat and 8YSZ top coat on Ni-based superalloy

NASA Astrophysics Data System (ADS)

Yao, Junqi; He, Yedong; Wang, Deren; Peng, Hui; Guo, Hongbo; Gong, Shengkai

2013-12-01

Developing new bond coat has been acknowledged as an effective way to extend the service life of thermal barrier coating (TBC) during high temperature. In this study, novel thermal barrier coating system, which is composed with an (Al2O3-Y2O3)/(Pt or Pt-Au) composite bond coat and a YSZ top coat on Ni-based superalloy, has been prepared by magnetron sputtering and EB-PVD, respectively. It is demonstrated, from the cyclic oxidation tests in air at 1100 °C for 200 h, that the YSZ top coat and alloy substrate can be bonded together effectively by the (Al2O3-Y2O3)/(Pt or Pt-Au) composite coating, showing excellent resistance to oxidation, cracking and buckling. These beneficial results can be attributed to the sealing effect of such composite coating, by which the alloy substrate can be protected from oxidation and the interdiffusion between the bond coat and alloy substrate can be avoided; and the toughening effect of noble metals and composite structure of bond coat, by which the micro-cracks propagation can be inhibited and the stress in bond coat can be relaxed. This ceramic/noble metal composite coating can be a considerable structure which would has great application prospect in the TBC.

Lower-Conductivity Ceramic Materials for Thermal-Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Low-Thermal-Conductivity Pyrochlore Oxide Materials Developed for Advanced Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Health Monitoring of Thermal Barrier Coatings by Mid-Infrared Reflectance

NASA Technical Reports Server (NTRS)

Eldridge, J. I.; Spuckler, C. M.; Nesbitt, J. A.; Street, K. W.

2002-01-01

Mid-infrared (MIR) reflectance is shown to be a powerful tool for monitoring the integrity of 8wt% yttria-stabilized zirconia (8YSZ) thermal barrier coatings (TBCs). Because of the translucent nature of plasma-sprayed 8YSZ TBCs, particularly at MIR wavelengths (3 to 5 microns), measured reflectance does not only originate from the TBC surface, but contains strong contributions from internal scattering within the coating as well as reflectance from the underlying TBC/substrate interface. Therefore, changes in MIR reflectance measurements can be used to monitor the progression of TBC delamination. In particular, MIR reflectance is shown to reproducibly track the progression of TBC delamination produced by repeated thermal cycling (to 1163 C) of plasma-sprayed 8YSZ TBCs on Rene N5 superalloy substrates. To understand the changes in MIR reflectance with the progression of a delamination crack network, a four-flux scattering model is used to predict the increase in MIR reflectance produced by the introduction of these cracks.

Thermal Conductivity and Erosion Durability of Composite Two-Phase Air Plasma Sprayed Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Failure Analysis of Multilayered Suspension Plasma-Sprayed Thermal Barrier Coatings for Gas Turbine Applications

NASA Astrophysics Data System (ADS)

Gupta, M.; Markocsan, N.; Rocchio-Heller, R.; Liu, J.; Li, X.-H.; Östergren, L.

2018-02-01

Improvement in the performance of thermal barrier coatings (TBCs) is one of the key objectives for further development of gas turbine applications. The material most commonly used as TBC topcoat is yttria-stabilized zirconia (YSZ). However, the usage of YSZ is limited by the operating temperature range which in turn restricts the engine efficiency. Materials such as pyrochlores, perovskites, rare earth garnets are suitable candidates which could replace YSZ as they exhibit lower thermal conductivity and higher phase stability at elevated temperatures. The objective of this work was to investigate different multilayered TBCs consisting of advanced topcoat materials fabricated by suspension plasma spraying (SPS). The investigated topcoat materials were YSZ, dysprosia-stabilized zirconia, gadolinium zirconate, and ceria-yttria-stabilized zirconia. All topcoats were deposited by TriplexPro-210TM plasma spray gun and radial injection of suspension. Lifetime of these samples was examined by thermal cyclic fatigue and thermal shock testing. Microstructure analysis of as-sprayed and failed specimens was performed with scanning electron microscope. The failure mechanisms in each case have been discussed in this article. The results show that SPS could be a promising route to produce multilayered TBCs for high-temperature applications.

Fracture Behaviour of Plasma Sprayed Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Malzbender, Jürgen; Wakui, Takashi; Wessel, Egbert; Steinbrech, Rolf W.

Thermal barrier coatings (TBCs) of plasma sprayed yttria stabilised zirconia (YSZ) are increasingly utilised for heat exposed components of advanced gas turbines1,2. An important reason for the application of zirconia coatings is the low thermal conductivity of this ceramic material which is further diminished in a TBC by the high concentration of spraying induced microstructural defects, e.g. crack-shaped defects between and within the spraying splats. Thus with TBCs on gas cooled turbine components stiff temperature gradients can be realised as an important prerequisite for an increased thermal efficiency of the energy conversion process.

Ceramic Top Coats of Plasma-Sprayed Thermal Barrier Coatings: Materials, Processes, and Properties

NASA Astrophysics Data System (ADS)

Bakan, Emine; Vaßen, Robert

2017-08-01

The ceramic top coat has a major influence on the performance of the thermal barrier coating systems (TBCs). Yttria-partially-stabilized zirconia (YSZ) is the top coat material frequently used, and the major deposition processes of the YSZ top coat are atmospheric plasma spraying and electron beam physical vapor deposition. Recently, also new thermal spray processes such as suspension plasma spraying or plasma spray-physical vapor deposition have been intensively investigated for TBC top coat deposition. These new processes and particularly the different coating microstructures that can be deposited with them will be reviewed in this article. Furthermore, the properties and the intrinsic-extrinsic degradation mechanisms of the YSZ will be discussed. Following the TBC deposition processes and standard YSZ material, alternative ceramic materials such as perovskites and hexaaluminates will be summarized, while properties of pyrochlores with regard to their crystal structure will be discussed more in detail. The merits of the pyrochlores such as good CMAS resistance as well as their weaknesses, e.g., low fracture toughness, processability issues, will be outlined.

Anomalous Epitaxial Growth in Thermally Sprayed YSZ and LZ Splats

NASA Astrophysics Data System (ADS)

Chen, Lin; Yang, Guan-Jun

2017-08-01

Thermally sprayed coatings are essentially layered materials, and lamellar interfaces are of great importance to coatings' performances. In the present study, to investigate the microstructures and defect features at thermally sprayed coating interfaces, homoepitaxial 8 mol.% yttria-stabilized zirconia (YSZ) and heteroepitaxial lanthanum zirconia (LZ) films were fabricated. The epitaxial interfaces were examined by high-resolution transmission electron microscope (HR-TEM) in detail. As a result, we report, for the first time, an anomalous incommensurate homoepitaxial growth with mismatch-induced dislocations in thermally sprayed YSZ splats to create a homointerface. We also find the anomalous heteroepitaxial growth in thermally sprayed LZ splats. The mechanism of the anomalous incommensurate growth was analyzed in detail. Essentially, it is a pseudo-heteroepitaxy because of the lattice mismatch between the film and the locally heated substrate, as the locally heated substrate is significantly strained by its cold surroundings. Moreover, the super-high-density dislocations were found in the interfacial region, which resulted from sufficient thermal fluctuations and extremely rapid cooling rates. Both the anomalous lattice mismatch and super-high-density dislocations lead to weak interfaces and violent cracking in thermally sprayed coatings. These were also the essential differences between the conventional and the present epitaxy by thermal spray technique.

Advanced study of thermal behaviour of CSZ comparing with the classic YSZ coating

NASA Astrophysics Data System (ADS)

Dragomirescu, A.; Constantin, N.; Ştefan, A.; Manoliu, V.; Truşcă, R.

2017-01-01

Thermal barrier coatings (TBC) are advanced materials typically applied to metal surfaces subjected to extreme temperatures to protect them and increase their lifetime. Ceria stabilized zirconia ceramic layer (CSZ) is increasingly used as an alternative improved as replace for classical TBC system - yttria stabilized zirconia - thanks to superior properties, including mechanical and high resistance to thermal corrosion. The paper describes the thermal shock testing of two types of thermal barrier coatings used to protect a nickel super alloy. For the experimental procedure, it was used plate samples from nickel super alloy with a bond coat and a ceramic top coat. The top coat was different: on some samples, it was used YSZ and on others CSZ. Ni based super alloys have good corrosion resistance in reducing environments action, but poor in oxidizing conditions. Extreme environments can lead to loss of material by oxidation / corrosion, along with decreased mechanical properties of the substrate due to damaging elements which diffuses into the substrate at high temperatures. Using laboratory equipment, the TBC systems were exposed repeatedly to extreme high temperatures for a short time and then cooled. After the thermal shock tests, the samples were morph-structured characterized using electronic microscopy to analyze the changes. The experimental results were compared to rank the TBC systems in order of performance.

Mueller matrix polarimetry on plasma sprayed thermal barrier coatings for porosity measurement.

PubMed

Luo, David A; Barraza, Enrique T; Kudenov, Michael W

2017-12-10

Yttria-stabilized zirconia (YSZ) is the most widely used material for thermal plasma sprayed thermal barrier coatings (TBCs) used to protect gas turbine engine parts in demanding operation environments. The superior material properties of YSZ coatings are related to their internal porosity level. By quantifying the porosity level, tighter control on the spraying process can be achieved to produce reliable coatings. Currently, destructive measurement methods are widely used to measure the porosity level. In this paper, we describe a novel nondestructive approach that is applicable to classify the porosity level of plasma sprayed YSZ TBCs via Mueller matrix polarimetry. A rotating retarder Mueller matrix polarimeter was used to measure the polarization properties of the plasma sprayed YSZ coatings with different porosity levels. From these measurements, it was determined that a sample's measured depolarization ratio is dependent on the sample's surface roughness and porosity level. To this end, we correlate the depolarization ratio with the samples' surface roughness, as measured by a contact profilometer, as well as the total porosity level, in percentage measured using a micrograph and stereological analysis. With the use of this technique, a full-field and rapid measurement of porosity level can be achieved.

Erosion Performance of Gadolinium Zirconate-Based Thermal Barrier Coatings Processed by Suspension Plasma Spray

NASA Astrophysics Data System (ADS)

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.

Thermal barrier coating resistant to sintering

DOEpatents

Subramanian, Ramesh; Sabol, Stephen M.

2001-01-01

A device (10) having a ceramic thermal barrier coating layer (16) characterized by a microstructure having gaps (18) with a sintering inhibiting material (22) disposed on the columns (20) within the gaps (18). The sintering resistant material (22) is stable over the range of operating temperatures of the device (10) and is not soluble with the underlying ceramic layer (16). For a YSZ ceramic layer (16) the sintering resistant layer (22) may preferably be aluminum oxide or yttrium aluminum oxide, deposited as a continuous layer or as nodules.

Columnar-Structured Mg-Al-Spinel Thermal Barrier Coatings (TBCs) by Suspension Plasma Spraying (SPS)

NASA Astrophysics Data System (ADS)

Schlegel, N.; Ebert, S.; Mauer, G.; Vaßen, R.

2015-01-01

The suspension plasma spraying (SPS) process has been developed to permit the feeding of sub-micrometer-sized powder into the plasma plume. In contrast to electron beam-physical vapor deposition and plasma spray-physical vapor deposition, SPS enables the cost-efficient deposition of columnar-structured coatings. Due to their strain tolerance, these coatings play an important role in the field of thermal barrier coatings (TBCs). In addition to the cost-efficient process, attention was turned to the TBC material. Nowadays, yttria partially stabilized zirconia (YSZ) is used as standard TBC material. However, its long-term application at temperatures higher than 1200 °C is problematic. At these high temperatures, phase transitions and sintering effects lead to the degradation of the TBC system. To overcome those deficits of YSZ, Mg-Al-spinel was chosen as TBC material. Even though it has a lower melting point (~2135 °C) and a higher thermal conductivity (~2.5 W/m/K) than YSZ, Mg-Al-spinel provides phase stability at high temperatures in contrast to YSZ. The Mg-Al-spinel deposition by SPS resulted in columnar-structured coatings, which have been tested for their thermal cycling lifetime. Furthermore, the influence of substrate cooling during the spraying process on thermal cycling behavior, phase composition, and stoichiometry of the Mg-Al-spinel has been investigated.

Development and evaluation of suspension plasma sprayed yttria stabilized zirconia coatings as thermal barriers

NASA Astrophysics Data System (ADS)

van Every, Kent J.

The insulating effects from thermal barrier coatings (TBCs) in gas turbine engines allow for increased operational efficiencies and longer service lifetimes. Consequently, improving TBCs can lead to enhanced gas turbine engine performance. This study was conducted to investigate if yttria-stabilized zirconia (YSZ) coatings, the standard industrial choice for TBCs, produced from nano-sized powder could provide better thermal insulation than current commericial YSZ coatings generated using micron-sized powders. The coatings for this research were made via the recently developed suspension plasma spraying (SPS) process. With SPS, powders are suspended in a solvent containing dispersing agents; the suspension is then injected directly into a plasma flow that evaporates the solvent and melts the powder while transporting it to the substrate. Although related to the industrial TBC production method of air plasma spraying (APS), SPS has two important differences---the ability to spray sub-micron diameter ceramic particles, and the ability to alloy the particles with chemicals dissolved in the solvent. These aspects of SPS were employed to generate a series of coatings from suspensions containing ˜100 nm diameter YSZ powder particles, some of which were alloyed with neodymium and ytterbium ions from the solvent. The SPS coatings contained columnar structures not observed in APS TBCs; thus, a theory was developed to explain the formation of these features. The thermal conductivity of the coatings was tested to evaluate the effects of these unique microstructures and the effects of the alloying process. The results for samples in the as-sprayed and heat-treated conditions were compared to conventional YSZ TBCs. This comparison showed that, relative to APS YSZ coatings, the unalloyed SPS samples typically exhibited higher as-sprayed and lower heat-treated thermal conductivities. All thermal conductivity values for the alloyed samples were lower than conventional YSZ TBCs

Evaluation of thermal barrier coating systems on novel substrates

NASA Astrophysics Data System (ADS)

Pint, B. A.; Wright, I. G.; Brindley, W. J.

2000-06-01

Testing was conducted on both plasma-sprayed (PS) and electron beam-physical vapor deposited (EB-PVD) Y2O3-stabilized ZrO2 (YSZ) thermal barrier coatings (TBCs) applied directly to oxidation-resistant substrates such as β-NiAl, oxide-dispersed FeCrAl, and NiCr. On an alloy that forms a very adherent alumina scale, β-NiAl+Zr, the coating lifetime of YSZ in furnace cyclic tests was 6 or more times longer than on state-of-the-art, YSZ coatings on single-crystal Ni-base superalloys with MCrAlY or Pt aluminide bond coats. Coatings on FeCrAl alloys appear to be a viable option for applications such as the external skin of the X-33, single stage to orbit, reusable launch vehicle. Model chromia-forming bond coat compositions also show promise for power generation applications at temperatures where hot corrosion may be a major problem. In general, while this work examined unique materials systems, many of the same fundamental failure mechanisms observed in conventional TBCs were observed.

Ultra-High Temperature Thermal Barrier Coatings

DOE Office of Scientific and Technical Information (OSTI.GOV)

Jordan, Eric; Gell, Maurice; Wang, Jiwen

In this project, HiFunda LLC worked with the University of Connecticut (UConn) to demonstrate an attractive option for thermal barrier coatings (TBCs), namely yttrium aluminum garnet (YAG), which was well known to have proven thermal stability and excellent high-temperature mechanical properties. YAG and other higher temperature TBCs have not been used to date because they exhibit inadequate durability, resulting from (a) poor erosion resistance and (b) greater thermal expansion mismatch strains compared to 7YSZ. UConn had previously demonstrated that the solution precursor plasma spray (SPPS) process could produce a durable 7YSZ TBC resulting from a highly strain tolerant microstructure, consistingmore » of through-coating-thickness vertical cracks. HiFunda/UConn reasoned at the start of Phase I that such a strain-tolerant microstructure could produce durable, higher temperature TBCs. The Phase I work demonstrated the feasibility of that concept and of SPPS YAG TBCs. The Phase II work demonstrated that SPPS YAG coating possessed the necessary range of properties to be a viable high temperature TBC, including cyclic durability and reduced elevated temperature thermal conductivity. The SPPS YAG TBCs were shown to have the potential to be used at temperatures 200°C higher than APS YSZ, based on thermal stability, sinter resistance, and CMAS resistance. The overall technical objectives of this Phase 2A project were to further improve the commercial viability of SPPS by improving their performance capabilities and manufacturing economics. The improved performance capability was to be achieved through: (1) further reductions in thermal conductivity, which allows higher gas temperatures and/or thinner coatings to achieve similar gas temperatures; and (2) improved resistance to calcium magnesium alumnoslicate (CMAS) attack of the TBCs, which can yield improved lifetimes. The improved thermal conductivity and CMAs resistance was to be accomplished through compositional

Effects of Laser Remelting and Oxidation on NiCrAlY/8Y2O3-ZrO2 Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Xu, S. Q.; Zhu, C.; Zhang, Y.

2018-02-01

In this study, three groups of thermal barrier coatings (TBCs) samples were remelted by CO2 laser with different laser energy densities (1, 5 and 10 J/mm2) to seal the surface of yttria-stabilized zirconia (YSZ) coatings. Microscopic observations showed that the cracks size and the remelted depth in YSZ coatings increased. A 50-μm-thick dense layer was formed on the surface of YSZ coating in samples with 1 J/mm2 energy density. Microindentation tests showed that the Vickers hardness of YSZ coatings increases with the increase in laser energy density. After isothermal oxidation at 1200 °C for 200 h, thinner thermally growth oxides were found in laser remelted YSZ samples under energy density of 1 J/mm2 (6.32 ± 0.28 μm). Cyclic oxidation results showed that the weight gain per unit area of low energy density laser remelted TBCs was smaller than that of the high energy density laser remelted and as-sprayed TBCs.

Double-Layer Gadolinium Zirconate/Yttria-Stabilized Zirconia Thermal Barrier Coatings Deposited by the Solution Precursor Plasma Spray Process

NASA Astrophysics Data System (ADS)

Jiang, Chen; Jordan, Eric H.; Harris, Alan B.; Gell, Maurice; Roth, Jeffrey

2015-08-01

Advanced thermal barrier coatings (TBCs) with lower thermal conductivity, increased resistance to calcium-magnesium-aluminosilicate (CMAS), and improved high-temperature capability, compared to traditional yttria-stabilized zirconia (YSZ) TBCs, are essential to higher efficiency in next generation gas turbine engines. Double-layer rare-earth zirconate/YSZ TBCs are a promising solution. From a processing perspective, solution precursor plasma spray (SPPS) process with its unique and beneficial microstructural features can be an effective approach to obtaining the double-layer microstructure. Previously durable low-thermal-conductivity YSZ TBCs with optimized layered porosity, called the inter-pass boundaries (IPBs) were produced using the SPPS process. In this study, an SPPS gadolinium zirconate (GZO) protective surface layer was successfully added. These SPPS double-layer TBCs not only retained good cyclic durability and low thermal conductivity, but also demonstrated favorable phase stability and increased surface temperature capabilities. The CMAS resistance was evaluated with both accumulative and single applications of simulated CMAS in isothermal furnaces. The double-layer YSZ/GZO exhibited dramatic improvement in the single application, but not in the continuous one. In addition, to explore their potential application in integrated gasification combined cycle environments, double-layer TBCs were tested under high-temperature humidity and encouraging performance was recorded.

Monitoring Delamination of Plasma-Sprayed Thermal Barrier Coatings by Reflectance-Enhanced Luminescence

NASA Technical Reports Server (NTRS)

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.

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

NASA Astrophysics Data System (ADS)

Bradley, Christopher M.

-section components has become critical, but at the same time the service conditions have put our best alloy systems to their limits. As a result, implementation of cooling holes and thermal barrier coatings are new advances in hot-section technologies now looked at for modifications to reach higher temperature applications. Current thermal barrier coatings used in today's turbine applications is known as 8%yttria-stabilized zirconia (YSZ) and there are no coatings for current thrust chambers. Current research is looking at the applicability of 8%yttria-stabilized hafnia (YSH) for turbine applications and the implementation of 8%YSZ onto thrust chambers. This study intends to determine if the use of thermal barrier coatings are applicable for high heat flux thrust chambers using industrial YSZ will be advantageous for improvements in efficiency, thrust and longer service life by allowing the thrust chambers to be used more than once.

Fracture toughness of plasma-sprayed thermal barrier ceramics: Influence of processing, microstructure, and thermal aging

DOE PAGES

Dwivedi, Gopal; Viswanathan, Vaishak; Sampath, Sanjay; ...

2014-06-09

Fracture toughness has become one of the dominant design parameters that dictates the selection of materials and their microstructure to obtain durable thermal barrier coatings (TBCs). Much progress has been made in characterizing the fracture toughness of relevant TBC compositions in bulk form, and it has become apparent that this property is significantly affected by process-induced microstructural defects. In this investigation, a systematic study of the influence of coating microstructure on the fracture toughness of atmospheric plasma sprayed (APS) TBCs has been carried out. Yttria partially stabilized zirconia (YSZ) coatings were fabricated under different spray process conditions inducing different levelsmore » of porosity and interfacial defects. Fracture toughness was measured on free standing coatings in as-processed and thermally aged conditions using the double torsion technique. Results indicate significant variance in fracture toughness among coatings with different microstructures including changes induced by thermal aging. Comparative studies were also conducted on an alternative TBC composition, Gd 2Zr 2O 7 (GDZ), which as anticipated shows significantly lower fracture toughness compared to YSZ. Furthermore, the results from these studies not only point towards a need for process and microstructure optimization for enhanced TBC performance but also a framework for establishing performance metrics for promising new TBC compositions.« less

Thermal Conductivity and Expansion Coefficient of (Sm1- x Yb x )2Ce2O7 Ceramics for Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Xiaoge, Chen; Hongsong, Zhang; Kun, Sun; Xudan, Dang; Haoming, Zhang; Bo, Ren; An, Tang

2017-12-01

In the current paper, the (Sm1- x Yb x )2Ce2O7 ceramics were prepared via sol-gel and high-temperature solid reaction methods. The phase composition, microstructure, thermal conductivity, and expansion coefficient were investigated. Results indicate that pure (Sm1- x Yb x )2Ce2O7 ceramics with single defect-fluorite structure are synthesized successfully. Owing to the phonon scattering caused by Yb addition, the thermal conductivity of (Sm1- x Yb x )2Ce2O7 ceramics decreases with increasing Yb2O3 content at identical temperatures, which is lower than that of YSZ. Due to the relatively low ionic radius of Yb3+ ions, the addition of Yb2O3 decreases the thermal expansion coefficient of (Sm1- x Yb x )2Ce2O7 ceramics, which is higher than that of 8YSZ. The synthesized (Sm1- x Yb x )2Ce2O7 ceramics can be explored as candidate materials for thermal barrier coatings.

Phosphor-Doped Thermal Barrier Coatings Deposited by Air Plasma Spray for In-Depth Temperature Sensing

PubMed Central

Peng, Di; Yang, Lixia; Cai, Tao; Liu, Yingzheng; Zhao, Xiaofeng; Yao, Zhiqi

2016-01-01

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. PMID:27690037

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

NASA Astrophysics Data System (ADS)

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

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

NASA Astrophysics Data System (ADS)

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

Non-contact temperature Raman measurement in YSZ and alumina ceramics

NASA Astrophysics Data System (ADS)

Thapa, Juddha; Chorpening, Benjamin T.; Buric, Michael P.

2018-02-01

Yttria-stabilized zirconia (YSZ: ZrO2 + Y2O3) and alumina (Al2O3) are widely used in high-temperature applications due to their high-temperature stability, low thermal conductivity, and chemical inertness. Alumina is used extensively in engineered ceramic applications such as furnace tubes and thermocouple protection tubes, while YSZ is commonly used in thermal barrier coatings on turbine blades. Because they are already often found in high temperature and combustion applications, these two substances have been compared as candidates for Raman thermometry in high-temperature energy-related applications. Both ceramics were used with as-received rough surfaces, i.e., without polishing or modification. This closely approximates surface conditions in practical high-temperature situations. A single-line argon ion laser at 488nm was used to excite the materials inside a cylindrical furnace while measuring Raman spectra with a fixed-grating spectrometer. The shift in the peak positions of the most intense A1g peak at 418cm-1 (room temperature position) of alumina ceramic and relatively more symmetric Eg peak at 470cm-1 (room temperature position) of YSZ were measured and reported along with a thermocouple-derived reference temperature up to about 1000°C. This study showed that alumina and YSZ ceramics can be used in high-temperature Raman thermometry with an accuracy of 4.54°C and 10.5°C average standard deviations respectively over the range of about 1000°C. We hope that this result will guide future researchers in selecting materials and utilizing Raman non-contact temperature measurements in harsh environments.

Higher Temperature Thermal Barrier Coatings with the Combined Use of Yttrium Aluminum Garnet and the Solution Precursor Plasma Spray Process

NASA Astrophysics Data System (ADS)

Gell, Maurice; Wang, Jiwen; Kumar, Rishi; Roth, Jeffery; Jiang, Chen; Jordan, Eric H.

2018-04-01

Gas-turbine engines are widely used in transportation, energy and defense industries. The increasing demand for more efficient gas turbines requires higher turbine operating temperatures. For more than 40 years, yttria-stabilized zirconia (YSZ) has been the dominant thermal barrier coating (TBC) due to its outstanding material properties. However, the practical use of YSZ-based TBCs is limited to approximately 1200 °C. Developing new, higher temperature TBCs has proven challenging to satisfy the multiple property requirements of a durable TBC. In this study, an advanced TBC has been developed by using the solution precursor plasma spray (SPPS) process that generates unique engineered microstructures with the higher temperature yttrium aluminum garnet (YAG) to produce a TBC that can meet and exceed the major performance standards of state-of-the-art air plasma sprayed YSZ, including: phase stability, sintering resistance, CMAS resistance, thermal cycle durability, thermal conductivity and erosion resistance. The temperature improvement for hot section gas turbine materials (superalloys & TBCs) has been at the rate of about 50 °C per decade over the last 50 years. In contrast, SPPS YAG TBCs offer the near-term potential of a > 200 °C improvement in temperature capability.

Oxidation behavior of thermal barrier coating systems with Al interlayer under isothermal loading

NASA Astrophysics Data System (ADS)

Ali, I.; Sokołowski, P.; Grund, T.; Pawłowski, L.; Lampke, T.

2018-06-01

In the present study, the phenomena related to the Thermally Grown Oxides (TGO) in atmospheric plasma sprayed Thermal Barrier Coatings (TBCs) are discussed. CoNiCrAlY bond coatings were sprayed on Inconel 600 substrates. Subsequently, thin Al layers were deposited by DC-Magnetron sputtering. Finally, yttria-stabilized zirconia (YSZ) top coatings were deposited to form a three-layered TBC system. The thus produced aluminum interlayer containing thermal barrier coatings (Al-TBC) were subjected to isothermal exposure with different holding times at 1150 °C and compared with reference TBCs of the same kind, but without Al interlayers (R-TBC). The oxide film formation in the interface between bond coating (BC) and top coating (TC) was investigated by scanning electron microscope (SEM) after 100 and 300 h of high temperature isothermal exposure. The growth of this oxide film as a function of the isothermal exposure time was studied. As a result, the designed Al-TBC system exhibited better oxidation resistance in the BC/TC interface than the two-layered R-TBC system. This was lead back to the Al enrichment, which slows down the formation rate of transition metal oxides during thermal loading.

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

PubMed

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.

Highly Segmented Thermal Barrier Coatings Deposited by Suspension Plasma Spray: Effects of Spray Process on Microstructure

NASA Astrophysics Data System (ADS)

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.

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

PubMed Central

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

Ultrasonic Detection of Delamination and Material Characterization of Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Chen, Hung-Liang Roger; Zhang, Binwei; Alvin, Mary Anne; Lin, Yun

2012-12-01

This article describes ultrasonic nondestructive evaluation (NDE) to detect the changes of material properties and provide early warning of delamination in thermal barrier coating (TBC) systems. NDE tests were performed on single-crystal René N5 superalloy coupons that were coated with a commercially available MCrAlY bond coat and an air plasma sprayed 7% yttria-stabilized zirconia (YSZ) top coat deposited by Air Plasma Spray method, as well as Haynes 230 superalloy coupons coated with MCrA1Y bond coat, and an electron beam physical vapor deposit of 7% YSZ top coat. The TBC coupons were subjected to either cyclic or isothermal exposure for various lengths of time at temperatures ranging from 900 to 1100 °C. The ultrasonic measurements performed on the coupons had provided an early warning of delamination along the top coat/TGO interface before exposure time, when delamination occurred. The material's property (Young's modulus) of the top coat was estimated using the measured wave speeds. Finite element analysis (FEA) of the ultrasonic wave propagation was conducted on a simplified TBC system to verify experimental observations. The technique developed was also demonstrated on an as-manufactured turbine blade to estimate normalized top coat thickness measurements.

Novel Functionally Graded Thermal Barrier Coatings in Coal-Fired Power Plant Turbines

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhang, Jing

This project presents a detailed investigation of a novel functionally graded coating material, pyrochlore oxide, for thermal barrier coating (TBC) in gas turbines used in coal-fired power plants. Thermal barrier coatings are refractory materials deposited on gas turbine components, which provide thermal protection for metallic components at operating conditions. The ultimate goal of this research is to develop a manufacturing process to produce the novel low thermal conductivity and high thermal stability pyrochlore oxide based coatings with improved high-temperature durability. The current standard TBC, yttria stabilized zirconia (YSZ), has service temperatures limited to <1200°C, due to sintering and phase transitionmore » at higher temperatures. In contrast, pyrochlore oxide, e.g., lanthanum zirconate (La 2Zr 2O 7, LZ), has demonstrated lower thermal conductivity and better thermal stability, which are crucial to high temperature applications, such as gas turbines used in coal-fired power plants. Indiana University – Purdue University Indianapolis (IUPUI) has collaborated with Praxair Surface Technologies (PST), and Changwon National University in South Korea to perform the proposed research. The research findings are critical to the extension of current TBCs to a broader range of high-temperature materials and applications. Several tasks were originally proposed and accomplished, with additional new opportunities identified during the course of the project. In this report, a description of the project tasks, the main findings and conclusions are given. A list of publications and presentations resulted from this research is listed in the Appendix at the end of the report.« less

Advanced thermal barrier coatings for operation in high hydrogen content fueled gas turbines.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sampath, Sanjay

2015-04-02

roughness and resulted in improved TBC lifetimes. Processing based approaches of identifying optimal processing regimes deploying advanced in-situ coating property measurements and in-flight diagnostic tools were used to develop process maps for bond coats. Having established a framework for the bond coat processing using the HVOF process, effort were channeled towards fabrication of APS and VPS bond coats with the same material composition. Comparative evaluation of the three deposition processes with regard to their microstrcuture , surface profiles and TBC performance were carried out and provided valuable insights into factors that require concurrent consideration for the development of bond coats for advanced TBC systems. Over the course of this program several advancements were made on the development of durable thermal barrier coatings. Process optimization techniques were utilized to identify processing regimes for both conventional YSZ as well as other TBC compositions such as Gadolinium Zirconate and other Co-doped materials. Measurement of critical properties for these formed the initial stages of the program to identify potential challenges in their implementation as part of a TBC system. High temperature thermal conductivity measurements as well as sintering behavior of both YSZ and GDZ coatings were evaluated as part of initial efforts to undersand the influence of processing on coating properties. By effectively linking fundamental coating properties of fracture toughness and elastic modulus to the cyclic performance of coatings, a durability strategy for APS YSZ coatings was developed. In order to meet the goals of fabricating a multimaterial TBC system further research was carried out on the development of a gradient thermal conductivity model and the evaluation of sintering behavior of multimaterial coatings. Layer optimization for desired properties in the multimaterial TBC was achieved by an iterative feedback approach utilizing process maps and in

Manufacturing of Composite Coatings by Atmospheric Plasma Spraying Using Different Feed-Stock Materials as YSZ and MoSi2

NASA Astrophysics Data System (ADS)

Koch, D.; Mauer, G.; Vaßen, R.

2017-04-01

Yttria-stabilized zirconia (YSZ) is the state-of-the-art material for the top coat of thermal barrier coatings. To increase the efficiency and lifetime of gas turbines, the integration of MoSi2 as a healing material was proposed. A new method of manufacture was explored in order to enable the spraying of a homogeneous mixed layer of YSZ and MoSi2. As the chemical and physical properties of these powders are very different, they require contrasting process conditions. Due to the evaporation of Si from MoSi2 at spraying conditions suitable for YSZ, more moderate conditions and a shorter time of flight are required for depositing MoSi2. At the same time, the spraying conditions still need to be sufficient for melting the YSZ particles in order to produce a coating. To obtain a homogeneous mixture, both conditions can be matched using an injection system that allows powder injection at two different locations of the plasma jet. Two-color pyrometry during flight (DPV-2000, Tecnar) was used to monitor the actual particle temperature. By optimizing the injection point for the MoSi2, a mixed coating was obtained without decomposition of the MoSi2, which has been analyzed by means of XRD and SEM.

Structure and Thermal Expansion of YSZ and La 2Zr 2O 7 Above 1500°C from Neutron Diffraction on Levitated Samples

DOE PAGES

Ushakov, Sergey V.; Navrotsky, Alexandra; Weber, Richard J. K.; ...

2015-07-28

High-temperature time-of-flight neutron diffraction experiments were performed in this paper on cubic yttria-stabilized zirconia (YSZ, 10 mol% YO 1.5) and lanthanum zirconate (LZ) prepared by laser melting. Three spheroids of each composition were aerodynamically levitated and rotated in argon flow and heated with a CO 2 laser. Unit cell, positional and atomic displacement parameters were obtained by Rietveld analysis. Below ~1650°C the mean thermal expansion coefficient (TEC) for YSZ is higher than for LZ (13 ± 1 vs. 10.3 ± 0.6) × 10 -6/K. From ~1650°C to the onset of melting of LZ at ~2250°C, TEC for YSZ and LZmore » are similar and within (7 ± 2) × 10 -6/K. LZ retains the pyrochlore structure up to the melting temperature with Zr coordination becoming closer to perfectly octahedral. Congruently melting LZ is La deficient. The occurrence of thermal disordering of oxygen sublattice (Bredig transition) in defect fluorite structure was deduced from the rise in YSZ TEC to ~25 × 10 -6/K at 2350°C–2550°C with oxygen displacement parameters (U iso) reaching 0.1 Å 2, similar to behavior observed in UO 2. Acquisition of powder-like high-temperature neutron diffraction data from solid-levitated samples is feasible and possible improvements are outlined. Finally, this methodology should be applicable to a wide range of materials for high-temperature applications.« less

Detecting Thermal Barrier Coating Delamination Using Visible and Near-Infrared Luminescence from Erbium-Doped Sublayers

NASA Technical Reports Server (NTRS)

Eldridge, J. I.; Bencic, T. J.; Martin, R. E.; Singh, J.; Wolfe, D. E.

2007-01-01

Nondestructive diagnostic tools are needed to monitor early stages of delamination progression in thermal barrier coatings (TBCs) because the risk of delamination induced coating failure will compromise engine performance and safety. Previous work has demonstrated that for TBCs composed of yttria-stabilized zirconia (YSZ), luminescence from a buried europium-doped sublayer can be utilized to identify the location of TBC delamination from the substantially higher luminescence intensity observed from the delaminated regions of the TBC. Luminescence measurements from buried europium-doped layers depend on sufficient transmittance of the 532 nm excitation and 606 nm emission wavelengths through the attenuating undoped YSZ overlayer to produce easily detected luminescence. In the present work, improved delamination indication is demonstrated using erbium-doped YSZ sublayers. For visible-wavelength luminescence, the erbium-doped sublayer offers the advantage of a very strong excitation peak at 517 nm that can be conveniently excited a 514 nm Ar ion laser. More importantly, the erbium-doped sublayer also produces near-infrared luminescence at 1550 nm that is effectively excited by a 980 nm laser diode. Both the 980 nm excitation and the 1550 nm emission are transmitted through the TBC with much less attenuation than visible wavelengths and therefore show great promise for delamination monitoring through thicker or more highly scattering TBCs. The application of this approach for both electron beam physical vapor deposited (EB-PVD) and plasma-sprayed TBCs is discussed.

Gadolinia doped hafnia (Gd2O3- HfO 2) thermal barrier coatings for gas turbine applications

NASA Astrophysics Data System (ADS)

Gullapalli, Satya Kiran

Thermal efficiency of the gas turbines is influenced by the operating temperature of the hot gas path components. The material used for the hot gas path components can only withstand temperature up to a certain limit. Thermal barrier coatings (TBC) provide the additional thermal protection for these components and help the gas turbine achieve higher firing temperatures. Traditionally available yttria stabilized zirconia (YSZ) TBCs have a limitation up to 1200 C due to their phase transformation. The present work focuses on gadolinia based hafnia (GSH) TBCs to study their potential to replace the YSZ coatings. Different compositions of gadolinia doped hafnia coatings have been deposited using electron beam physical vapor deposition (EB-PVD) technique and characterized using x-ray diffraction (XRD) and scanning electron microscope (SEM). The crystal structure analysis performed using XRD confirmed the stabilization of the high temperature cubic phase of hafnia. Cross sectional analysis confirmed the presence of columnar structure in the coatings which is a signature of the EB-PVD coatings. Mechanical properties of the coatings were investigated using nanoindentation and nano impact testing at both room temperature and high temperature. Indentation tests indicate a reduction in hardness with an increase in temperature and gadolinia content in hafnia. Impact testing reveals the fracture resistance of the coatings as a function of stabilizer content and heat treatment. Thermal measurements and impedance testing was performed on the bulk material to study the effect of gadolinia content. Thermal cycling was performed to study the spallation behavior of the as deposited and aged samples. Finite element models were developed to study the interfacial stress development in the coatings subjected to thermal cycling.

Polypropylene Oil as a Fuel for Ni-YSZ | YSZ | LSCF Solid Oxide Fuel Cell

NASA Astrophysics Data System (ADS)

Pratiwi, Andini W.; Rahmawati, Fitria; Rochman, Refada A.; Syahputra, Rahmat J. E.; Prameswari, Arum P.

2018-01-01

This research aims to convert polypropylene plastic to polypropylene oil through pyrolysis method and use the polypropylene oil as fuel for Solid Oxide Fuel Cell, SOFC, to produce electricity. The material for SOFC single cell are Ni-YSZ, YSZ, and LSCF as anode, electrolyte and cathode, respectively. YSZ is yttria-stabilized-zirconia. Meanwhile, LSCF is a commercial La0.6Sr0.4Co0.2Fe0.8O3. The Ni-YSZ is a composite of YSZ with nickel powder. LSCF and Ni-YSZ slurry coated both side of YSZ electrolyte pellet through screen printing method. The result shows that, the produced polypropylene oil consist of C8 to C27 hydrocarbon chain. Meanwhile, a single cell performance test at 673 K, 773 K and 873 K with polypropylene oil as fuel, found that the maximum power density is 1.729 μW. cm-2 at 673 K with open circuit voltage value of 9.378 mV.

Determination of Scattering and Absorption Coefficients for Plasma-Sprayed Yttria-Stabilized Zirconia Thermal Barrier Coatings at Elevated Temperatures

NASA Technical Reports Server (NTRS)

Eldridge, Jeffrey I.; Spuckler, Charles M.; Markham, James R.

2009-01-01

The temperature dependence of the scattering and absorption coefficients for a set of freestanding plasma-sprayed 8 wt% yttria-stabilized zirconia (8YSZ) thermal barrier coatings (TBCs) was determined at temperatures up to 1360 C in a wavelength range from 1.2 micrometers up to the 8YSZ absorption edge. The scattering and absorption coefficients were determined by fitting the directional-hemispherical reflectance and transmittance values calculated by a four-flux Kubelka Munk method to the experimentally measured hemispherical-directional reflectance and transmittance values obtained for five 8YSZ thicknesses. The scattering coefficient exhibited a continuous decrease with increasing wavelength and showed no significant temperature dependence. The scattering is primarily attributed to the relatively temperature-insensitive refractive index mismatch between the 8YSZ and its internal voids. The absorption coefficient was very low (less than 1 per centimeter) at wavelengths between 2 micrometers and the absorption edge and showed a definite temperature dependence that consisted of a shift of the absorption edge to shorter wavelengths and an increase in the weak absorption below the absorption edge with increasing temperature. The shift in the absorption edge with temperature is attributed to strongly temperature-dependent multiphonon absorption. While TBC hemispherical transmittance beyond the absorption edge can be predicted by a simple exponential decrease with thickness, below the absorption edge, typical TBC thicknesses are well below the thickness range where a simple exponential decrease in hemispherical transmittance with TBC thickness is expected. [Correction added after online publication August 11, 2009: "edge to a shorter wavelengths" has been updated as edge to shorter wavelengths."

Multilayer thermal barrier coating systems

DOEpatents

Vance, Steven J.; Goedjen, John G.; Sabol, Stephen M.; Sloan, Kelly M.

2000-01-01

The present invention generally describes multilayer thermal barrier coating systems and methods of making the multilayer thermal barrier coating systems. The thermal barrier coating systems comprise a first ceramic layer, a second ceramic layer, a thermally grown oxide layer, a metallic bond coating layer and a substrate. The thermal barrier coating systems have improved high temperature thermal and chemical stability for use in gas turbine applications.

Catalytic thermal barrier coatings

DOEpatents

Kulkarni, Anand A.; Campbell, Christian X.; Subramanian, Ramesh

2009-06-02

A catalyst element (30) for high temperature applications such as a gas turbine engine. The catalyst element includes a metal substrate such as a tube (32) having a layer of ceramic thermal barrier coating material (34) disposed on the substrate for thermally insulating the metal substrate from a high temperature fuel/air mixture. The ceramic thermal barrier coating material is formed of a crystal structure populated with base elements but with selected sites of the crystal structure being populated by substitute ions selected to allow the ceramic thermal barrier coating material to catalytically react the fuel-air mixture at a higher rate than would the base compound without the ionic substitutions. Precious metal crystallites may be disposed within the crystal structure to allow the ceramic thermal barrier coating material to catalytically react the fuel-air mixture at a lower light-off temperature than would the ceramic thermal barrier coating material without the precious metal crystallites.

Evolution of the plasma-sprayed microstructure in 7 wt% yttria-stabilized zirconia thermal barrier coatings during uniaxial stress relaxation and the concomitant changes in material properties

NASA Astrophysics Data System (ADS)

Petorak, Christopher

The understanding of failure mechanisms in plasma sprayed 7 wt% yttria stabilized zirconia (YSZ) is a key step toward optimizing thermal barrier coating (TBC) usage, design, and life prediction. The purpose of the present work is to characterize and understand the stress relaxation behavior occurring in plasma-sprayed YSZ coatings, so that the correlating magnitude of unfavorable tensile stress, which coatings experienced upon cooling, may be reduced through microstructural design. The microstructure and properties of as-sprayed coatings changes immensely during service at high temperature, and therefore the effects of long heat-treatment times, and the concomitant change within the microstructure, on the time-dependent mechanical behavior of stand-alone YSZ coatings was studied in parallel with the as-sprayed coating condition. Aside from influencing the mechanical properties, stress relaxation also affects the insulating efficiency of plasma-sprayed 7wt% YSZ coatings. Directionally dependent changes in microstructure due to stress relaxation of a uniaxially applied stress at 1200°C were observed in plasma-sprayed coatings. Small angle neutron scattering (SANS) investigation of coatings after stress relaxation displayed a 46% reduction in the specific surface area connected to the load-orientation dependent closure of void surface area perpendicular to the applied load when compared to coatings sintered in air, i.e. no applied load. These anisotropic microstructural changes were linked to the thermal properties of the coating. For example, a coating stress relaxed from 60 MPa for 5-min at 1200°C exhibited a thermal conductivity of 2.1 W/m-K. A coating that was only heat-treated for 5-min at 1200°C (i.e. no stress applied) exhibited a thermal conductivity of 1.7 W/m·K. In the current study, uniaxial stress relaxation in plasma-sprayed 7wt% YSZ coatings was determined the result of: (1) A more uniform distribution of the applied load with time, (2) A reduction

Environmental degradation of oxidation resistant and thermal barrier coatings for fuel-flexible gas turbine applications

NASA Astrophysics Data System (ADS)

Mohan, Prabhakar

The development of thermal barrier coatings (TBCs) has been undoubtedly the most critical advancement in materials technology for modern gas turbine engines. TBCs are widely used in gas turbine engines for both power-generation and propulsion applications. Metallic oxidation-resistant coatings (ORCs) are also widely employed as a stand-alone protective coating or bond coat for TBCs in many high-temperature applications. Among the widely studied durability issues in these high-temperature protective coatings, one critical challenge that received greater attention in recent years is their resistance to high-temperature degradation due to corrosive deposits arising from fuel impurities and CMAS (calcium-magnesium-alumino-silicate) sand deposits from air ingestion. The presence of vanadium, sulfur, phosphorus, sodium and calcium impurities in alternative fuels warrants a clear understanding of high-temperature materials degradation for the development of fuel-flexible gas turbine engines. Degradation due to CMAS is a critical problem for gas turbine components operating in a dust-laden environment. In this study, high-temperature degradation due to aggressive deposits such as V2O5, P2O 5, Na2SO4, NaVO3, CaSO4 and a laboratory-synthesized CMAS sand for free-standing air plasma sprayed (APS) yttria stabilized zirconia (YSZ), the topcoat of the TBC system, and APS CoNiCrAlY, the bond coat of the TBC system or a stand-alone ORC, is examined. Phase transformations and microstructural development were examined by using x-ray diffraction, scanning electron microscopy, and transmission electron microscopy. This study demonstrated that the V2O5 melt degrades the APS YSZ through the formation of ZrV2O7 and YVO 4 at temperatures below 747°C and above 747°C, respectively. Formation of YVO4 leads to the depletion of the Y2O 3 stabilizer and the deleterious transformation of the YSZ to the monoclinic ZrO2 phase. The investigation on the YSZ degradation by Na 2SO4 and a Na2SO4 + V2

The effect of environment on thermal barrier coating lifetime

DOE PAGES

Pint, Bruce A.; Unocic, Kinga A.; Haynes, James Allen

2016-03-15

While the water vapor content of the combustion gas in natural gas-fired land-based turbines is ~10%, it can be 20–85% with coal-derived (syngas or H 2) fuels or innovative turbine concepts for more efficient carbon capture. Additional concepts envisage working fluids with high CO 2 contents to facilitate carbon capture and sequestration. To investigate the effects of changes in the gas composition on thermal barrier coating (TBC) lifetime, furnace cycling tests (1-h and 100-h cycles) were performed in air with 10, 50, and 90 vol. % water vapor and CO 2-10% H 2O and compared to prior results in drymore » air or O 2. Two types of TBCs were investigated: (1) diffusion bond coatings (Pt-diffusion or Pt-modified aluminide) with commercial electron-beam physical vapor-deposited yttria-stabilized zirconia (YSZ) top coatings on second-generation superalloy N5 and N515 substrates and (2) high-velocity oxygen fuel (HVOF) sprayed MCrAlYHfSi bond coatings with air plasma-sprayed YSZ top coatings on superalloys X4, 1483, or 247 substrates. For both types of coatings exposed in 1-h cycles, the addition of water vapor resulted in a decrease in coating lifetime, except for Pt-diffusion coatings which were unaffected by the environment. In 100-h cycles, environment was less critical, perhaps because coating failure was chemical (i.e., due to interdiffusion) rather than mechanical. As a result, in both 1-h and 100-h cycles, CO 2 did not appear to have any negative effect on coating lifetime.« less

Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

1993-01-01

In order to reduce heat transfer between a hot gas heat source and a metallic engine component, a thermal insulating layer of material is placed between them. This thermal barrier coating is applied by plasma spray processing the thin films. The coating has been successfully employed in aerospace applications for many years. Lewis Research Center, a leader in the development engine components coating technology, has assisted Caterpillar, Inc. in applying ceramic thermal barrier coatings on engines. Because these large engines use heavy fuels containing vanadium, engine valve life is sharply decreased. The barrier coating controls temperatures, extends valve life and reduces operating cost. Additional applications are currently under development.

Low Conductivity Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Investigation on the thermo-chemical reaction mechanism between yttria-stabilized zirconia (YSZ) and calcium-magnesium-alumino-silicate (CMAS)

NASA Astrophysics Data System (ADS)

Zhang, Dong-Bo; Wang, Bin-Yi; Cao, Jian; Song, Guan-Yu; Liu, Juan-Bo

2015-03-01

Thermal barrier coatings (TBCs) with Y2O3-stabilized ZrO2 (YSZ) top coat play a very important role in advanced turbine blades by considerably increasing the engine efficiency and improving the performance of highly loaded blades. However, at high temperatures, environment factors result in the failure of TBCs. The influence of calcium-magnesium-alumino-silicate (CMAS) is one of environment factors. Although thermo-physical effect is being paid attention to, the thermo-chemical reaction becomes the hot-spot in the research area of TBCs affected by CMAS. In this paper, traditional twolayered structured TBCs were prepared by electron beam physical vapor deposition (EBPVD) as the object of study. TBCs coated with CMAS were heated at 1240°C for 3 h. Additionally, 15 wt.% simulated molten CMAS powder and YSZ powder were mixed and heated at 1240°C or 1350°C for 48 h. SEM and EDS were adopted to detect morphology and elements distribution. According to XRD and TEM results, it was revealed that CMAS react with YSZ at high temperature and form ZrSiO4, Ca0.2Zr0.8O1.8 and Ca0.15Zr0.85O1.85 after reaction, as a result, leading to the failure of TBCs and decreasing the TBC lifetime.

Air Plasma-Sprayed Yttria and Yttria-Stabilized Zirconia Thermal Barrier Coatings Subjected to Calcium-Magnesium-Alumino-Silicate (CMAS)

NASA Astrophysics Data System (ADS)

Li, Wenshuai; Zhao, Huayu; Zhong, Xinghua; Wang, Liang; Tao, Shunyan

2014-08-01

Yttria (Y2O3) and zirconia (ZrO2) stabilized by 8 and 20 wt.%Y2O3 thermal barrier coatings (TBCs) subjected to calcium-magnesium-alumino-silicate (CMAS) have been investigated. Free-standing Y2O3, 8 and 20 wt.%YSZ coatings covered with synthetic CMAS slurry were heated at 1300 °C in air for 24 h in order to assess the effect of Y2O3 on the corrosion resistance of the coatings subjected to CMAS. The microstructures and phase compositions of the coatings were characterized by SEM, EDS, XRD, RS, and TEM. TBCs with higher Y2O3 content exhibited better CMAS corrosion resistance. Phase transformation of ZrO2 from tetragonal (t) to monoclinic (m) occurred during the interaction of 8YSZ TBCs and CMAS, due to the depletion of Y2O3 in the coating. Some amounts of original c-ZrO2 still survived in 20YSZ TBCs along with a small amount of m-ZrO2 that appeared after reaction with CMAS. Furthermore, Y2O3 coating was found to be particularly highly effective in resisting the penetration of molten CMAS glass at high temperature (1300 °C). This may be ascribed to the formation of sealing layers composed of Y-apatite phase [based on Ca4Y6 (SiO4)6O and Y4.67(SiO4)3O] by the high-temperature chemical interactions of Y2O3 coating and CMAS glass.

Phase Transformation and Lattice Parameter Changes of Non-trivalent Rare Earth-Doped YSZ as a Function of Temperature

NASA Astrophysics Data System (ADS)

Jiang, Shengli; Huang, Xiao; He, Zhang; Buyers, Andrew

2018-01-01

To examine the effect of doping/co-doping on high-temperature phase compositions of YSZ, stand-alone YSZ and CeO2 and Nb2O5 co-doped YSZ samples were prepared using mechanical alloy and high-temperature sintering. XRD analysis was performed on these samples from room temperature to 1100 °C. The results show that the structure for the co-doped samples tends to be thermally stable when the test temperature is higher than a critical value. Monoclinic phase was dominant in Nb2O5 co-doped YSZ at temperatures lower than 600 °C, while for the YSZ and CeO2 co-doped YSZ, cubic/tetragonal phase was dominant in the whole test temperature range. The lattice parameters for all the samples increase with increasing test temperature generally. The lattice parameters for the two non-trivalent rare earth oxides co-doped YSZ show that the lattice parameter a for the cubic phase of the Ce4+ co-doped YSZ is consistently greater than that of 7YSZ which is related to the presence of larger radius of Ce4+ in the matrix. The lattice parameters a, b, c for the monoclinic phase of Ce4+ co-doped YSZ are much closer to each other than that of the Nb5+ co-doped YSZ, indicating the former has better tendency to form cubic/tetragonal phase, which is desired for vast engineering applications.

Phase Transformation and Lattice Parameter Changes of Non-trivalent Rare Earth-Doped YSZ as a Function of Temperature

NASA Astrophysics Data System (ADS)

Jiang, Shengli; Huang, Xiao; He, Zhang; Buyers, Andrew

2018-05-01

To examine the effect of doping/co-doping on high-temperature phase compositions of YSZ, stand-alone YSZ and CeO2 and Nb2O5 co-doped YSZ samples were prepared using mechanical alloy and high-temperature sintering. XRD analysis was performed on these samples from room temperature to 1100 °C. The results show that the structure for the co-doped samples tends to be thermally stable when the test temperature is higher than a critical value. Monoclinic phase was dominant in Nb2O5 co-doped YSZ at temperatures lower than 600 °C, while for the YSZ and CeO2 co-doped YSZ, cubic/tetragonal phase was dominant in the whole test temperature range. The lattice parameters for all the samples increase with increasing test temperature generally. The lattice parameters for the two non-trivalent rare earth oxides co-doped YSZ show that the lattice parameter a for the cubic phase of the Ce4+ co-doped YSZ is consistently greater than that of 7YSZ which is related to the presence of larger radius of Ce4+ in the matrix. The lattice parameters a, b, c for the monoclinic phase of Ce4+ co-doped YSZ are much closer to each other than that of the Nb5+ co-doped YSZ, indicating the former has better tendency to form cubic/tetragonal phase, which is desired for vast engineering applications.

Low Conductive Thermal Barrier Coatings Produced by Ion Beam Assisted EB-PVD with Controlled Porosity, Microstructure Refinement and Alloying Additions for High Temperature Applications

NASA Technical Reports Server (NTRS)

Wolfe, Douglas E.; Singh, Jogender

2005-01-01

Various advanced Hafnia-based thermal barrier coatings (TBC) were applied on nickel-based superalloy coupons by electron beam physical vapor deposition. In addition, microstructural modifications to the coating material were made in an effort to reduce the thermal conductivity of the coating materials. Various processing parameters and coating system modifications were made in order to deposit the alloyed TBC with the desired microstructure and thus coating performance, some of which include applying coatings at substrate temperatures of 1150 C on both PtAl and CoNiCrAlY bond coated samples, as well as using 8YSZ as a bond layer. In addition, various characterization techniques including thermal cyclic tests, scanning electron microscopy, x-ray diffraction, thermal conductivity, and reflectivity measurements were performed. Although the coating microstructure was never fully optimized due to funding being cut short, significant reductions in thermal conductivity were accomplished through both chemistry changes (composition) and microstructural modifications.

Rocket Motor Joint Construction Including Thermal Barrier

NASA Technical Reports Server (NTRS)

Steinetz, Bruce M. (Inventor); Dunlap, Patrick H., Jr. (Inventor)

2002-01-01

A thermal barrier for extremely high temperature applications consists of a carbon fiber core and one or more layers of braided carbon fibers surrounding the core. The thermal barrier is preferably a large diameter ring, having a relatively small cross-section. The thermal barrier is particularly suited for use as part of a joint structure in solid rocket motor casings to protect low temperature elements such as the primary and secondary elastomeric O-ring seals therein from high temperature gases of the rocket motor. The thermal barrier exhibits adequate porosity to allow pressure to reach the radially outward disposed O-ring seals allowing them to seat and perform the primary sealing function. The thermal barrier is disposed in a cavity or groove in the casing joint, between the hot propulsion gases interior of the rocket motor and primary and secondary O-ring seals. The characteristics of the thermal barrier may be enhanced in different applications by the inclusion of certain compounds in the casing joint, by the inclusion of RTV sealant or similar materials at the site of the thermal barrier, and/or by the incorporation of a metal core or plurality of metal braids within the carbon braid in the thermal barrier structure.

Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Robinson, Craig

2017-01-01

This presentation summarizes NASA's advanced thermal barrier and environmental barrier coating systems, and the coating performance improvements that has recently been achieved and documented in laboratory simulated rig test conditions. One of the emphases has been placed on the toughness and impact resistance enhancements of the low conductivity, defect cluster thermal barrier coating systems. The advances in the next generation environmental barrier coatings for SiCSiC ceramic matrix composites have also been highlighted, particularly in the design of a new series of oxide-silicate composition systems to be integrated with next generation SiC-SiC turbine engine components for 2700F coating applications. Major technical barriers in developing the thermal and environmental barrier coating systems are also described. The performance and model validations in the rig simulated turbine combustion, heat flux, steam and calcium-magnesium-aluminosilicate (CMAS) environments have helped the current progress in improved temperature capability, environmental stability, and long-term fatigue-environment system durability of the advanced thermal and environmental barrier coating systems.

Derivative effect of laser cladding on interface stability of YSZ@Ni coating on GH4169 alloy: An experimental and theoretical study

NASA Astrophysics Data System (ADS)

Zheng, Haizhong; Li, Bingtian; Tan, Yong; Li, Guifa; Shu, Xiaoyong; Peng, Ping

2018-01-01

Yttria-stabilized zirconia YSZ@Ni core-shell nanoparticles were used to prepare a thermal barrier coating (TBC) on a GH4169 alloy by laser cladding. Microstructural analysis showed that the TBC was composed of two parts: a ceramic and a bonding layer. In places where the ZrO2/Al2O3 eutectic structure was present in the ceramic layer, the Ni atoms diffused into the bonding layer, as confirmed by energy-dispersive X-ray spectroscopy (EDS). The derivative effect of laser cladding results in the original YSZ@Ni core-shell nanoparticles being translated into the Al2O3 crystal, activating the YSZ. The mechanism of ceramic/metal interface cohesion was studied in depth via first-principles and molecular dynamics simulation. The results show that the trend in the diffusion coefficients of Ni, Fe, Al, and Ti is DNi > DFe > DTi > DAl in the melting or solidification process of the material. The enthalpy of formation for Al2O3 is less than that of TiO2, resulting in a thermally grown oxide (TGO) Al2O3 phase transformation. With regard to the electronic structure, the trend in Mulliken population is QO-Ni > QZr-O > QO-Al. Although the bonding is slightly weakened between ZrO2/Al2O3 (QZr-O = 0.158 < QO-Ni = 0.220) compared to that in ZrO2/Ni, TGO Al2O3 can improve the oxidation resistance of the metal matrix. Thus, by comparing the connective and diffusive processes, our findings lay the groundwork for detailed and comprehensive studies of the laser cladding process for the production of composite materials.

The Effect of Core Configuration on Thermal Barrier Thermal Performance

NASA Technical Reports Server (NTRS)

DeMange, Jeffrey J.; Bott, Robert H.; Druesedow, Anne S.

2015-01-01

Thermal barriers and seals are integral components in the thermal protection systems (TPS) of nearly all aerospace vehicles. They are used to minimize heat transfer through interfaces and gaps and protect underlying temperature-sensitive components. The core insulation has a significant impact on both the thermal and mechanical properties of compliant thermal barriers. Proper selection of an appropriate core configuration to mitigate conductive, convective and radiative heat transfer through the thermal barrier is challenging. Additionally, optimization of the thermal barrier for thermal performance may have counteracting effects on mechanical performance. Experimental evaluations have been conducted to better understand the effect of insulation density on permeability and leakage performance, which can significantly impact the resistance to convective heat transfer. The effect of core density on mechanical performance was also previously investigated and will be reviewed. Simple thermal models were also developed to determine the impact of various core parameters on downstream temperatures. An extended understanding of these factors can improve the ability to design and implement these critical TPS components.

The glass-like thermal conductivity in ZrO2-Dy3TaO7 ceramic for promising thermal barrier coating application

NASA Astrophysics Data System (ADS)

Wu, Peng; Hu, Ming Yu; Chong, Xiao Yu; Feng, Jing

2018-03-01

Using the solid-state reaction method, the (ZrO2)x-(Dy3TaO7)1-x (x = 0, 0.02, 0.04, 0.06, 0.08, and 0.1) ceramics are synthesized in this work. The identification of the crystal structures indicates that the (ZrO2)x-(Dy3TaO7)1-x ceramics belong to the orthorhombic system, and the space group is C2221 in spite of the value of x increasing to 0.1. The thermal conductivities of the (ZrO2)x-(Dy3TaO7)1-x ceramics range from 1.3 W/(m K) to 1.8 W/(m K), and this value is much lower than that of 7-8 YSZ (yttria-stabilized zirconia). Besides, the (ZrO2)x-(Dy3TaO7)1-x ceramics possess the glass-like thermal conductivity caused by intrinsic oxygen vacancies existing in the lattice of Dy3TaO7. Moreover, the results of thermal expansion rates demonstrate that the (ZrO2)x-(Dy3TaO7)1-x ceramics possess excellent high temperature phase stability, and the thermal expansion coefficients [(9.7-11) × 10-6 K-1] are comparable to that of 7-8 YSZ.

Investigation of the Mechanical Performance of Compliant Thermal Barriers

NASA Technical Reports Server (NTRS)

DeMange, Jeffrey J.; Bott, Robert J.; Dunlap, Patrick H.

2011-01-01

Compliant thermal barriers play a pivotal role in the thermal protection systems of advanced aerospace vehicles. Both the thermal properties and mechanical performance of these barriers are critical in determining their successful implementation. Due to the custom nature of many thermal barriers, designers of advanced spacecraft have little guidance as to the design, selection, and implementation of these elements. As part of an effort to develop a more fundamental understanding of the interrelationship between thermal barrier design and performance, mechanical testing of thermal barriers was conducted. Two different types of thermal barriers with several core insulation density levels ranging from 62 to 141 kg/cu m were investigated. Room-temperature compression tests were conducted on samples to determine load performance and assess thermal barrier resiliency. Results showed that the loading behavior of these thermal barriers was similar to other porous, low-density, compliant materials, such as elastomeric foams. Additionally, the insulation density level had a significant non-linear impact on the stiffness and peak loads of the thermal barriers. In contrast, neither the thermal barrier type nor the level of insulation density significantly influenced the room-temperature resiliency of the samples.

Improvement of adhesion and barrier properties of biomedical stainless steel by deposition of YSZ coatings using RF magnetron sputtering

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sánchez-Hernández, Z.E.; CICATA—Altamira, IPN. Grupo CIAMS, Km 14.5, Carretera Tampico-Puerto Industrial Altamira, C. P. 89600, Altamira, Tamps, México; Domínguez-Crespo, M.A., E-mail: mdominguezc@ipn.mx

The AISI 316L stainless steel (SS) has been widely used in both artificial knee and hip joints in biomedical applications. In the present study, yttria stabilized zirconia (YSZ, ZrO{sub 2} + 8% Y{sub 2}O{sub 3}) films were deposited on AISI 316L SS by radio-frequency magnetron sputtering using different power densities (50–250 W) and deposition times (30–120 min) from a YSZ target. The crystallographic orientation and surface morphology were studied using X-ray diffraction (XRD), scanning electron microscopy (SEM) and transmission electron microscopy (TEM). The effects of the surface modification on the corrosion performance of AISI 316L SS were evaluated in phosphatemore » buffered saline (PBS) solution using an electrochemical test on both the virgin and coated samples. The YSZ coatings have a (111) preferred orientation during crystal growth along the c-axis for short deposition times (30–60 min), whereas a polycrystalline structure forms during deposition times from 90 to 120 min. The corrosion protective character of the YSZ coatings depends on the crystal size and film thickness. A significant increase in adhesion and corrosion resistance by at least a factor of 46 and a higher breakdown potential were obtained for the deposited coatings at 200 W (120 min). - Highlights: • Well-formed and protective YSZ coatings were achieved on AISI 316L SS substrates. • Films grown at high power and long deposition time have polycrystalline structures. • The crystal size varies from ∼ 5 to 30 nm as both power and deposition time increased. • The differences of corrosion resistance are attributed to internal film structure.« less

Metallic seal for thermal barrier coating systems

NASA Technical Reports Server (NTRS)

Miller, Robert A. (Inventor)

1990-01-01

The invention is particularly concerned with sealing thermal barrier coating systems of the type in use and being contemplated for use in diesel and other internal combustion engines. The invention also would find application in moderately high temperature regions of gas turbine engines and any other application employing a thermal barrier coating at moderate temperatures. Ni-35Cr-6Al-1Y, Ni-35Cr-6Al-1Yb, or other metallic alloy denoted as MCrAlx is applied over a zirconia-based thermal barrier overlayer. The close-out layer is glass-bead preened to densify its surface. This seals and protects the thermal barrier coating system.

Overview of thermal barrier coatings in diesel engines

NASA Technical Reports Server (NTRS)

Yonushonis, T. M.

1995-01-01

An understanding of delamination mechanisms in thermal barrier coatings has been developed for diesel applications through nondestructive evaluation, structural analysis modeling and engine evaluation of various thermal barrier coatings. This knowledge has resulted in improved thermal barrier coatings which survive abusive cyclic fatigue tests in high output diesel engines. Significant efforts are still required to improve the plasma spray processing capability and the economics for complex geometry diesel engine components. Data obtained from advanced diesel engines on the effect of thermal barrier coatings on engine fuel economy and emission has not been encouraging. Although the underlying metal component temperatures have been reduced through the use of thermal barrier coating, engine efficiency and emission trends have not been promising.

Thermal Conductivity and Sintering Behavior of Advanced Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Thermal Barrier Coating Workshop, 1997

NASA Technical Reports Server (NTRS)

Brindley, William J. (Compiler)

1998-01-01

This document contains papers from the 1997 Thermal Barrier Coatings Workshop, sponsored by the TBC Interagency Coordination Committee. The Workshop was held in Fort Mitchell, Kentucky, May 19-21, 1997. The papers cover the topics of heat transfer and conductivity of thermal barrier coatings, failure mechanisms and characterization of the coatings as well as characterization of coating deposition methods. Speakers included research, development and user groups in academia, industry and government.

Porosity determination of thermal barrier coatings

NASA Technical Reports Server (NTRS)

Van Roode, Mark; Beardsley, Brad

1988-01-01

Coating porosity is believed to be a critical factor for the thermal conductivity of thermal barrier coatings (TBCs). A number of different techniques have been used to determine the porosities of thermal barrier coatings for diesel applications as part of a NASA/DOE sponsored study. A comparison is made between methods based on water immersion, optical microscopy, eddy current thickness measurements, and Archimedes principle for TBC porosity determination.

A sputtered zirconia primer for improved thermal shock resistance of plasma sprayed ceramic turbine seals

NASA Technical Reports Server (NTRS)

Bill, R. C.; Sovey, J.; Allen, G. P.

1981-01-01

The development of plasma-sprayed yttria stabilized zirconia (YSZ) ceramic turbine blade tip seal components is discussed. The YSZ layers are quite thick (0.040 to 0.090 in.). The service potential of seal components with such thick ceramic layers is cyclic thermal shock limited. The most usual failure mode is ceramic layer delamination at or very near the interface between the plasma sprayed YSZ layer and the NiCrAlY bondcoat. Deposition of a thin RF sputtered YSZ primer to the bondcoat prior to deposition of the thick plasma sprayed YSZ layer was found to reduce laminar cracking in cyclic thermal shock testing. The cyclic thermal shock life of one ceramic seal design was increased by a factor of 5 to 6 when the sputtered YSZ primer was incorporated. A model based on thermal response of plasma sprayed YSZ particles impinging on the bondcoat surface with and without the sputtered YSZ primer provides a basis for understanding the function of the primer.

RETRACTED: Chemical densification of plasma sprayed yttria stabilized zirconia (YSZ) coatings for high temperature wear and corrosion resistance

NASA Astrophysics Data System (ADS)

Ye, Yaping; Fehr, Karl Thomas; Faulstich, Martin; Wolf, Gerhard

2012-12-01

Plasma-sprayed yttria stabilized zirconia (YSZ) ceramic coatings have been widely used as wear- and corrosion-resistant coatings in high temperature applications and an aggressive environment due to their high hardness, wear resistance, heat and chemical resistance, and low thermal conductivity. The highly porous structure of plasma-sprayed ceramic coatings and their poor adhesion to the substrate usually lead to the coating degradation and failure. In this study, a two-layer system consisting of atmospheric plasma-sprayed 8 wt.% yttria-stabilized zirconia (8YSZ) and Ni-based alloy coatings was post-treated by means of a novel chemical sealing process at moderate temperatures of 600-800 °C. Microstructure characteristics of the YSZ coatings were studied using an electron probe micro-analyzer (EPMA). Results revealed that the ceramic top coat was densified by the precipitated zirconia in the open pores. Therefore, the sealed YSZ coatings exhibit reduced porosity, higher hardness and a better adhesion onto the bond coat. The mechanisms for the sealing process were also proposed.

Thermal barriers for compartments

DOEpatents

Kreutzer, Cory J.; Lustbader, Jason A.

2017-10-17

An aspect of the present disclosure is a thermal barrier that includes a core layer having a first surface, a second surface, and a first edge, and a first outer layer that includes a third surface and a second edge, where the third surface substantially contacts the first surface, the core layer is configured to minimize conductive heat transfer through the barrier, and the first outer layer is configured to maximize reflection of light away from the barrier.

Thermal conductivity of zirconia thermal barrier coatings

NASA Technical Reports Server (NTRS)

Dinwiddie, R. B.; Beecher, S. C.; Nagaraj, B. A.; Moore, C. S.

1995-01-01

Thermal barrier coatings (TBC's) 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 TBC's is of primary importance. Physical vapor description (PVD) and plasma spraying (PS) are the two most commonly used coating techniques. These techniques produce coatings with unique microstructures which control their performance and stability. The PS coatings were applied with either standard power or hollow sphere particles. The hollow sphere particles yielded a lower density and lower thermal conductivity coating. The thermal conductivity of both fully and partially stabilized zirconia, before and after thermal aging, will be compared. The thermal conductivity of the coatings permanently increase upon being exposed to high temperatures. These increases are attributed to microstructural changes within the coatings. Sintering of the as fabricated plasma sprayed lamellar structure is observed by scanning electron microscopy of coatings isothermally heat treated at temperatures greater than 1100 C. During this sintering process the planar porosity between lamella is converted to a series of small spherical pores. The change in pore morphology is the primary reason for the observed increase in thermal conductivity. This increase in thermal conductivity can be modeled using a relationship which depends on both the temperature and time of exposure. Although the PVD coatings are less susceptible to thermal aging effects, preliminary results suggest that they have a higher thermal conductivity than PS coatings, both before and after thermal aging. The increases in thermal conductivity due to thermal aging for partially stabilized plasma sprayed zirconia have been found to be less than for fully stabilized plasma sprayed zirconia coatings. The high temperature thermal diffusivity data indicates that if these coatings reach a temperature above

Thermal conductivity of zirconia thermal barrier coatings

NASA Technical Reports Server (NTRS)

Dinwiddie, R. B.; Beecher, S. C.; Nagaraj, B. A.; Moore, C. S.

1995-01-01

Thermal barrier coatings (TBC's) 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 TBC's is of primary importance. Physical vapor deposition (PVD) and plasma spraying (PS) are the two most commonly used coating techniques. These techniques produce coatings with unique microstructures which control their performance and stability. The PS coatings were applied with either standard powder or hollow sphere particles. The hollow sphere particles yielded a lower density and lower thermal conductivity coating. The thermal conductivity of both fully and partially stabilized zirconia, before and after thermal aging, will be compared. The thermal conductivity of the coatings permanently increases upon exposed to high temperatures. These increases are attributed to microstructural changes within the coatings. Sintering of the as-fabricated plasma sprayed lamellar structure is observed by scanning electron microscopy of coatings isothermally heat treated at temperatures greater than 1100 C. During this sintering process the planar porosity between lamella is converted to a series of small spherical pores. The change in pore morphology is the primary reason for the observed increase in thermal conductivity. This increase in thermal conductivity can be modeled using a relationship which depends on both the temperature and time of exposure. Although the PVD coatings are less susceptible to thermal aging effects, preliminary results suggest that they have a higher thermal conductivity than PS coatings, both before and after thermal aging. The increases in thermal conductivity due to thermal aging for partially stabilized plasma sprayed zirconia have been found to be less than for fully stabilized plasma sprayed zirconia coatings. The high temperature thermal diffusivity data indicate that if these coatings reach a temperature above 1100 C

Overview of thermal barrier coatings in diesel engines

NASA Technical Reports Server (NTRS)

Yonushonis, Thomas M.

1995-01-01

An understanding of delamination mechanisms in thermal barrier coatings has been developed for diesel engine applications through rig tests, structural analysis modeling, nondestructive evaluation, and engine evaluation of various thermal barrier coatings. This knowledge has resulted in improved thermal barrier coatings which survive abusive cyclic fatigue tests in high output diesel engines. Although much conflicting literature now exists regarding the impact of thermal barrier coatings on engine performance and fuel consumption, the changes in fuel consumption appear to be less than a few percent and can be negative for state-of-the-art diesel engines. The ability of the thermal barrier coating to improve fuel economy tends to be dependent on a number of factors including the fuel injection system, combustion chamber design, and the initial engine fuel economy. Limited investigations on state-of-the-art diesel engines have indicated that the surface connected porosity and coating surface roughness may influence engine fuel economy. Current research efforts on thermal barrier coatings are primarily directed at reducing in-cylinder heat rejection, thermal fatigue protection of underlying metal surfaces and a possible reduction in diesel engine emissions. Significant efforts are still required to improve the plasma spray processing capability and the economics for complex geometry diesel engine components.

Thermal barrier skylight

DOE Office of Scientific and Technical Information (OSTI.GOV)

Couture, P.A.

1984-08-21

The skylight may be of the domed-type or flat-type and of single or double glass (acrylic or other transparent or translucent plastic) construction. The skylight fits within an opening in a roof or the like and has a peripheral base that may be constructed of a metal material such as aluminum, and which is fixed to the roof about the opening. The base comprises inner and outer base frames separated by a thermal break, a peripheral curb frame disposed over the base, and a retainer for securing the skylight cover over the curb frame. The curb frame or support framemore » has inner and outer sections connected by a heat insulating thermal barrier. The curb frame is constructed by welding at the corners of the support frame but eliminating the welding in the area of the thermal barrier thus alleviating a caulking operation at the top and the bottom of the curb frame. The base frame and curb frame have therebetween a compliant sealing means extending contiguously about and overlying the base frame and for sealing between the base frame and support frame.« less

Extending Our Understanding of Compliant Thermal Barrier Performance

NASA Technical Reports Server (NTRS)

Demange, Jeffrey J.; Finkbeiner, Joshua R.; Dunlap, Patrick H.

2014-01-01

Thermal barriers and seals are integral components in the thermal protection systems (TPS) of nearly all aerospace vehicles. They are used to minimize the flow of hot gases through interfaces and protect underlying temperature-sensitive components and systems. Although thermal barriers have been used extensively on many aerospace vehicles, the factors affecting their thermal and mechanical performance are not well-understood. Because of this, vehicle TPS designers are often left with little guidance on how to properly design and optimize these barriers. An ongoing effort to better understand thermal barrier performance and develop models and design tools is in progress at the NASA Glenn Research Center. Testing has been conducted to understand the degree to which insulation density influences structural performance and permeability. In addition, the development of both thermal and mechanical models is ongoing with the goal of providing an improved ability to design and implement these critical TPS components.

Thermal barrier coatings application in diesel engines

NASA Technical Reports Server (NTRS)

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 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.

Chemical vapor deposition of yttria-stabilized zirconia as a thermal barrier coating for gas turbine engines

NASA Astrophysics Data System (ADS)

Varanasi, Venu Gopal

The gas turbine engine uses an yttria-stabilized zirconia (YSZ) coating to provide thermal insulation for its turbine blades. This YSZ coating must be tetragonal in crystal structure, columnar in microstructure, and be 100--250 mum thick to provide for adequate protection for the turbine blades in the severe engine environment. Currently, YSZ coatings are fabricated by electron-beam physical vapor deposition (EB-PVD), but this fabrication method is cost intensive. Chemical vapor deposition (CVD) is a more commercially viable processing method and a possible alternative to EB-PVD. The deposition of tetragonal YSZ from gaseous metal and oxidation sources were studied. A chemical equilibrium analysis modeled the feasibility of depositing tetragonal YSZ for both chloride CVD (Zr-Y-C-O-Cl-H-Inert system) and metal-organic CVD (MOCVD) (Zr-Y-C-O-H system). Pure thermochemical properties and the assessed YSZ phase diagram were used in this analysis. Using the molar input of metals ((nY + nZr) and ( nY/(nY + nZr ) = 0.08)) as bases, equilibrium calculations showed that tetragonal YSZ formation was feasible. Tetragonal YSZ formation was feasible with high oxygen content (nO/(nY + nZr) > 8) and high temperature (T > 100°C) in the case of chloride CVD (Zr-Y-C-O-Cl-H-Inert). Tetragonal YSZ formation was feasible with high oxygen content (nO/( nY + nZr) > 5) and high temperature (T > 950°C) in the case of MOCVD (Zr-Y-C-O-H). Although solid carbon formation did not appear in chloride CVD, additional oxygen (nO/( nY + nZr) > 32) and low hydrogen content relative to carbon (nH/nC < 2) were required to avoid solid carbon formation in MOCVD. Coatings were deposited using a set of base conditions derived from the chemical equilibrium analysis. In chloride CVD, YCl3 was not included because of its low vapor pressure, thus, ZrCl4 was oxidized with the H2-CO2 gas mixture. Monoclinic ZrO2 coatings were deposited at the thermochemically optimized conditions (n O/(nY + nZr) > 8, T > 1004�

Thermal Conductivity of Ceramic Thermal Barrier and Environmental Barrier Coating Materials

NASA Technical Reports Server (NTRS)

Zhu, Dong-Ming; Bansal, Narottam P.; Lee, Kang N.; Miller, Robert A.

2001-01-01

Thermal barrier and environmental barrier coatings (TBC's and EBC's) have been developed to protect metallic and Si-based ceramic components in gas turbine engines from high temperature attack. Zirconia-yttria based oxides and (Ba,Sr)Al2Si2O8(BSAS)/mullite based silicates have been used as the coating materials. In this study, thermal conductivity values of zirconia-yttria- and BSAS/mullite-based coating materials were determined at high temperatures using a steady-state laser heat flux technique. During the laser conductivity test, the specimen surface was heated by delivering uniformly distributed heat flux from a high power laser. One-dimensional steady-state heating was achieved by using thin disk specimen configuration (25.4 mm diam and 2 to 4 mm thickness) and the appropriate backside air-cooling. The temperature gradient across the specimen thickness was carefully measured by two surface and backside pyrometers. The thermal conductivity values were thus determined as a function of temperature based on the 1-D heat transfer equation. The radiation heat loss and laser absorption corrections of the materials were considered in the conductivity measurements. The effects of specimen porosity and sintering on measured conductivity values were also evaluated.

Advanced Low Conductivity Thermal Barrier Coatings: Performance and Future Directions

NASA Technical Reports Server (NTRS)

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.

Thermal barrier coating having high phase stability

DOEpatents

Subramanian, Ramesh

2002-01-01

A device (10) comprising a substrate (22) having a deposited ceramic thermal barrier coating characterized by a microstructure having gaps (28) where the thermal barrier coating comprises a first thermal barrier layer (40), and a second thermal barrier layer (30) with a pyrochlore crystal structure having a chemical formula of A.sup.n+.sub.2-x B.sup.m+.sub.2+x O.sub.7-y, where A is selected from the group of elements consisting of La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and mixtures thereof, where B is selected from the group of elements consisting of Zr, Hf, Ti and mixtures thereof, where n and m are the valence of A and B respectively, and for -0.5.ltoreq.x.ltoreq.0.5, ##EQU1## and excluding the following combinations for x=0, y=0: A=La and B=Zr; A=La and B=Hf; A=Gd and B=Hf; and A=Yb and B=Ti.

Low Thermal Conductivity Yttrium Aluminum Garnet Thermal Barrier Coatings Made by the Solution Precursor Plasma Spray: Part II—Planar Pore Formation and CMAS Resistance

NASA Astrophysics Data System (ADS)

Kumar, Rishi; Jiang, Chen; Wang, Jiwen; Cietek, Drew; Roth, Jeffery; Gell, Maurice; Jordan, Eric H.

2018-06-01

Low thermal conductivity in yttrium aluminum garnet (YAG)-based thermal barrier coatings (TBCs) made by solution precursor plasma spray (SPPS) can be achieved by creating planar arrays of porosity called inter-pass boundaries (IPBs) as shown in Part I. In the current work, the mechanism of IPBs formation is studied through analysis of precursor entrainment and collection of single/raster step deposition patterns. It is concluded that the IPBs are formed by trapping precursor that under/over penetrates the plasma jet. CMAS interaction tests on SPPS YAG TBCs with heavy IPBs show an improvement of 123X and 15X over APS YSZ and SPPS YAG-light IPBs TBCs, respectively. It is demonstrated that the exceptional coating performance is because of the engineered heavy IPBs which branch out from the vertical cracks and run parallel to the surface. The CMAS melt gets drawn in the IPBs due to the capillary forces, leading to a shallow infiltration depth. The IPBs have a porosity of 70%, thus act as reservoirs for CMAS. Based on the favorable results, an alternate CMAS mitigation strategy is proposed that solely relies on microstructural features instead of the conventional approach where a vigorous reaction between CMAS-TBCs is desirable to form secondary phases.

A design perspective on thermal barrier coatings

NASA Astrophysics Data System (ADS)

Soechting, F. O.

1999-12-01

This article addresses the challenges for maximizing the benefit of thermal barrier coatings for turbine engine applications. The perspective is from the viewpoint of a customer, a turbine airfoil designer who is continuously challenged to increase the turbine inlet temperature capability for new products while maintaining cooling flow levels or even reducing them. This is a fundamental requirement for achieving increased engine thrust levels. Developing advanced material systems for the turbine flowpath airfoils, such as high-temperature nickel-base superalloys or thermal barrier coatings to insulate the metal airfoils from the hot flowpath environment, is one approach to solve this challenge. The second approach is to increase the cooling performance of the turbine airfoil, which enables increased flowpath temperatures and reduced cooling flow levels. Thermal barrier coatings have been employed in jet engine applications for almost 30 years. The initial application was on augmentor liners to provide thermal protection during afterburner operation. However, the production use of thermal barrier coatings in the turbine section has only occurred in the past 15 years. The application was limited to stationary parts and only recently incorporated on the rotating turbine blades. This lack of endorsement of thermal barrier coatings resulted from the poor initial duratbility of these coatings in high heat flux environments. Significant improvements have been made to enhance spallation resistance and erosion resistance, which has resulted in increased reliability of these coatings in turbine applications.

Thermal barrier coatings for gas turbine and diesel engines

NASA Technical Reports Server (NTRS)

Miller, Robert A.; Brindley, William J.; Bailey, M. Murray

1989-01-01

The present state of development of thin thermal barrier coatings for aircraft gas turbine engines and thick thermal barrier coatings for truck diesel engines is assessed. Although current thermal barrier coatings are flying in certain gas turbine engines, additional advances will be needed for future engines. Thick thermal barrier coatings for truck diesel engines have advanced to the point where they are being seriously considered for the next generation of engine. Since coatings for truck engines is a young field of inquiry, continued research and development efforts will be required to help bring this technology to commercialization.

Evaluation of Erosion Resistance of Advanced Turbine Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Thermal barrier coating

DOEpatents

Bowker, Jeffrey Charles; Sabol, Stephen M.; Goedjen, John G.

2001-01-01

A thermal barrier coating for hot gas path components of a combustion turbine based on a zirconia-scandia system. A layer of zirconium scandate having the hexagonal Zr.sub.3 Sc.sub.4 O.sub.12 structure is formed directly on a superalloy substrate or on a bond coat formed on the substrate.

Multicomponent, Rare-Earth-Doped Thermal-Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Thermal Fatigue and Fracture Behavior of Ceramic Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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

2001-01-01

Thermal fatigue and fracture behavior of plasma-sprayed ceramic thermal barrier coatings has been investigated under high heat flux and thermal cyclic conditions. The coating crack propagation is studied under laser heat flux cyclic thermal loading, and is correlated with dynamic fatigue and strength test results. The coating stress response and inelasticity, fatigue and creep interactions, and interface damage mechanisms during dynamic thermal fatigue processes are emphasized.

Thick thermal barrier coatings for diesel components

NASA Technical Reports Server (NTRS)

Yonushonis, T. M.

1991-01-01

An engineered thick thermal barrier coating consisting of multiple layers of zirconia and CoCrAlY with a zirconia top layer and having a system thermal conductance less than 410 w/m(exp 2)K exceeded the 100 hour engine durability goals set forth in this program. The thermal barrier coatings were intact at the test conclusion. Back to back single cylinder research engine tests were conducted with watercooled, metal hardware and oil-cooled, thermal barrier coating insulated hardware to determine apparent heat release and fuel economy. Apparent heat release data revealed that the insulated engine had a shorter ignition delay and a longer combustion duration than the metal engine. The insulated engine fuel economy was approximately two percent worse on average for this series of tests. There was no attempt to optimize engine efficiency of the insulated engine by modifying the engine timing, coating, or other techniques.

Metallographic techniques for evaluation of thermal barrier coatings

NASA Technical Reports Server (NTRS)

Brindley, William J.; Leonhardt, Todd A.

1990-01-01

The performance of ceramic thermal barrier coatings is strongly dependent on the amount and shape of the porosity in the coating. Current metallographic techniques do not provide polished surfaces that are adequate for a repeatable interpretation of the coating structures. A technique recently developed at NASA-Lewis for preparation of thermal barrier coating sections combines epoxy impregnation, careful sectioning and polishing, and interference layering to provide previously unobtainable information on processing-induced porosity. In fact, increased contrast and less ambiguous structure developed by the method make automatic quantitative metallography a viable option for characterizing thermal barrier coating structures.

Thermal model of attic systems with radiant barriers

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wilkes, K.E.

This report summarizes the first phase of a project to model the thermal performance of radiant barriers. The objective of this phase of the project was to develop a refined model for the thermal performance of residential house attics, with and without radiant barriers, and to verify the model by comparing its predictions against selected existing experimental thermal performance data. Models for the thermal performance of attics with and without radiant barriers have been developed and implemented on an IBM PC/AT computer. The validity of the models has been tested by comparing their predictions with ceiling heat fluxes measured inmore » a number of laboratory and field experiments on attics with and without radiant barriers. Cumulative heat flows predicted by the models were usually within about 5 to 10 percent of measured values. In future phases of the project, the models for attic/radiant barrier performance will be coupled with a whole-house model and further comparisons with experimental data will be made. Following this, the models will be utilized to provide an initial assessment of the energy savings potential of radiant barriers in various configurations and under various climatic conditions. 38 refs., 14 figs., 22 tabs.« less

Development of Advanced Low Conductivity Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Thermal-barrier coatings for utility gas turbines

NASA Technical Reports Server (NTRS)

Levine, S. R.; Miller, R. A.

1982-01-01

The potential of thermal barrier coatings for use in utility gas turbines was assessed. Pressurized passage and ambient pressure doped fuel burner rig tests revealed that thermal barrier coatings are not resistant to dirty combustion environments. However, present thermal barrier coatings, such as duplex partially stabilized zirconia and duplex Ca2SiO4 have ample resistance to the thermo-mechanical stress and temperature levels anticipated for heavy duty gas turbines firing clean fuel as revealed by clean fuel pressurized passage and ambient pressure burner rig tests. Thus, it is appropriate to evaluate such coatings on blades, vanes and combustors in the field. However, such field tests should be backed up with adequate effort in the areas of coating application technology and design analysis so that the field tests yield unequivocal results.

Buckling of thermally fluctuating spherical shells: Parameter renormalization and thermally activated barrier crossing

NASA Astrophysics Data System (ADS)

Baumgarten, Lorenz; Kierfeld, Jan

2018-05-01

We study the influence of thermal fluctuations on the buckling behavior of thin elastic capsules with spherical rest shape. Above a critical uniform pressure, an elastic capsule becomes mechanically unstable and spontaneously buckles into a shape with an axisymmetric dimple. Thermal fluctuations affect the buckling instability by two mechanisms. On the one hand, thermal fluctuations can renormalize the capsule's elastic properties and its pressure because of anharmonic couplings between normal displacement modes of different wavelengths. This effectively lowers its critical buckling pressure [Košmrlj and Nelson, Phys. Rev. X 7, 011002 (2017), 10.1103/PhysRevX.7.011002]. On the other hand, buckled shapes are energetically favorable already at pressures below the classical buckling pressure. At these pressures, however, buckling requires to overcome an energy barrier, which only vanishes at the critical buckling pressure. In the presence of thermal fluctuations, the capsule can spontaneously overcome an energy barrier of the order of the thermal energy by thermal activation already at pressures below the critical buckling pressure. We revisit parameter renormalization by thermal fluctuations and formulate a buckling criterion based on scale-dependent renormalized parameters to obtain a temperature-dependent critical buckling pressure. Then we quantify the pressure-dependent energy barrier for buckling below the critical buckling pressure using numerical energy minimization and analytical arguments. This allows us to obtain the temperature-dependent critical pressure for buckling by thermal activation over this energy barrier. Remarkably, both parameter renormalization and thermal activation lead to the same parameter dependence of the critical buckling pressure on temperature, capsule radius and thickness, and Young's modulus. Finally, we study the combined effect of parameter renormalization and thermal activation by using renormalized parameters for the energy

Similarity tests of turbine vanes, effects of ceramic thermal barrier coatings

NASA Technical Reports Server (NTRS)

Gladden, H. J.

1980-01-01

The role of material thermal conductivity was analyzed for its effect on the thermal performance of air-cooled gas turbine components coated with a ceramic thermal barrier material when tested at reduced temperatures and pressures. It is shown that the thermal performance can be evaluated reliably at reduced gas and coolant conditions; however, thermal conductivity corrections are required for the data at reduced conditions. Corrections for a ceramic thermal barrier coated vane are significantly different than for an uncoated vane. Comparison of uncorrected test data, therefore, would show erroneously that the thermal barrier coating was ineffective. When thermal conductivity corrections are applied to the test data these data are then shown to be representative of engine data and also show that the thermal barrier coating increases the vane cooling effectiveness by 12.5 percent.

Reusable Thermal Barrier for Insulation Gaps

NASA Technical Reports Server (NTRS)

Saladee, C. E.

1985-01-01

Filler composed of resilient, heat-resistant materials. Thermal barrier nestles snugly in gap between two tiles with minimal protrusion beyond faces of surrounding tiles. When removed from gap, barrier springs back to nearly original shape. Developed for filling spaces between tiles on Space Shuttle, also used in furnaces and kilns.

Characterization of Microstructure and Thermal Properties of YSZ Coatings Obtained by Axial Suspension Plasma Spraying (ASPS)

NASA Astrophysics Data System (ADS)

Ganvir, Ashish; Curry, Nicholas; Björklund, Stefan; Markocsan, Nicolaie; Nylén, Per

2015-10-01

The paper aims at demonstrating various microstructures which can be obtained using the suspension spraying technique and their respective significance in enhancing the thermal insulation property of a thermal barrier coating. Three different types of coating microstructures are discussed which were produced by the Axial Suspension Plasma Spraying. Detailed characterization of coatings was then performed. Optical and scanning electron microscopy were utilized for microstructure evaluations; x-ray diffraction for phase analysis; water impregnation, image analysis, and mercury intrusion porosimetry for porosity analysis, and laser flash analysis for thermal diffusivity measurements were used. The results showed that Axial Suspension Plasma Spraying can generate vertically cracked, porous, and feathery columnar-type microstructures. Pore size distribution was found in micron, submicron, and nanometer range. Higher overall porosity, the lower density of vertical cracks or inter-column spacing, and higher inter-pass porosity favored thermal insulation property of the coating. Significant increase in thermal diffusivity and conductivity was found at higher temperature, which is believed to be due to the pore rearrangement (sintering and pore coarsening). Thermal conductivity values for these coatings were also compared with electron beam physical vapor deposition (EBPVD) thermal barrier coatings from the literature and found to be much lower.

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

NASA Technical Reports Server (NTRS)

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.

Some aspects of the hot corrosion of thermal barrier coatings

NASA Technical Reports Server (NTRS)

Jones, Robert L.

1995-01-01

This paper provides a pro tem review of the hot corrosion of zirconia-based thermal barrier coatings for engine applications. Emphasis is placed on trying to understand the chemical reactions, and such other mechanisms as can be identified, that cause corrosive degradation of the thermal barrier coating. The various approaches taken in attempts to improve the hot corrosion resistance of thermal barrier coatings are also briefly described and critiqued.

Prolonging thermal barrier coated specimen life by thermal cycle management

NASA Technical Reports Server (NTRS)

Hendricks, R. C.; Mcdonald, G.; Poolos, N. P.

1981-01-01

Thermal barrier coatings applied to the heated side of engine components such as seals, combustor, and blades of a gas turbine offer a potential increase in efficiency through the use of higher gas temperatures or less cooling air or benefits arising from extended component life by reducing component metal temperatures. The considered investigation has the objective to show that while a thermal barrier coated (TBC) specimen can be brought to a fixed temperature using various fuel-air ratio (F/A) values, lower calculated stresses are associated with lower (F/A) values. This implies that control of (F/A) values (i.e., rates of heat input) during the starting transient and to a lesser extent during shutdown and operation, offers a potential method of improving TBC lifetime through thermal cycle management.

Atlas V Launch Incorporated NASA Glenn Thermal Barrier

NASA Technical Reports Server (NTRS)

Dunlap, Patrick H., Jr.; Steinetz, Bruce M.

2004-01-01

In the Spring of 2002, Aerojet experienced a major failure during a qualification test of the solid rocket motor that they were developing for the Atlas V Enhanced Expendable Launch Vehicle. In that test, hot combustion gas reached the O-rings in the nozzle-to-case joint and caused a structural failure that resulted in loss of the nozzle and aft dome sections of the motor. To improve the design of this joint, Aerojet decided to incorporate three braided carbon-fiber thermal barriers developed at the NASA Glenn Research Center. The thermal barriers were used to block the searing-hot 5500 F pressurized gases from reaching the temperature-sensitive O-rings that seal the joint. Glenn originally developed the thermal barriers for the nozzle joints of the space shuttle solid rocket motors, and Aerojet decided to use them on the basis of the results of several successful ground tests of the thermal barriers in the shuttle rockets. Aerojet undertook an aggressive schedule to redesign the rocket nozzle-to-case joint with the thermal barriers and to qualify it in time for a launch planned for the middle of 2003. They performed two successful qualification tests (Oct. and Dec. 2002) in which the Glenn thermal barriers effectively protected the O-rings. These qualification tests saved hundreds of thousands of dollars in development costs and put the Lockheed-Martin/Aerojet team back on schedule. On July 17, 2003, the first flight of an Atlas V boosted with solid rocket motors successfully launched a commercial satellite into orbit from Cape Canaveral Air Force Station. Aero-jet's two 67-ft solid rocket boosters performed flawlessly, with each providing thrust in excess of 250,000 lbf. Both motors incorporated three Glenn-developed thermal barriers in their nozzle-to-case joints. The Cablevision satellite launched on this mission will be used to provide direct-to-home satellite television programming for the U.S. market starting in late 2003. The Atlas V is a product of the

Thermal barrier coatings application in diesel engines

NASA Technical Reports Server (NTRS)

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

Thermal barrier coating on high temperature industrial gas turbine engines

NASA Technical Reports Server (NTRS)

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.

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

NASA Technical Reports Server (NTRS)

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.

Are thermal barriers "higher" in deep sea turtle nests?

PubMed

Santidrián Tomillo, Pilar; Fonseca, Luis; Paladino, Frank V; Spotila, James R; Oro, Daniel

2017-01-01

Thermal tolerances are affected by the range of temperatures that species encounter in their habitat. Daniel Janzen hypothesized in his "Why mountain passes are higher in the tropics" that temperature gradients were effective barriers to animal movements where climatic uniformity was high. Sea turtles bury their eggs providing some thermal stability that varies with depth. We assessed the relationship between thermal uniformity and thermal tolerance in nests of three species of sea turtles. We considered that barriers were "high" when small thermal changes had comparatively large effects and "low" when the effects were small. Mean temperature was lower and fluctuated less in species that dig deeper nests. Thermal barriers were comparatively "higher" in leatherback turtle (Dermochelys coriacea) nests, which were the deepest, as embryo mortality increased at lower "high" temperatures than in olive ridley (Lepidochelys olivacea) and green turtle (Chelonia mydas) nests. Sea turtles have temperature-dependent sex determination (TSD) and embryo mortality increased as temperature approached the upper end of the transitional range of temperatures (TRT) that produces both sexes (temperature producing 100% female offspring) in leatherback and olive ridley turtles. As thermal barriers are "higher" in some species than in others, the effects of climate warming on embryo mortality is likely to vary among sea turtles. Population resilience to climate warming may also depend on the balance between temperatures that produce female offspring and those that reduce embryo survival.

Thermal Diffusivity Measurement for Thermal Spray Coating Attached to Substrate Using Laser Flash Method

NASA Astrophysics Data System (ADS)

Akoshima, Megumi; Tanaka, Takashi; Endo, Satoshi; Baba, Tetsuya; Harada, Yoshio; Kojima, Yoshitaka; Kawasaki, Akira; Ono, Fumio

2011-11-01

Ceramic-based thermal barrier coatings are used as heat and wear shields of gas turbine blades. There is a strong need to evaluate the thermal conductivity of coating for thermal design and use. The thermal conductivity of a bulk material is obtained as the product of thermal diffusivity, specific heat capacity, and density above room temperature in many cases. Thermal diffusivity and thermal conductivity are unique for a given material because they are sensitive to the structure of the material. Therefore, it is important to measure them in each sample. However it is difficult to measure the thermal diffusivity and thermal conductivity of coatings because coatings are attached to substrates. In order to evaluate the thermal diffusivity of a coating attached to the substrate, we have examined the laser flash method with the multilayer model on the basis of the response function method. We carried out laser flash measurements in layered samples composed of a CoNiCrAlY bond coating and a 8YSZ top coating by thermal spraying on a Ni-based superalloy substrate. It was found that the procedure using laser flash method with the multilayer model is useful for the thermal diffusivity evaluation of a coating attached to a substrate.

Degradation of a two-layer thermal barrier coating under thermal cycling. [for superalloys of aircraft turbine engine blades

NASA Technical Reports Server (NTRS)

Maier, R. D.; Scheuermann, C. M.; Andrews, C. W.

1981-01-01

A two-layer plasma-sprayed thermal barrier coating on a directionally solidified nickel-base eutectic alloy substrate was characterized prior to and after thermal cycling to 1095 C in an accelerated furnace test. The coating was comprised of an inner layer of Ni-16.4Cr-5.1Al-0.15Y (wt%) bond coat and an outer layer of ZrO2-7.9Y2O3 (wt%) thermal barrier. Characterization of the bond coat revealed that substantial amounts of yttrium and aluminum were oxidized during plasma-spraying in air. The oxidation of these elements reduced the protective capacity of the bond coat so that, on thermal exposure, severe degradation of the bond coat resulted and large amounts of nickel oxide formed. This nickel oxide was demonstrated to grow outward into the thermal barrier, which appears to have increased the stresses in the thermal barrier and contributed to its failure near the thermal barrier-bond coat interface.

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

NASA Technical Reports Server (NTRS)

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.

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

NASA Technical Reports Server (NTRS)

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.

Noncontacting Laser Inspection System for Dimensional Profiling of Space Application Thermal Barriers

NASA Technical Reports Server (NTRS)

Taylor, Shawn C.

2011-01-01

A noncontacting, two-dimensional (2-D) laser inspection system has been designed and implemented to dimensionally profile thermal barriers being developed for space vehicle applications. In a vehicle as-installed state, thermal barriers are commonly compressed between load sensitive thermal protection system (TPS) panels to prevent hot gas ingestion through the panel interface during flight. Loads required to compress the thermal barriers are functions of their construction, as well as their dimensional characteristics relative to the gaps in which they are installed. Excessive loads during a mission could damage surrounding TPS panels and have catastrophic consequences. As such, accurate dimensional profiling of thermal barriers prior to use is important. Due to the compliant nature of the thermal barriers, traditional contact measurement techniques (e.g., calipers and micrometers) are subjective and introduce significant error and variability into collected dimensional data. Implementation of a laser inspection system significantly enhanced the method by which thermal barriers are dimensionally profiled, and improved the accuracy and repeatability of collected data. A statistical design of experiments study comparing laser inspection and manual caliper measurement techniques verified these findings.

Thermal Cyclic Behavior of Thermal and Environmental Barrier Coatings Investigated Under High-Heat-Flux Conditions

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Lee, Kang N.; Miller, Robert A.

2002-01-01

Environmental barrier coatings (EBC's) have been developed to protect silicon-carbide- (SiC) based ceramic components in gas turbine engines from high-temperature environmental attack. With continuously increasing demands for significantly higher engine operating temperature, future EBC systems must be designed for both thermal and environmental protection of the engine components in combustion gases. In particular, the thermal barrier functions of EBC's become a necessity for reducing the engine-component thermal loads and chemical reaction rates, thus maintaining the required mechanical properties and durability of these components. Advances in the development of thermal and environmental barrier coatings (TBC's and EBC's, respectively) will directly impact the successful use of ceramic components in advanced engines. To develop high-performance coating systems, researchers must establish advanced test approaches. In this study, a laser high-heat-flux technique was employed to investigate the thermal cyclic behavior of TBC's and EBC's on SiC-reinforced SiC ceramic matrix composite substrates (SiC/SiC) under high thermal gradient and thermal cycling conditions. Because the laser heat flux test approach can monitor the coating's real-time thermal conductivity variations at high temperature, the coating thermal insulation performance, sintering, and delamination can all be obtained during thermal cycling tests. Plasma-sprayed yttria-stabilized zirconia (ZrO2-8 wt% Y2O3) thermal barrier and barium strontium aluminosilicate-based environmental barrier coatings (BSAS/BSAS+mullite/Si) on SiC/SiC ceramic matrix composites were investigated in this study. These coatings were laser tested in air under thermal gradients (the surface and interface temperatures were approximately 1482 and 1300 C, respectively). Some coating specimens were also subject to alternating furnace cycling (in a 90-percent water vapor environment at 1300 C) and laser thermal gradient cycling tests

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

NASA Astrophysics Data System (ADS)

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

Vacuum application of thermal barrier plasma coatings

NASA Technical Reports Server (NTRS)

Holmes, R. R.; Mckechnie, T. N.

1988-01-01

Coatings are presently applied to Space Shuttle Main Engine (SSME) turbine blades for protection against the harsh environment realized in the engine during lift off-to-orbit. High performance nickel, chromium, aluminum, and yttrium (NiCrAlY) alloy coatings, which are applied by atmospheric plasma spraying, crack and spall off because of the severe thermal shock experienced during start-up and shut-down of the engine. Ceramic coatings of yttria stabilized zirconia (ZrO2-Y2O3) were applied initially as a thermal barrier over coating to the NiCrAlY but were removed because of even greater spalling. Utilizing a vacuum plasma spraying process, bond coatings of NiCrAlY were applied in a low pressure atmosphere of argon/helium, producing significantly improved coating-to-blade bonding. The improved coatings showed no spalling after 40 MSFC burner rig thermal shock cycles, cycling between 1700 and -423 F. The current atmospheric plasma NiCrAlY coatings spalled during 25 test cycles. Subsequently, a process was developed for applying a durable thermal barrier coating of ZrO2-Y2O3 to the turbine blades of first stage high-pressure fuel turbopumps utilizing the vacuum plasma process. The improved thermal barrier coating has successfully passed 40 burner rig thermal shock cycles without spalling. Hot firing in an SSME turbine engine is scheduled for the blades. Tooling was installed in preparation for vacuum plasma spray coating other SSME hardware, e.g., the titanium main fuel valve housing (MFVH) and the fuel turbopump nozzle/stator.

Controlled Thermal Expansion Coat for Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Are thermal barriers "higher" in deep sea turtle nests?

PubMed Central

Santidrián Tomillo, Pilar; Fonseca, Luis; Paladino, Frank V.; Spotila, James R.; Oro, Daniel

2017-01-01

Thermal tolerances are affected by the range of temperatures that species encounter in their habitat. Daniel Janzen hypothesized in his “Why mountain passes are higher in the tropics” that temperature gradients were effective barriers to animal movements where climatic uniformity was high. Sea turtles bury their eggs providing some thermal stability that varies with depth. We assessed the relationship between thermal uniformity and thermal tolerance in nests of three species of sea turtles. We considered that barriers were “high” when small thermal changes had comparatively large effects and “low” when the effects were small. Mean temperature was lower and fluctuated less in species that dig deeper nests. Thermal barriers were comparatively “higher” in leatherback turtle (Dermochelys coriacea) nests, which were the deepest, as embryo mortality increased at lower “high” temperatures than in olive ridley (Lepidochelys olivacea) and green turtle (Chelonia mydas) nests. Sea turtles have temperature-dependent sex determination (TSD) and embryo mortality increased as temperature approached the upper end of the transitional range of temperatures (TRT) that produces both sexes (temperature producing 100% female offspring) in leatherback and olive ridley turtles. As thermal barriers are “higher” in some species than in others, the effects of climate warming on embryo mortality is likely to vary among sea turtles. Population resilience to climate warming may also depend on the balance between temperatures that produce female offspring and those that reduce embryo survival. PMID:28545092

Thermal barrier coating life prediction model

NASA Technical Reports Server (NTRS)

Pilsner, B. H.; Hillery, R. V.; Mcknight, R. L.; Cook, T. S.; Kim, K. S.; Duderstadt, E. C.

1986-01-01

The objectives of this program are to determine the predominant modes of degradation of a plasma sprayed thermal barrier coating system, and then to develop and verify life prediction models accounting for these degradation modes. The program is divided into two phases, each consisting of several tasks. The work in Phase 1 is aimed at identifying the relative importance of the various failure modes, and developing and verifying life prediction model(s) for the predominant model for a thermal barrier coating system. Two possible predominant failure mechanisms being evaluated are bond coat oxidation and bond coat creep. The work in Phase 2 will develop design-capable, causal, life prediction models for thermomechanical and thermochemical failure modes, and for the exceptional conditions of foreign object damage and erosion.

Thermal barrier coating life prediction model development

NASA Technical Reports Server (NTRS)

Demasi, J. T.; Sheffler, K. D.

1986-01-01

The objective of this program is to establish a methodology to predict Thermal Barrier Coating (TBC) life on gas turbine engine components. The approach involves experimental life measurement coupled with analytical modeling of relevant degradation modes. The coating being studied is a flight qualified two layer system, designated PWA 264, consisting of a nominal ten mil layer of seven percent yttria partially stabilized zirconia plasma deposited over a nominal five mil layer of low pressure plasma deposited NiCoCrAlY. Thermal barrier coating degradation modes being investigated include: thermomechanical fatigue, oxidation, erosion, hot corrosion, and foreign object damage.

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

NASA Technical Reports Server (NTRS)

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.

Investigations of thermal barrier coatings of turbine parts using gas flame heating

NASA Astrophysics Data System (ADS)

Lepeshkin, A. R.; Bichkov, N. G.; Ilinskaja, O. I.; Nazarov, V. V.

2017-09-01

The development of methods for the calculated and experimental investigations thermal barrier coatings and thermal state of gas-turbine engine parts with a thermal barrier coatings is actual work. The gas flame heating was demonstrated to be effectively used during investigations of a thermal ceramic barrier coatings and thermal state of such gas-turbine engine parts with a TBC as the cooled turbine blades and vanes and combustion liner components. The gas-flame heating is considered to be preferable when investigating the gas-turbine engine parts with a TBC in the special cases when both the convective and radiant components of thermal flow are of great importance. The small-size rig with gas-flame flow made it possible to conduct the comparison investigations with the purpose of evaluating the efficiency of thermal protection of the ceramic deposited thermal barrier coatings on APS and EB techniques. The developed design-experiment method was introduced in bench tests of turbine blades and combustion liner components of gas turbine engines.

Thick thermal barrier coatings for diesel engines

NASA Technical Reports Server (NTRS)

Beardsley, M. B.

1995-01-01

Caterpillar's approach to applying Thick Thermal Barrier Coatings (TTBC's) to diesel engine combustion chambers has been to use advanced modeling techniques to predict engine conditions and combine this information with fundamental property evaluation of TTBC systems to predict engine performance and TTBC stress states. Engine testing has been used to verify the predicted performance of the TTBC systems and provide information on failure mechanisms. The objective of Caterpillar's subcontract with ORNL is to advance the fundamental understanding of thick thermal barrier coating systems. 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 TTBC's to diesel engines. Areas of TTBC technology being examined in this program include powder characteristics and chemistry; bond coat 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. Methods to evaluate the reliability and durability of TTBC's have been developed that attempt to understand the fundamental strength of TTBC's for particular stress states.

Thick thermal barrier coatings for diesel engines

NASA Technical Reports Server (NTRS)

Beardsley, M. Brad

1995-01-01

Caterpillar's approach to applying thick thermal barrier coatings (TTBC's) to diesel engine combustion chambers has been to use advanced modeling techniques to predict engine conditions and combine this information with fundamental property evaluation of TTBC systems to predict engine performance and TTBC stress states. Engine testing has been used to verify the predicted performance of the TTBC systems and provide information on failure mechanisms. The objective Caterpillar's program to date has been to advance the fundamental understanding of thick thermal barrier coating systems. 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 impeded the application of TTBC's to diesel engines. Areas of TTBC technology being examined in this program include powder characteristics and chemistry; bond coat 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. Methods to evaluate the reliability and durability of TTBC's have been developed that attempt to understand the fundamental strength of TTBC's for particular stress states.

Evidence of yttrium silicate inclusions in YSZ-porcelain veneers.

PubMed

Stoner, Brian R; Griggs, Jason A; Neidigh, John; Piascik, Jeffrey R

2014-04-01

This report introduces the discovery of crystalline defects that can form in the porcelain veneering layer when in contact with yttria-stabilized zirconia (YSZ). The focus was on dental prostheses and understanding the defects that form in the YSZ/porcelain system; however the data reported herein may have broader implications toward the use and stability of YSZ-based ceramics in general. Specimens were cut from fully sintered YSZ plates and veneering porcelain was applied (<1 mm thick) to one surface and fired under manufacturer's recommended protocol. Scanning electron microscopy (SEM) with integrated electron dispersive X-ray (EDAX) was used for microstructural and elemental analysis. EDAX, for chemical analysis and transmission electron diffraction (TED) for structural analysis were both performed in the transmission electron microscope (TEM). Additionally, in order to spatially resolve Y-rich precipitates, micro-CT scans were conducted at varying depths within the porcelain veneer. Local EDAX (SEM) was performed in the regions of visible inclusions and showed significant increases in yttrium concentration. TEM specimens also showed apparent inclusions in the porcelain and selected area electron diffraction was performed on these regions and found the inclusions to be crystalline and identified as either yttrium-silicate (Y2 SiO5 ) or yttrium-disilicate (Y2 Si2 O7 ). Micro-CT data showed that yttrium-silicate precipitates were distributed throughout the thickness of the porcelain veneer. Future studies are needed to determine whether many of the premature failures associated with this materials system may be the result of crystalline flaws that form as a result of high temperature yttrium diffusion near the surfaces of YSZ. © 2013 Wiley Periodicals, Inc.

The influence of pore formers on the microstructure of plasma-sprayed NiO-YSZ anodes

NASA Astrophysics Data System (ADS)

Poon, Michael; Kesler, Olivera

2012-07-01

Four types of pore formers: high-density polyethylene (HDPE), polyether-ether-ketone (PEEK), mesocarbon-microbead (MCMB) carbon powder, and baking flour, are processed and characterized, then incorporated with NiO-YSZ nano-agglomerate powder to produce plasma sprayed SOFC anode coatings. Scanning electron microscopy (SEM) of the coating microstructure, gas permeability measurements, and porosity determinations by image analysis are used to evaluate the effectiveness of each potential pore former powder. Under the spray conditions studied, the flour and MCMB pore former powders are effective as plasma sprayed pore formers, increasing the permeability of the coatings by factors of four and two, respectively, compared to a similarly sprayed NiO-YSZ coating without pore formers. The HDPE powder is unable to survive the plasma spray process and does not contribute to the final coating porosity. The PEEK pore former, though ineffective with the current powder characteristics and spray parameters, exhibits the highest relative deposition efficiency and the most favorable thermal characteristics.

Thermal barrier coating life prediction model development

NASA Technical Reports Server (NTRS)

Demasi, J. T.

1986-01-01

A methodology is established to predict thermal barrier coating life in a environment similar to that experienced by gas turbine airfoils. Experiments were conducted to determine failure modes of the thermal barrier coating. Analytical studies were employed to derive a life prediction model. A review of experimental and flight service components as well as laboratory post evaluations indicates that the predominant mode of TBC failure involves thermomechanical spallation of the ceramic coating layer. This ceramic spallation involves the formation of a dominant crack in the ceramic coating parallel to and closely adjacent to the topologically complex metal ceramic interface. This mechanical failure mode clearly is influenced by thermal exposure effects as shown in experiments conducted to study thermal pre-exposure and thermal cycle-rate effects. The preliminary life prediction model developed focuses on the two major damage modes identified in the critical experiments tasks. The first of these involves a mechanical driving force, resulting from cyclic strains and stresses caused by thermally induced and externally imposed mechanical loads. The second is an environmental driving force based on experimental results, and is believed to be related to bond coat oxidation. It is also believed that the growth of this oxide scale influences the intensity of the mechanical driving force.

Development of Thermal Barriers for Solid Rocket Motor Nozzle Joints

NASA Technical Reports Server (NTRS)

Steinetz, Bruce M.; Dunlap, Patrick H., Jr.

1999-01-01

The Space Shuttle solid rocket motor case assembly joints are sealed using conventional 0-ring seals. The 5500+F combustion gases are kept a safe distance away from the seals by thick layers of insulation. Special joint-fill compounds are used to fill the joints in the insulation to prevent a direct flowpath to the seals. On a number of occasions. NASA has observed in several of the rocket nozzle assembly joints hot gas penetration through defects in the joint- fill compound. The current nozzle-to-case joint design incorporates primary, secondary and wiper (inner-most) 0-rings and polysulfide joint-fill compound. In the current design, 1 out of 7 motors experience hot gas to the wiper 0-ring. Though the condition does not threaten motor safety, evidence of hot gas to the wiper 0-ring results in extensive reviews before resuming flight. NASA and solid rocket motor manufacturer Thiokol are working to improve the nozzle-to-case joint design by implementing a more reliable J-leg design and a thermal barrier, This paper presents burn-resistance, temperature drop, flow and resiliency test results for several types of NASA braided carbon-fiber thermal barriers. Burn tests were performed to determine the time to burn through each of the thermal barriers when exposed to the flame of an oxy-acetylene torch (5500 F), representative of the 5500 F solid rocket motor combustion temperatures. Thermal barriers braided out of carbon fibers endured the flame for over 6 minutes, three times longer than solid rocket motor burn time. Tests were performed on two thermal barrier braid architectures, denoted Carbon-3 and Carbon-6, to measure the temperature drop across and along the barrier in a compressed state when subjected to the flame of an oxyacetylene torch. Carbon-3 and Carbon-6 thermal barriers were excellent insulators causing temperature drops through their diameter of up to a 2800 and 2560 F. respectively. Gas temperature 1/4" downstream of the thermal barrier were within the

Factors Influencing Residual Stresses in Yttria Stabilized Zirconia Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Novel Prospects for Plasma Spray-Physical Vapor Deposition of Columnar Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Anwaar, Aleem; Wei, Lianglinag; Guo, Qian; Zhang, Baopeng; Guo, Hongbo

2017-12-01

Plasma spray-physical vapor deposition (PS-PVD) is an emerging coating technique that can produce columnar thermal barrier coatings from vapor phase. Feedstock treatment at the start of its trajectory in the plasma torch nozzle is important for such vapor-phase deposition. This study describes the effects of the plasma composition (Ar/He) on the plasma characteristics, plasma-particle interaction, and particle dynamics at different points spatially distributed inside the plasma torch nozzle. The results of calculations show that increasing the fraction of argon in the plasma gas mixture enhances the momentum and heat flow between the plasma and injected feedstock. For the plasma gas combination of 45Ar/45He, the total enthalpy transferred to a representative powder particle inside the plasma torch nozzle is highest ( 9828 kJ/kg). Moreover, due to the properties of the plasma, the contribution of the cylindrical throat, i.e., from the feed injection point (FIP) to the start of divergence (SOD), to the total transferred energy is 69%. The carrier gas flow for different plasma gas mixtures was also investigated by optical emission spectroscopy (OES) measurements of zirconium emissions. Yttria-stabilized zirconia (YSZ) coating microstructures were produced when using selected plasma gas compositions and corresponding carrier gas flows; structural morphologies were found to be in good agreement with OES and theoretical predictions. Quasicolumnar microstructure was obtained with porosity of 15% when applying the plasma composition of 45Ar/45He.

Thermal barrier coating for alloy systems

DOEpatents

Seals, Roland D.; White, Rickey L.; Dinwiddie, Ralph B.

2000-01-01

An alloy substrate is protected by a thermal barrier coating formed from a layer of metallic bond coat and a top coat formed from generally hollow ceramic particles dispersed in a matrix bonded to the bond coat.

High-Tc thermal bridges for space-borne cryogenic infrared detectors

NASA Technical Reports Server (NTRS)

Wise, S. A.; Buckley, J. D.; Nolt, I.; Hooker, M. W.; Haertling, G. H.; Selim, R.; Caton, R.; Buoncristiani, A. M.

1993-01-01

The potential for using high-temperature superconductive elements, screen-printed onto ceramic substrates, as thermal bridges to replace the currently employed manganin wires is studied at NASA-LaRC. Substrate selection is considered to be the most critical parameter in device production. Due to the glass-like thermal behavior of yttria-stabilized-zirconia (YSZ) and fused silica substrates, these materials are found to reduce the heat load significantly. The estimated thermal savings for superconductive leads printed onto YSZ or fused silica substrates range from 6 to 14 percent.

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

NASA Technical Reports Server (NTRS)

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.

Evaluation of Oxidation Damage in Thermal Barrier Coating Systems

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Miller, Robert A.

1996-01-01

A method based on the technique of dilatometry has been established to quantitatively evaluate the interfacial damage due to the oxidation in a thermal barrier coating system. Strain isolation and adhesion coefficients have been proposed to characterize the thermal barrier coating (TBC) performance based on its thermal expansion behavior. It has been found that, for a thermal barrier coating system consisting of ZrO2-8%Y2O3/FeCrAlY/4140 steel substrate, the oxidation of the bond coat and substrate significantly reduced the ceramic coating adherence, as inferred from the dilatometry measurements. The in-situ thermal expansion measurements under 30 deg C to 700 deg C thermal cycling in air showed that the adhesion coefficient, A(sub i) decreased by 25% during the first 35 oxidation cycles. Metallography showed that delamination occurred at both the ceramic/bond coat and bond coat/substrate interfaces. In addition, the strain isolation effect has been improved by increasing the FeCrAlY bond coat thickness. The strain isolation coefficient, Si, increased from about 0.04 to 0.25, as the bond coat thickness changed from 0.1 mm to 1.0 mm. It may be possible to design optimum values of strain isolation and interface adhesion coefficients to achieve the best TBC performance.

Nuclear reactor vessel fuel thermal insulating barrier

DOEpatents

Keegan, C. Patrick; Scobel, James H.; Wright, Richard F.

2013-03-19

The reactor vessel of a nuclear reactor installation which is suspended from the cold leg nozzles in a reactor cavity is provided with a lower thermal insulating barrier spaced from the reactor vessel that has a hemispherical lower section that increases in volume from the center line of the reactor to the outer extent of the diameter of the thermal insulating barrier and smoothly transitions up the side walls of the vessel. The space between the thermal insulating harrier and the reactor vessel forms a chamber which can be flooded with cooling water through passive valving to directly cool the reactor vessel in the event of a severe accident. The passive inlet valve for the cooling water includes a buoyant door that is normally maintained sealed under its own weight and floats open when the cavity is Hooded. Passively opening steam vents are also provided.

Development and Testing of Ceramic Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Choi, Sung R.; Miller, Robert A.

2004-01-01

Ceramic thermal barrier coatings 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. Durability of the coating systems remains a critical issue with the ever-increasing temperature requirements. Thermal conductivity increase and coating degradation due to sintering and phase changes are known to be detrimental to coating performance. There is a need to characterize the coating behavior and temperature limits, in order to potentially take full advantage of the current coating capability, and also accurately assess the benefit gained from advanced coating development. In this study, thermal conductivity behavior and cyclic durability of plasma-sprayed ZrO2-8wt%Y2O3 thermal barrier coatings were evaluated under laser heat-flux simulated high temperature, large thermal gradient and thermal cycling conditions. The coating degradation and failure processes were assessed by real-time monitoring of the coating thermal conductivity under the test conditions. The ceramic coating crack propagation driving forces and resulting failure modes will be discussed in light of high temperature mechanical fatigue and fracture testing results.

Development and Fatigue Testing of Ceramic Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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

2004-01-01

Ceramic thermal barrier coatings 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. Durability of the coating systems remains a critical issue with the ever-increasing temperature requirements. Thermal conductivity increase and coating degradation due to sintering and phase changes are known to be detrimental to coating performance. There is a need to characterize the coating thermal fatigue behavior and temperature limit, in order to potentially take full advantage of the current coating capability. In this study, thermal conductivity and cyclic fatigue behaviors of plasma-sprayed ZrO2-8wt%Y2O3 thermal barrier coatings were evaluated under high temperature, large thermal gradient and thermal cycling conditions. The coating degradation and failure processes were assessed by real-time monitoring of the coating thermal conductivity under the test conditions. The ceramic coating crack initiation and propagation driving forces and failure modes under the cyclic thermal loads will be discussed in light of the high temperature mechanical fatigue and fracture testing results.

Low conductivity and sintering-resistant thermal barrier coatings

NASA Technical Reports Server (NTRS)

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.

Low conductivity and sintering-resistant thermal barrier coatings

NASA Technical Reports Server (NTRS)

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

2006-01-01

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.

Thermal and Environmental Barrier Coating Development for Advanced Propulsion Engine Systems

NASA Technical Reports Server (NTRS)

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.

Corrosion resistant thermal barrier coating. [protecting gas turbines and other engine parts

NASA Technical Reports Server (NTRS)

Levine, S. R.; Miller, R. A.; Hodge, P. E. (Inventor)

1981-01-01

A thermal barrier coating system for protecting metal surfaces at high temperature in normally corrosive environments is described. The thermal barrier coating system includes a metal alloy bond coating, the alloy containing nickel, cobalt, iron, or a combination of these metals. The system further includes a corrosion resistant thermal barrier oxide coating containing at least one alkaline earth silicate. The preferred oxides are calcium silicate, barium silicate, magnesium silicate, or combinations of these silicates.

Effect of Ni content on the morphological evolution of Ni-YSZ solid oxide fuel cell electrodes

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chen-Wiegart, Yu-chen Karen; Kennouche, David; Scott Cronin, J.

2016-02-22

The coarsening of Ni in Ni–yttria-stabilized zirconia (YSZ) anodes is a potential cause of long term solid oxide fuel cells (SOFC) performance degradation. The specifics of the Ni-YSZ structure—including Ni/YSZ ratio, porosity, and particle size distributions—are normally selected to minimize anode polarization resistance, but they also impact long-term stability. A better understanding of how these factors influence long-term stability is important for designing more durable anodes. The effect of structural details, e.g., Ni-YSZ ratio, on Ni coarsening has not been quantified. Furthermore, prior measurements have been done by comparing evolved structures with control samples, such that sample-to-sample variations introduce errors.more » Here, we report a four dimensional (three spatial dimensions and time) study of Ni coarsening in Ni-YSZ anode functional layers with different Ni/YSZ ratios, using synchrotron x-ray nano-tomography. The continuous structural evolution was observed and analyzed at sub-100 nm resolution. It is shown quantitatively that increasing the Ni/YSZ ratio increases the Ni coarsening rate. This is due to both increased pore volume and a decrease in the YSZ volume fraction, such that there is more free volume and a less obtrusive YSZ network, both of which allow greater Ni coarsening. The results are shown to be in good agreement with a power-law coarsening model. The finding is critical for informing the design of SOFC electrode microstructures that limit coarsening and performance degradation.« less

Effect of Ni content on the morphological evolution of Ni-YSZ solid oxide fuel cell electrodes

NASA Astrophysics Data System (ADS)

Chen-Wiegart, Yu-chen Karen; Kennouche, David; Scott Cronin, J.; Barnett, Scott A.; Wang, Jun

2016-02-01

The coarsening of Ni in Ni-yttria-stabilized zirconia (YSZ) anodes is a potential cause of long term solid oxide fuel cells (SOFC) performance degradation. The specifics of the Ni-YSZ structure—including Ni/YSZ ratio, porosity, and particle size distributions—are normally selected to minimize anode polarization resistance, but they also impact long-term stability. A better understanding of how these factors influence long-term stability is important for designing more durable anodes. The effect of structural details, e.g., Ni-YSZ ratio, on Ni coarsening has not been quantified. Furthermore, prior measurements have been done by comparing evolved structures with control samples, such that sample-to-sample variations introduce errors. Here, we report a four dimensional (three spatial dimensions and time) study of Ni coarsening in Ni-YSZ anode functional layers with different Ni/YSZ ratios, using synchrotron x-ray nano-tomography. The continuous structural evolution was observed and analyzed at sub-100 nm resolution. It is shown quantitatively that increasing the Ni/YSZ ratio increases the Ni coarsening rate. This is due to both increased pore volume and a decrease in the YSZ volume fraction, such that there is more free volume and a less obtrusive YSZ network, both of which allow greater Ni coarsening. The results are shown to be in good agreement with a power-law coarsening model. The finding is critical for informing the design of SOFC electrode microstructures that limit coarsening and performance degradation.

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

NASA Technical Reports Server (NTRS)

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.

Life modeling of thermal barrier coatings for aircraft gas turbine engines

NASA Technical Reports Server (NTRS)

Miller, R. A.

1989-01-01

Thermal barrier coating life models developed under the NASA Lewis Research Center's Hot Section Technology (HOST) Program are summarized. An initial laboratory model and three design-capable models are discussed. Current understanding of coating failure mechanisms are also summarized. The materials and structural aspects of thermal barrier coatings have been successfully integrated under the HOST program to produce models which may now or in the near future be used in design. Efforts on this program continue at Pratt and Whitney Aircraft where their model is being extended to the life prediction of physical vapor deposited thermal barrier coatings.

Effects of plasma spray parameters on two layer thermal barrier

NASA Technical Reports Server (NTRS)

Stecura, S.

1981-01-01

The power level and the type of arc gas used during plasma spraying of a two layer thermal barrier system (TBS) were found to affect the life of the system. Life at 1095 C in a cyclic furnace test was improved by about 140 percent by increasing the power during plasma spray applications of the bond and thermal barrier coatings. This improvement is due to increases in the densities of the bond and thermal barrier coatings by 3 and 5 percent, respectively. These increases in densities are equivalent to about 45 and 30 percent reduction in mean porosities, respectively. The addition of hydrogen to the argon arc gas had the same effect as the reduction in power level and caused a reduction in TBS life.

Effect of Ni content on the morphological evolution of Ni-YSZ solid oxide fuel cell electrodes

DOE PAGES

Chen-Wiegart, Yu-chen Karen; Kennouche, David; Scott Cronin, J.; ...

2016-02-25

The coarsening of Ni in Ni–yttria-stabilized zirconia (YSZ) anodes is a potential cause of long term solid oxide fuel cells (SOFC) performance degradation. The specifics of the Ni-YSZ structure—including Ni/YSZ ratio, porosity, and particle size distributions—are normally selected to minimize anode polarization resistance, but they also impact long-term stability. A better understanding of how these factors influence long-term stability is important for designing more durable anodes. The effect of structural details, e.g., Ni-YSZ ratio, on Ni coarsening has not been quantified. Furthermore, prior measurements have been done by comparing evolved structures with control samples, such that sample-to-sample variations introduce errors.more » Here in this paper, we report a four dimensional (three spatial dimensions and time) study of Ni coarsening in Ni-YSZ anode functional layers with different Ni/YSZ ratios, using synchrotron x-ray nano-tomography. The continuous structural evolution was observed and analyzed at sub-100 nm resolution. It is shown quantitatively that increasing the Ni/YSZ ratio increases the Ni coarsening rate. This is due to both increased pore volume and a decrease in the YSZ volume fraction, such that there is more free volume and a less obtrusive YSZ network, both of which allow greater Ni coarsening. The results are shown to be in good agreement with a power-law coarsening model. In conclusion, the finding is critical for informing the design of SOFC electrode microstructures that limit coarsening and performance degradation.« less

Effect of Ni content on the morphological evolution of Ni-YSZ solid oxide fuel cell electrodes

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chen-Wiegart, Yu-chen Karen; Kennouche, David; Scott Cronin, J.

The coarsening of Ni in Ni–yttria-stabilized zirconia (YSZ) anodes is a potential cause of long term solid oxide fuel cells (SOFC) performance degradation. The specifics of the Ni-YSZ structure—including Ni/YSZ ratio, porosity, and particle size distributions—are normally selected to minimize anode polarization resistance, but they also impact long-term stability. A better understanding of how these factors influence long-term stability is important for designing more durable anodes. The effect of structural details, e.g., Ni-YSZ ratio, on Ni coarsening has not been quantified. Furthermore, prior measurements have been done by comparing evolved structures with control samples, such that sample-to-sample variations introduce errors.more » Here in this paper, we report a four dimensional (three spatial dimensions and time) study of Ni coarsening in Ni-YSZ anode functional layers with different Ni/YSZ ratios, using synchrotron x-ray nano-tomography. The continuous structural evolution was observed and analyzed at sub-100 nm resolution. It is shown quantitatively that increasing the Ni/YSZ ratio increases the Ni coarsening rate. This is due to both increased pore volume and a decrease in the YSZ volume fraction, such that there is more free volume and a less obtrusive YSZ network, both of which allow greater Ni coarsening. The results are shown to be in good agreement with a power-law coarsening model. In conclusion, the finding is critical for informing the design of SOFC electrode microstructures that limit coarsening and performance degradation.« less

Zirconia and Pyrochlore Oxides for Thermal Barrier Coatings in Gas Turbine Engines

DOE PAGES

Fergus, Jeffrey W.

2014-04-12

One of the important applications of yttria stabilized zirconia is as a thermal barrier coating for gas turbine engines. While yttria stabilized zirconia performs well in this function, the need for increased operating temperatures to achieve higher energy conversion efficiencies, requires the development of improved materials. To meet this challenge, some rare-earth zirconates that form the cubic fluorite derived pyrochlore structure are being developed for use in thermal barrier coatings due to their low thermal conductivity, excellent chemical stability and other suitable properties. In this paper, the thermal conductivities of current and prospective oxides for use in thermal barrier coatingsmore » are reviewed. The factors affecting the variations and differences in the thermal conductivities and the degradation behaviors of these materials are discussed.« less

Ceramic thermal barrier coating for rapid thermal cycling applications

DOEpatents

Scharman, Alan J.; Yonushonis, Thomas M.

1994-01-01

A thermal barrier coating for metal articles subjected to rapid thermal cycling includes a metallic bond coat deposited on the metal article, at least one MCrAlY/ceramic layer deposited on the bond coat, and a ceramic top layer deposited on the MCrAlY/ceramic layer. The M in the MCrAlY material is Fe, Ni, Co, or a mixture of Ni and Co. The ceramic in the MCrAlY/ceramic layer is mullite or Al.sub.2 O.sub.3. The ceramic top layer includes a ceramic with a coefficient of thermal expansion less than about 5.4.times.10.sup.-6 .degree.C.sup.-1 and a thermal conductivity between about 1 J sec.sup.-1 m.sup.-1 .degree.C.sup.-1 and about 1.7 J sec.sup.-1 m.sup.-1 .degree.C.sup.-1.

Anisotropic Thermal Diffusivities of Plasma-Sprayed Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Akoshima, Megumi; Takahashi, Satoru

2017-09-01

Thermal barrier coatings (TBCs) are used to shield the blades of gas turbines from heat and wear. There is a pressing need to evaluate the thermal conductivity of TBCs in the thermal design of advanced gas turbines with high energy efficiency. These TBCs consist of a ceramic-based top coat and a bond coat on a superalloy substrate. Usually, the focus is on the thermal conductivity in the thickness direction of the TBC because heat tends to diffuse from the surface of the top coat to the substrate. However, the in-plane thermal conductivity is also important in the thermal design of gas turbines because the temperature distribution within the turbine cannot be ignored. Accordingly, a method is developed in this study for measuring the in-plane thermal diffusivity of the top coat. Yttria-stabilized zirconia top coats are prepared by thermal spraying under different conditions. The in-plane and cross-plane thermal diffusivities of the top coats are measured by the flash method to investigate the anisotropy of thermal conduction in a TBC. It is found that the in-plane thermal diffusivity is higher than the cross-plane one for each top coat and that the top coats have significantly anisotropic thermal diffusivity. The cross-sectional and in-plane microstructures of the top coats are observed, from which their porosities are evaluated. The thermal diffusivity and its anisotropy are discussed in detail in relation to microstructure and porosity.

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

NASA Technical Reports Server (NTRS)

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.

Degradation of yttria-stabilized zirconia thermal barrier coatings by vanadium pentoxide, phosphorous pentoxide, and sodium sulfate

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mohan, P.; Yuan, B.; Patterson, T.

2007-11-15

The presence of vanadium, phosphorus, and sodium impurities in petcoke and coal/petcoke blends used in integrated gasification combined cycle (IGCC) plants warrants a clear understanding of high-temperature material degradation for the development of fuel-flexible gas turbines. In this study, degradation reactions of free-standing air plasma-sprayed (APS) yttria-stabilized zirconia (YSZ) in contact with V{sub 2}O{sub 5}, P{sub 2}O{sub 5}, and Na{sub 2}SO{sub 4} were investigated at temperatures up to 1200{sup o}C. Phase transformations and microstructural development were examined using X-ray diffraction, scanning electron microscopy, and transmission electron microscopy. Molten V{sub 2}O{sub 5} reacted with solid YSZ to form ZrV{sub 2}O{sub 7}more » at temperatures below 747{sup o}C. However, at temperatures above 747{sup o}C, molten V{sub 2}O{sub 5} reacted with YSZ to form yttrium vanadate (YVO{sub 4}). The formation of YVO{sub 4} led to the depletion of the Y2O{sub 3} stabilizer and deleterious transformation to the monoclinic ZrO{sub 2} phase. In addition, studies on YSZ degradation by Na{sub 2}SO{sub 4} and a Na{sub 2}SO{sub 4}+V{sub 2}O{sub 5} mixture (50-50 mol%) showed that Na{sub 2}SO{sub 4} itself had no effect on the degradation of YSZ. However, in the presence of V{sub 2}O{sub 5} at high temperatures, Na{sub 2}SO{sub 4} forms vanadate compounds having a lower melting point such as sodium metavanadate (610{sup o}C), which was found to degrade YSZ by the formation of YVO{sub 4} at a relatively lower temperature of 700{sup o}C. P{sub 2}O{sub 5} was found to react with APS YSZ by the formation of ZrP{sub 2}O{sub 7} at all the temperatures studied. At temperatures as low as 200{sup o}C and as high as 1200{sup o}C, molten P{sub 2}O{sub 5} was observed to react with solid YSZ to yield ZrP{sub 2}O{sub 7}, which led to the depletion of ZrO{sub 2} in YSZ that promoted the formation of the fluorite-cubic ZrO{sub 2} phase.« less

Thermal Barrier Coatings. Abstracts and figures

NASA Technical Reports Server (NTRS)

1985-01-01

The Thermal Barrier Coatings Workshop was held May 21 and 22, 1985, at the NASA Lewis Research Center in Cleveland, Ohio. Six sessions covered Failure Mechanisms and Life Modeling, Effects of Oxidation and Creep, Phase Stability and Microstructural Aspects, Nondestructive and Analytical Assessment, Coating Development, and Alternative Applications.

Health Sensing Functions in Thermal Barrier Coatings Incorporating Rare-Earth-Doped Luminescent Sublayers

NASA Technical Reports Server (NTRS)

Eldridge, J. I.; Singh, J.; Wolfe, D. E.

2004-01-01

Great effort has been directed towards developing techniques to monitor the health of thermal barrier coatings (TBCs) that would detect the approach of safety-threatening conditions. An unconventional approach is presented here where health sensing functionality is integrated into the TBC itself by the incorporation of rare-earth-doped luminescent sublayers to monitor erosion as well as whether the TBC is maintaining the underlying substrate at a sufficiently low temperature. Erosion indication is demonstrated in electron-beam physical vapor deposited (EB-PVD) TBCs consisting of 7wt% yttria-stabilized zirconia (7YSZ) with europium-doped and terbium-doped sublayers. Multiple ingot deposition produced sharp boundaries between the doped sublayers without interrupting the columnar growth of the TBC. The TBC-coated specimens were subjected to alumina particle jet erosion, and the erosion depth was then indicated under ultraviolet illumination that excited easily visible luminescence characteristic of sublayer that was exposed by erosion. In addition, temperature measurements from a bottom-lying europium-doped sublayer in a TBC produced by multiple ingot EB-PVD were accomplished by measuring the temperature-dependent decay time from the 606 nm wavelength emission excited in that sublayer with a 532 nm wavelength laser that was selected for its close match to one of the europium excitation wavelengths as well as being at a wavelength where the TBC is relatively transparent. It is proposed the low dopant levels and absence of interruption of the TBC columnar growth allow the addition of the erosion and temperature sensing functions with minimal effects on TBC performance.

Damage Accumulation and Failure of Plasma-Sprayed Thermal Barrier Coatings under Thermal Gradient Cyclic Conditions

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Choi, Sung R.; Ghosn, Louis J.; Miller, rober A.

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. A fundamental understanding of the sintering and thermal cycling induced delamination of thermal barrier coating systems under engine-like heat flux conditions will potentially help to improve the coating temperature capability. In this study, a test approach is established to emphasize the real-time monitoring and assessment of the coating thermal conductivity, which can initially increase under the steady-state high temperature thermal gradient test due to coating sintering, and later decrease under the thermal gradient cyclic test due to coating cracking and delamination. Thermal conductivity prediction models have been established for a ZrO2-(7- 8wt%)Y2O3 model coating system in terms of heat flux, time, and testing temperatures. The coating delamination accumulation is then assessed based on the observed thermal conductivity response under the combined steady-state and cyclic thermal gradient tests. The coating thermal gradient cycling associated delaminations and failure mechanisms under simulated engine heat-flux conditions will be discussed in conjunction with the coating sintering and fracture testing results.

Ceramic thermal barrier coatings for commercial gas turbine engines

NASA Technical Reports Server (NTRS)

Meier, Susan Manning; Gupta, Dinesh K.; Sheffler, Keith D.

1991-01-01

The paper provides an overview of the short history, current status, and future prospects of ceramic thermal barrier coatings for gas turbine engines. Particular attention is given to plasma-sprayed and electron beam-physical vapor deposited yttria-stabilized (7 wt pct Y2O3) zirconia systems. Recent advances include improvements in the spallation life of thermal barrier coatings, improved bond coat composition and spraying techniques, and improved component design. The discussion also covers field experience, life prediction modeling, and future directions in ceramic coatings in relation to gas turbine engine design.

Evaluation of hot corrosion behavior of thermal barrier coatings

NASA Technical Reports Server (NTRS)

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.

Thermal Barrier Coatings for Advanced Gas Turbine and Diesel Engines

NASA Technical Reports Server (NTRS)

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.

Two-layer thermal barrier coating for turbine airfoils - furnace and burner rig test results

NASA Technical Reports Server (NTRS)

Stecura, S.

1976-01-01

A simple, two-layer plasma-sprayed thermal barrier coating system was developed which has the potential for protecting high temperature air-cooled gas turbine components. Of those coatings initially examined, the most promising system consisted of a Ni-16Cr-6Al-0.6Y (in wt%) thermal barrier coating (about 0.005 to 0.010 cm thick) and a ZrO2-12Y2O3 (in wt%) thermal barrier coating (about 0.025 to 0.064 cm thick). This thermal barrier substantially lowered the metal temperature of an air-cooled airfoil. The coating withstood 3,200 cycles (80 sec at 1,280 C surface temperature) and 275 cycles (1 hr at 1,490 C surface temperature) without cracking or spalling. No separation of the thermal barrier from the bond coating or the bond coating from the substrate was observed.

The Lattice and Thermal Radiation Conductivity of Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Modeling of Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

Ferguson, B. L.; Petrus, G. J.; Krauss, T. M.

1992-01-01

The project examined the effectiveness of studying the creep behavior of thermal barrier coating system through the use of a general purpose, large strain finite element program, NIKE2D. Constitutive models implemented in this code were applied to simulate thermal-elastic and creep behavior. Four separate ceramic-bond coat interface geometries were examined in combination with a variety of constitutive models and material properties. The reason for focusing attention on the ceramic-bond coat interface is that prior studies have shown that cracking occurs in the ceramic near interface features which act as stress concentration points. The model conditions examined include: (1) two bond coat coefficient of thermal expansion curves; (2) the creep coefficient and creep exponent of the bond coat for steady state creep; (3) the interface geometry; and (4) the material model employed to represent the bond coat, ceramic, and superalloy base.

Thermal Gradient Cyclic Behavior of a Thermal/Environmental Barrier Coating System on SiC/SiC Ceramic Matrix Composites

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Lee, Kang N.; Miller, Robert A.

2002-01-01

Thermal barrier and environmental barrier coatings (TBCs and EBCs) will play a crucial role in future advanced gas turbine engines because of their ability to significantly extend the temperature capability of the ceramic matrix composite (CMC) engine components in harsh combustion environments. In order to develop high performance, robust coating systems for effective thermal and environmental protection of the engine components, appropriate test approaches for evaluating the critical coating properties must be established. In this paper, a laser high-heat-flux, thermal gradient approach for testing the coatings will be described. Thermal cyclic behavior of plasma-sprayed coating systems, consisting of ZrO2-8wt%Y2O3 thermal barrier and NASA Enabling Propulsion Materials (EPM) Program developed mullite+BSAS/Si type environmental barrier coatings on SiC/SiC ceramic matrix composites, was investigated under thermal gradients using the laser heat-flux rig in conjunction with the furnace thermal cyclic tests in water-vapor environments. The coating sintering and interface damage were assessed by monitoring the real-time thermal conductivity changes during the laser heat-flux tests and by examining the microstructural changes after the tests. The coating failure mechanisms are discussed based on the cyclic test results and are correlated to the sintering, creep, and thermal stress behavior under simulated engine temperature and heat flux conditions.

An Investigation of LSF-YSZ Conductive Scaffolds for Infiltrated SOFC Cathodes

DOE Office of Scientific and Technical Information (OSTI.GOV)

Cheng, Yuan; Oh, Tae-Sik; Wilson, Rachel

Porous composites of Sr-doped LaFeO 3 (LSF) and yttria-stabilized zirconia (YSZ) were investigated as conductive scaffolds for infiltrated SOFC cathodes with the goal of producing scaffolds for which only a few perovskite infiltration steps are required to achieve sufficient conductivity. While no new phases form when LSF-YSZ composites are calcined to 1623 K, shifts in the lattice parameters indicate Zr can enter the perovskite phase. Measurements on dense, LSF-YSZ composites show that the level of Zr doping depends on the Sr:La ratio. Because conductivity of undoped LSF increases with Sr content while both the ionic and electronic conductivities of Zr-dopedmore » LSF decrease with the level of Zr in the perovskite phase, there is an optimum initial Sr content corresponding to La 0.9Sr 0.1FeO 3 (LSF91). Although scaffolds made with 100% LSF had a higher conductivity than scaffolds made with 50:50 LSF-YSZ mixtures, the 50:50 mixture provides the optimal interfacial structure with the electrolyte and sufficient conductivity, providing the best cathode performance upon infiltration of La 0.6Sr 0.4Co 0.2Fe 0.8O 3 (LSCF).« less

An Investigation of LSF-YSZ Conductive Scaffolds for Infiltrated SOFC Cathodes

DOE PAGES

Cheng, Yuan; Oh, Tae-Sik; Wilson, Rachel; ...

2017-03-24

Porous composites of Sr-doped LaFeO 3 (LSF) and yttria-stabilized zirconia (YSZ) were investigated as conductive scaffolds for infiltrated SOFC cathodes with the goal of producing scaffolds for which only a few perovskite infiltration steps are required to achieve sufficient conductivity. While no new phases form when LSF-YSZ composites are calcined to 1623 K, shifts in the lattice parameters indicate Zr can enter the perovskite phase. Measurements on dense, LSF-YSZ composites show that the level of Zr doping depends on the Sr:La ratio. Because conductivity of undoped LSF increases with Sr content while both the ionic and electronic conductivities of Zr-dopedmore » LSF decrease with the level of Zr in the perovskite phase, there is an optimum initial Sr content corresponding to La 0.9Sr 0.1FeO 3 (LSF91). Although scaffolds made with 100% LSF had a higher conductivity than scaffolds made with 50:50 LSF-YSZ mixtures, the 50:50 mixture provides the optimal interfacial structure with the electrolyte and sufficient conductivity, providing the best cathode performance upon infiltration of La 0.6Sr 0.4Co 0.2Fe 0.8O 3 (LSCF).« less

Thermophysical and Thermomechanical Properties of Thermal Barrier Coating Systems

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Miller, Robert A.

2000-01-01

Thermal barrier coatings have been developed for advanced gas turbine and diesel engine applications to improve engine reliability and fuel efficiency. However, the issue of coating durability under high temperature cyclic conditions is still of major concern. The coating failure is closely related to thermal stresses and oxidation in the coating systems. Coating shrinkage cracking resulting from ceramic sintering and creep at high temperatures can further accelerate the coating failure process. The purpose of this paper is to address critical issues such as ceramic sintering and creep, thermal fatigue and their relevance to coating life prediction. Novel test approaches have been established to obtain critical thermophysical and thermomechanical properties of the coating systems under near-realistic temperature and stress gradients encountered in advanced engine systems. Emphasis is placed on the dynamic changes of the coating thermal conductivity and elastic modulus, fatigue and creep interactions, and resulting failure mechanisms during the simulated engine tests. Detailed experimental and modeling results describing processes occurring in the thermal barrier coating systems provide a framework for developing strategies to manage ceramic coating architecture, microstructure and properties.

Covering solid, film cooled surfaces with a duplex thermal barrier coating

NASA Technical Reports Server (NTRS)

Liebert, C. H. (Inventor)

1983-01-01

Thermal barrier coating systems were applied to hardware having passageways in the walls connecting apertures in the surface to a gas supply for film cooling. An inert gas, such as argon, is discharged through the apertures during the application of the thermal barrier coating system by plasma spraying. This flow of inert gas reduces both blocking of the holes and base metal oxidation during the coating operation.

Thermal barrier coating life prediction model development

NASA Technical Reports Server (NTRS)

Sheffler, K. D.; Demasi, J. T.

1985-01-01

A methodology was established to predict thermal barrier coating life in an environment simulative of that experienced by gas turbine airfoils. Specifically, work is being conducted to determine failure modes of thermal barrier coatings in the aircraft engine environment. Analytical studies coupled with appropriate physical and mechanical property determinations are being employed to derive coating life prediction model(s) on the important failure mode(s). An initial review of experimental and flight service components indicates that the predominant mode of TBC failure involves thermomechanical spallation of the ceramic coating layer. This ceramic spallation involves the formation of a dominant crack in the ceramic coating parallel to and closely adjacent to the metal-ceramic interface. Initial results from a laboratory test program designed to study the influence of various driving forces such as temperature, thermal cycle frequency, environment, and coating thickness, on ceramic coating spalling life suggest that bond coat oxidation damage at the metal-ceramic interface contributes significantly to thermomechanical cracking in the ceramic layer. Low cycle rate furnace testing in air and in argon clearly shows a dramatic increase of spalling life in the non-oxidizing environments.

Synthesis of multi-hierarchical structured yttria-stabilized zirconia powders and their enhanced thermophysical properties

NASA Astrophysics Data System (ADS)

Cao, Fengmei; Gao, Yanfeng; Chen, Hongfei; Liu, Xinling; Tang, Xiaoping; Luo, Hongjie

2013-06-01

Multi-hierarchical structured yttria-stabilized zirconia (YSZ) powders were successfully synthesized by a hydrothermal-calcination process. The morphology, crystallinity, and microstructure of the products were characterized by SEM, XRD, TEM, and BET. A possible formation mechanism of the unique structure formed during hydrothermal processing was also investigated. The measured thermophysical results indicated that the prepared YSZ powders had a low thermal conductivity (0.63-1.27 W m-1 K-1), good short-term high-temperature stability up to 1300 °C. The influence of the morphology and microstructure on their thermophysical properties was briefly discussed. The unique multi-hierarchical structure makes the prepared YSZ powders candidates for use in enhanced applications involving thermal barrier coatings.

Development of graded Ni-YSZ composite coating on Alloy 690 by Pulsed Laser Deposition technique to reduce hazardous metallic nuclear waste inventory.

PubMed

Sengupta, Pranesh; Rogalla, Detlef; Becker, Hans Werner; Dey, Gautam Kumar; Chakraborty, Sumit

2011-08-15

Alloy 690 based 'nuclear waste vitrification furnace' components degrade prematurely due to molten glass-alloy interactions at high temperatures and thereby increase the volume of metallic nuclear waste. In order to reduce the waste inventory, compositionally graded Ni-YSZ (Y(2)O(3) stabilized ZrO(2)) composite coating has been developed on Alloy 690 using Pulsed Laser Deposition technique. Five different thin-films starting with Ni80YSZ20 (Ni 80 wt%+YSZ 20 wt%), through Ni60YSZ40 (Ni 60 wt%+YSZ 40 wt%), Ni40YSZ60 (Ni 40 wt%+YSZ 60 wt%), Ni20YSZ80 (Ni 20 wt%+YSZ 80 wt%) and Ni0YSZ100 (Ni 0 wt%+YSZ 100 wt%), were deposited successively on Alloy 690 coupons. Detailed analyses of the thin-films identify them as homogeneous, uniform, pore free and crystalline in nature. A comparative study of coated and uncoated Alloy 690 coupons, exposed to sodium borosilicate melt at 1000°C for 1-6h suggests that the graded composite coating could substantially reduced the chemical interactions between Alloy 690 and borosilicate melt. Copyright © 2011 Elsevier B.V. All rights reserved.

Microstructure and mechanical properties of plasma sprayed HA/YSZ/Ti-6Al-4V composite coatings.

PubMed

Khor, K A; Gu, Y W; Pan, D; Cheang, P

2004-08-01

Plasma sprayed hydroxyapatite (HA) coatings on titanium alloy substrate have been used extensively due to their excellent biocompatibility and osteoconductivity. However, the erratic bond strength between HA and Ti alloy has raised concern over the long-term reliability of the implant. In this paper, HA/yttria stabilized zirconia (YSZ)/Ti-6Al-4V composite coatings that possess superior mechanical properties to conventional plasma sprayed HA coatings were developed. Ti-6Al-4V powders coated with fine YSZ and HA particles were prepared through a unique ceramic slurry mixing method. The so-formed composite powder was employed as feedstock for plasma spraying of the HA/YSZ/Ti-6Al-4V coatings. The influence of net plasma energy, plasma spray standoff distance, and post-spray heat treatment on microstructure, phase composition and mechanical properties were investigated. Results showed that coatings prepared with the optimum plasma sprayed condition showed a well-defined splat structure. HA/YSZ/Ti-6Al-4V solid solution was formed during plasma spraying which was beneficial for the improvement of mechanical properties. There was no evidence of Ti oxidation from the successful processing of YSZ and HA coated Ti-6Al-4V composite powders. Small amount of CaO apart from HA, ZrO(2) and Ti was present in the composite coatings. The microhardness, Young's modulus, fracture toughness, and bond strength increased significantly with the addition of YSZ. Post-spray heat treatment at 600 degrees C and 700 degrees C for up to 12h was found to further improve the mechanical properties of coatings. After the post-spray heat treatment, 17.6% increment in Young's modulus (E) and 16.3% increment in Vicker's hardness were achieved. The strengthening mechanisms of HA/YSZ/Ti-6Al-4V composite coatings were related to the dispersion strengthening by homogeneous distribution of YSZ particles in the matrix, the good mechanical properties of Ti-6Al-4V and the formation of solid solution among HA

Flexible pile thermal barrier insulator

NASA Technical Reports Server (NTRS)

Anderson, G. E.; Fell, D. M.; Tesinsky, J. S. (Inventor)

1978-01-01

A flexible pile thermal barrier insulator included a plurality of upstanding pile yarns. A generally planar backing section supported the upstanding pile yarns. The backing section included a plurality of filler yarns forming a mesh in a first direction. A plurality of warp yarns were looped around said filler yarns and pile yarns in the backing section and formed a mesh in a second direction. A binder prevented separation of the yarns in the backing section.

Ceramic thermal barrier coatings for electric utility gas turbine engines

NASA Technical Reports Server (NTRS)

Miller, R. A.

1986-01-01

Research and development into thermal barrier coatings for electric utility gas turbine engines is reviewed critically. The type of coating systems developed for aircraft applications are found to be preferred for clear fuel electric utility applications. These coating systems consists of a layer of plasma sprayed zirconia-yttria ceramic over a layer of MCrAly bond coat. They are not recommended for use when molten salts are presented. Efforts to understand coating degradation in dirty environments and to develop corrosion resistant thermal barrier coatings are discussed.

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

NASA Technical Reports Server (NTRS)

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

Method of Producing Controlled Thermal Expansion Coat for Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Thermal barrier coating having high phase stability

DOEpatents

Subramanian, Ramesh

2001-01-01

A device (10) comprising a substrate (22) having a deposited ceramic thermal barrier coating layer (20) characterized by a microstructure having gaps (28) where the thermal barrier coating (20) consists essentially of a pyrochlore crystal structure having a chemical formula consisting essentially of A.sup.n+.sub.2-x B.sup.m+.sub.2+x O.sub.7-y, where A is selected from the group of elements selected from La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and mixtures thereof; where B is selected from the group of elements selected from Zr, Hf, Ti and mixtures thereof; n and m are the valence of A and B respectively, and for -0.5.ltoreq.x.ltoreq.0.5, ##EQU1## and excluding the following combinations for x=0, y=0: A=La and B=Zr; A=La and B=Hf; A=Gd and B=Hf; and A=Yb and B=Ti.

Nondestructive evaluation of plasma-sprayed thermal barrier coatings

DOE Office of Scientific and Technical Information (OSTI.GOV)

Andrews, D.J.; Taylor, J.A.T.

Acoustic emission has been used as a nondestructive evaluation technique to examine the thermal shock response of thermal barrier coatings. In this study, samples of partially stabilized zirconia powder were sprayed and acoustic emission (AE) data were taken in a series of thermal shock tests in an effort to correlate AE with a given failure mechanism. Microstructural evidence was examined using parallel beam x-ray diffraction and optical microscopy. The AE data are discussed in terms of cumulative amplitude distributions and the use of this technique to characterize fracture events.

Real-Time Thermographic-Phosphor-Based Temperature Measurements of Thermal Barrier Coating Surfaces Subjected to a High-Velocity Combustor Burner Environment

NASA Technical Reports Server (NTRS)

Eldridge, Jeffrey I.; Jenkins, Thomas P.; Allison, Stephen W.; Cruzen, Scott; Condevaux, J. J.; Senk, J. R.; Paul, A. D.

2011-01-01

Surface temperature measurements were conducted on metallic specimens coated with an yttria-stabilized zirconia (YSZ) thermal barrier coating (TBC) with a YAG:Dy phosphor layer that were subjected to an aggressive high-velocity combustor burner environment. Luminescence-based surface temperature measurements of the same TBC system have previously been demonstrated for specimens subjected to static furnace or laser heating. Surface temperatures were determined from the decay time of the luminescence signal of the YAG:Dy phosphor layer that was excited by a pulsed laser source. However, the furnace and laser heating provides a much more benign environment than that which exists in a turbine engine, where there are additional challenges of a highly radiant background and high velocity gases. As the next step in validating the suitability of luminescence-based temperature measurements for turbine engine environments, new testing was performed where heating was provided by a high-velocity combustor burner rig at Williams International. Real-time surface temperature measurements during burner rig heating were obtained from the decay of the luminescence from the YAG:Dy surface layer. The robustness of several temperature probe designs in the sonic velocity, high radiance flame environment was evaluated. In addition, analysis was performed to show whether the luminescence decay could be satisfactorily extracted from the high radiance background.

Thermal barrier coating experience in the gas turbine engine

NASA Technical Reports Server (NTRS)

Bose, S.; Demasi-Marcin, J.

1995-01-01

Thermal Barrier Coatings (TBC), provide thermal insulation and oxidation resistance in an environment consisting of hot combustion gases. TBC's consist of a two layer system. The outer ceramic layer provides good thermal insulation due to the low thermal conductivity of the ceramic coatings used, while the inner metallic bond coat layer provides needed oxidation resistance to the underlying superalloy. Pratt & Whitney has over a decade of experience with several generations of TBC systems on turbine airfoils. This paper will focus on the latest TBC field experience along with a proposed durability model.

Resistance of Nanostructured Environmental Barrier Coatings to the Movement of Molten Salts

NASA Astrophysics Data System (ADS)

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.

Carbon tolerance of Ni-Cu and Ni-Cu/YSZ sub-μm sized SOFC thin film model systems

NASA Astrophysics Data System (ADS)

Götsch, Thomas; Schachinger, Thomas; Stöger-Pollach, Michael; Kaindl, Reinhard; Penner, Simon

2017-04-01

Thin films of YSZ, unsupported Ni-Cu 1:1 alloy phases and YSZ-supported Ni-Cu 1:1 alloy solutions have been reproducibly prepared by magnetron sputter deposition on Si wafers and NaCl(001) single crystal facets at two selected substrate temperatures of 298 K and 873 K. Subsequently, the layer properties of the resulting sub-μm thick thin films as well as the tendency towards carbon deposition following treatment in pure methane at 1073 K has been tested comparatively. Well-crystallized structures of cubic YSZ, cubic NiCu and cubic NiCu/YSZ have been obtained following deposition at 873 K on both substrates. Carbon is deposited on all samples following the trend Ni-Cu (1:1) = Ni-Cu (1:1)/YSZ > pure YSZ, indicating that at least the 1:1 composition of layered Ni-Cu alloy phases is not able to suppress the carbon deposition completely, rendering it unfavorable for usage as anode component in sub-μm sized fuel cells. It is shown that surfaces with a high Cu/Ni ratio nevertheless prohibit any carbon deposition.

Effect of coating thickness on microstructure and low temperature cyclic thermal fatigue behavior of thermal barrier coating (Al2O3)

NASA Astrophysics Data System (ADS)

Verma, Vijay; Patel, Sachin; Swarnkar, Vikas; K, Rajput S.

2018-03-01

Effect of coating thickness on low temperature cyclic thermal fatigue behaviour of Al2O3 thermal barrier coating (TBC) was concluded through the cyclic furnace thermal fatigue test (CFTF). Detonation gun (Thermal Spray) process was used for bond coating of NiCr and top coating of Al2O3 on Aluminium Alloy 6061 substrate. Top coating was done at two level of thickness to investigate the effect of coating thickness on low temperature cyclic thermal fatigue. The top coat of thickness 100μm-150μm was considered as thin TBC while the top coat of thickness 250μm-300μm was considered as thick TBC. The thickness of bond coat was taken as 120μm constant for both level of Al2O3 top coating. During CFTF test appearance of any crack on coated surface was adapted as main criterion of coating failure. Crack initiation was observed at edges and corner of thin thermal barrier coating after 60 number of thermal fatigue cycles while in case of thick thermal barrier coating these crack initiation was observed after 72 cycles of cyclic thermal fatigue test. During the study, it was observed that thick thermal barrier coating survived for long duration in comparison of thin TBC. Hence it can be concluded that application of thick TBC is more favourable to improve thermal durability of any component.

Colour centre recovery in yttria-stabilised zirconia: photo-induced versus thermal processes

NASA Astrophysics Data System (ADS)

Costantini, Jean-Marc; Touati, Nadia; Binet, Laurent; Lelong, Gérald; Guillaumet, Maxime; Beuneu, François

2018-05-01

The photo-annealing of colour centres in yttria-stabilised zirconia (YSZ) was studied by electron paramagnetic resonance spectroscopy upon UV-ray or laser light illumination, and compared to thermal annealing. Stable hole centres (HCs) were produced in as-grown YSZ single crystals by UV-ray irradiation at room temperature (RT). The HCs produced by 200-MeV Au ion irradiation, as well as the F+-type centres (? centres involving oxygen vacancies) were left unchanged upon UV illumination. In contrast, a significant photo-annealing of the latter point defects was achieved in 1.4-MeV electron-irradiated YSZ by 553-nm laser light irradiation at RT. Almost complete photo-bleaching was achieved by laser irradiation inside the absorption band of ? centres centred at a wavelength 550 nm. Thermal annealing of these colour centres was also followed by UV-visible absorption spectroscopy showing full bleaching at 523 K. Colour-centre evolutions by photo-induced and thermally activated processes are discussed on the basis of charge exchange processes between point defects.

Impact of yttria stabilized zirconia nanoinclusions on the thermal conductivity of n-type Si80Ge20 alloys prepared by spark plasma sintering

NASA Astrophysics Data System (ADS)

Lahwal, Ali; Bhattacharya, S.; He, Jian; Wu, Di; Peterson, A.; Poon, S. J.; Williams, L.; Dehkordi, A. Mehdizadeh; Tritt, T. M.

2015-04-01

Nanocomposites have become a new paradigm for thermoelectric research in recent years and have resulted in the reduction of thermal conductivity via the nano-inclusion and grain boundary scattering. In this work, we report the preparation and thermoelectric study of SiGe-yttria stabilized zirconia (YSZ) nanocomposites prepared by Spark Plasma Sintering (SPS). We experimentally investigated the reduction of lattice thermal conductivity (κL) in the temperature range (30-800 K) of n-type Si80Ge20P2 alloys with the incorporation of YSZ nanoparticles (20-40 nm diameter) into the Si-Ge matrix. These samples synthesized by using the SPS technique were found to have densities > 95% of the theoretical density. The thermal conductivity, at both low and high temperatures, was measured by steady state and laser flash techniques, respectively. At room temperature, we observed approximately a 50% reduction in the lattice thermal conductivity as result of adding 10% YSZ by volume to the Si80Ge20P2 host matrix. A phenomenological model developed by Callaway was used to corroborate both the temperature dependence and reduction of κ L over the measured temperature range (30-800 K) of both Si80Ge20P2 and Si80Ge20P2 + YSZ samples. The observed κL is discussed and interpreted in terms of various phonon scattering mechanisms such as alloy disorder, the Umklapp phonon scattering, and boundary scattering. In addition, a contribution from the phonon scattering by YSZ nanoparticles was further included to account for the κL of Si80Ge20P2 + YSZ sample. The theoretical calculations are in reasonably good agreement with the experimental results for both the Si80Ge20P2 and Si80Ge20P2 + YSZ alloys.

Thermal barrier coatings issues in advanced land-based gas turbines

NASA Technical Reports Server (NTRS)

Parks, W. P.; Lee, W. Y.; Wright, I. G.

1995-01-01

The Department of Energy's Advanced Turbine System (ATS) program is aimed at forecasting 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 turbines will require the use of different criteria in the design of the materials for the critical hot gas path components. In particular, thermal barrier coatings will be an essential feature of the hot gas path components in these machines. While such coatings are routinely used in high-performance aircraft engines and are becoming established in land-based turbines, the requirements of the ATS turbine application are sufficiently different that significant improvements in thermal barrier coating technology will be necessary. In particular, it appears that thermal barrier coatings will have to function on all airfoil sections of the first stage vanes and blades to provide the significant temperature reduction required. In contrast, such coatings applied to the blades and vances of advanced aircraft engines are intended primarily to reduce air cooling requirements and extend component lifetime; failure of those coatings can be tolerated without jeopardizing mechanical or corrosion performance. A major difference is that in ATS turbines these components will be totally reliant on thermal barrier coatings which will, therefore, need to be highly reliable even over the leading edges of first stage blades. Obviously, the ATS program provides a very challenging opportunity for TBC's, and involves some significant opportunities to extend this technology.

The crystal structure and morphology of NiO-YSZ composite that prepared from local zircon concentrate of Bangka Island

DOE Office of Scientific and Technical Information (OSTI.GOV)

Rahmawati, F., E-mail: fitria@mipa.uns.ac.id; Apriyani, K.; Heraldy, E.

2016-03-29

In order to increase the economic value of local zircon concentrate from Bangka Island, NiO-YSZ was synthesized from Zirconia, ZrO{sub 2} that was prepared from local zircon concentrate. The NiO-YSZ composite was synthesized by solid state reaction method. XRD analysis equipped with Le Bail refinement was carried out to analyze the crystal structure and cell parameters of the prepared materials. The result showed that zirconia was crystallized in tetragonal structure with a space group of P42/NMC. Yttria-Stabilized-Zirconia (YSZ) was prepared by doping 8% mol yttrium oxide into zirconia and then sintered at 1250°C for 3 hours. Doping of 8% molmore » Yttria allowed phase transformation of zirconia from tetragonal into the cubic structure. Meanwhile, the composite of NiO-YSZ consists of two crystalline phases, i.e. the NiO with cubic structure and the YSZ with cubic structure. SEM analysis of the prepared materials shows that the addition of NiO into YSZ allows the morphology to become more roughness with larger grain size.« less

Brazing of Stainless Steels to Yttria Stabilized Zirconia (YSZ) Using Silver -Base Brazes

NASA Technical Reports Server (NTRS)

Singh, Mrityunjay; Shpargel, Tarah P.; Asthana, Rajiv

2005-01-01

Three silver-base brazes containing either noble metal palladium (Palcusil-10 and Palcusil-15) or active metal titanium (Ticusil) were evaluated for high-temperature oxidation resistance, and their effectiveness in joining yttria stabilized zirconia (YSZ) to a corrosion-resistant ferritic stainless steel. Thermogravimetric analysis (TGA), and optical- and scanning electron microscopy (SEM) coupled with energy dispersive spectrometry (EDS) were used to evaluate the braze oxidation behavior and the structure and chemistry of the YSZ/braze/steel joints. The effect of the braze type and processing conditions on the interfacial microstructure and composition of the joint regions is discussed with reference to the chemical changes that occur at the interface. It was found that chemical interdiffusion of the constituents of YSZ, steel and the brazes led to compositional changes and/or interface reconstruction, and metallurgically sound joints.

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

NASA Technical Reports Server (NTRS)

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.

Furnace Cyclic Oxidation Behavior of Multi-Component Low Conductivity Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

Zhu, Dong-Ming; Nesbitt, James A.; Barrett, Charles A.; McCue, Terry R.; Miller, Robert A.

2004-01-01

Ceramic thermal barrier coatings will play an increasingly important role in advanced gas turbine engines because of their ability to further increase engine operating temperatures and reduce cooling, thus helping achieve future engine low emission, high efficiency and improved reliability goals. Advanced multi-component zirconia-based thermal barrier coatings are being developed using an oxide defect clustering design approach to achieve the required coating low thermal conductivity and high temperature stability. Although the new composition coatings were not yet optimized for cyclic durability, an initial durability screening of the candidate coating materials was conducted using conventional furnace cyclic oxidation tests. In this paper, furnace cyclic oxidation behavior of plasma-sprayed zirconia-based defect cluster thermal barrier coatings was investigated at 1163 C using 45 min hot cycles. The ceramic coating failure mechanisms were studied using scanning electron microscopy (SEM) combined with X-ray diffraction (XRD) phase analysis after the furnace tests. The coating cyclic lifetime is also discussed in relation to coating processing, phase structures, dopant concentration, and other thermo-physical properties.

Thermal barrier coatings for aircraft engines: History and directions

NASA Technical Reports Server (NTRS)

Miller, R. A.

1995-01-01

Thin thermal barrier coatings for protecting aircraft turbine section airfoils are examined. The discussion focuses on those advances that led first to their use for component life extension and more recently as an integral part of airfoil design. It is noted that development has been driven by laboratory rig and furnace testing corroborated by engine testing and engine field experience. The technology has also been supported by performance modeling to demonstrate benefits and life modeling for mission analysis. Factors which have led to the selection of the current state-of-the-art plasma sprayed and physical vapor deposited zirconia-yttria/MCrAlY TBC's is emphasized in addition to observations fundamentally related to their behavior. Current directions in research into thermal barrier coatings and recent progress at NASA is also noted.

Thermal Residual Stress in Environmental Barrier Coated Silicon Nitride - Modeled

NASA Technical Reports Server (NTRS)

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.

Thermal barrier coating resistant to sintering

DOEpatents

Subramanian, Ramesh; Seth, Brij B.

2004-06-29

A device (10) is made, having a ceramic thermal barrier coating layer (16) characterized by a microstructure having gaps (18) with a sintering inhibiting material (22) disposed on the columns (20) within the gaps (18). The sintering resistant material (22) is stable over the range of operating temperatures of the device (10), is not soluble with the underlying ceramic layer (16) and is applied by a process that is not an electron beam physical vapor deposition process.

Further industrial tests of ceramic thermal barrier coatings

NASA Technical Reports Server (NTRS)

Liebert, C. H.; Levine, S. R.

1982-01-01

The NASA Lewis Research Center made technical assistance arrangements (contracts) with several commercial organizations under which Lewis designed plasma-sprayed thermal-barrier coatings (TBC) for their products. Lewis was then furnished with the test conditions and evaluations of coating usefulness. The coating systems were developed and sprayed at Lewis. All of the systems incorporated a two-layer, ceramic-bond coating concept. Coating thickness and chemical composition were varied to fit three applications: the leading edges of first-stage turbine vanes for an advanced gas turbine engine; the flame impingement surfaces of a combustor transition section; and diesel engine valves and head surfaces. The TBC incorporated yytria-stabilized zirconia, which lowered metal temperatures, protected metal parts, and increased metal part life. In some cases metal burning, melting, and warping were eliminated. Additional benefits were realized from these endeavors: hands-on experience with thermal-barrier coatings was provided to industry; the success of these endeavors encourages these and other organizations to accelerate the implementation of TBC technology.

GaN on Diamond with Ultra-Low Thermal Barrier Resistance

DTIC Science & Technology

2016-03-31

GaN-on-Diamond with Ultra-Low Thermal Barrier Resistance Xing Gu1, Cathy Lee1, Jinqiao Xie1, Edward Beam1, Michael Becker2, Timothy A. Grotjohn2...Bristol BS8 1TL, UK Abstract: We investigated the effective thermal boundary resistance (TBReff) of GaN-on-Diamond interfaces for diamond growth... thermal boundary resistance; TBReff , interfacial layers; high density dielectric Introduction While GaN-based RF transistors, typically on SiC

An Electromagnetic/Capacitive Composite Sensor for Testing of Thermal Barrier Coatings

PubMed Central

Ren, Yuan; Pan, Mengchun; Chen, Dixiang; Tian, Wugang

2018-01-01

Thermal barrier coatings (TBCs) can significantly reduce the operating temperature of the aeroengine turbine blade substrate, and their testing technology is very urgently demanded. Due to their complex multi-layer structure, it is hard to evaluate TBCs with a single function sensor. In this paper, an electromagnetic/capacitive composite sensor is proposed for the testing of thermal barrier coatings. The dielectric material is tested with planar capacitor, and the metallic material is tested with electromagnetic coils. Then, the comprehensive test and evaluation of thermal barrier coating system can be realized. The sensor is optimized by means of theoretical and simulation analysis, and the interaction between the planar capacitor and the electromagnetic coil is studied. The experimental system is built based on an impedance analyser and multiplex unit to evaluate the performance of the composite sensor. The transimpedances and capacitances are measured under different coating parameters, such as thickness and permittivity of top coating as well as bond layer conductivity. The experimental results agree with the simulation analysis, and the feasibility of the sensor is proved. PMID:29783746

Computational design and experimental validation of new thermal barrier systems

DOE Office of Scientific and Technical Information (OSTI.GOV)

Guo, Shengmin

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 validationmore » 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 TaZr 2.75O 8 and confirmed it’s hot corrosion performance.« less

Modeling Oxidation Induced Stresses in Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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

1998-01-01

The use of thermal barrier coatings (TBC's) in gas turbines has increased dramatically in recent years, due mainly to the need for component protection from ever increasing service temperatures. Oxidation of the bond coat has been identified as an important contributing factor to spallation of the ceramic top coat during service. Additional variables found to influence TBC thermal cycle life include bond coat coefficient of thermal expansion, creep behavior of both the ceramic and bond coat layers, and modulus of elasticity. The purpose of this work was to characterize the effects of oxidation on the stress states within the TBC system, as well as to examine the interaction of oxidation with other factors affecting TBC life.

Thermal and Environmental Barrier Coatings for Advanced Propulsion Engine Systems

NASA Technical Reports Server (NTRS)

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.

Greener, meaner diesels sport thermal barrier coatings

DOE Office of Scientific and Technical Information (OSTI.GOV)

Winkler, M.F.; Parker, D.W.

1992-05-01

The highly reliable diesel engine has long been the workhorse of the transportation, industrial power, utility, and marine industries. Demand for diesels is expected to accelerate well into the next century, driven by the engine's ability to economically produce power in almost any environment. Increasingly stringent environmental, efficiency, and durability requirements, however, present new challenges to diesel engine manufacturers and operators. This paper reports that many of these challenges can be met entirely, or in part, by thermal barrier coatings (TBCs). Diesel engine TBCs are plasma-spray-applied ceramics, which insulate combustion system components, such as pistons, valves, and piston fire decks,more » from heat and thermal shock.« less

Insights on the High-Temperature Operational Limits of ZrO2-Y2O3 TBCs Manufactured via Air Plasma Spray

NASA Astrophysics Data System (ADS)

Lima, Rogerio S.; Marple, Basil R.

2017-03-01

The effective high-temperature operation limit of a ZrO2-7-8 wt.%Y2O3 (YSZ) thermal barrier coating (TBC) manufactured via air plasma spray (APS) is considered to be 1300 °C. This is related to the metastable tetragonal t'-phase formed during the rapid quenching of the YSZ particles during spraying. The t'-phase transforms into the equilibrium tetragonal and cubic phases at temperatures ≥ 1300 °C, which can lead to the formation of the monoclinic phase of YSZ upon cooling to room temperature. This formation of the monoclinic phase is accompanied by a volume expansion that leads to TBC failure due to extensive micro-cracking. To further investigate this limitation, an APS YSZ TBC was sprayed on a CMSX-4 substrate. By using a thermal (laser) gradient cyclic testing, a temperature gradient was generated across the TBC/substrate system. The YSZ T- front and substrate backside T- back temperature levels were 1500 and 1000 °C, respectively. In cycle conditions (5-min or 1-h hot and 2-min cool), no TBC failure has been observed. This behavior was partially attributed to the unexpected absence of the monoclinic phase of the YSZ in the cycled coatings. Although preliminary, these results are promising regarding increasing the effective high-temperature operational limits of APS YSZ TBCs.

Investigation of Thermal High Cycle and Low Cycle Fatigue Mechanisms of Thick Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Miller, Robert A.

1998-01-01

Thick thermal barrier coating systems in a diesel engine experience severe thermal low cycle fatigue (LCF) and high cycle fatigue (HCF) during engine operation. In this paper, the mechanisms of fatigue crack initiation and propagation in a ZrO2-8wt.% Y2O3 thermal barrier coating, under simulated engine thermal LCF and HCF conditions, are investigated using a high power CO2 laser. Experiments showed that the combined LCF/HCF tests induced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. Lateral crack branching and the ceramic/bond coat interface delaminations were also facilitated by HCF thermal loads, even in the absence of severe interfacial oxidation. Fatigue damages at crack wake surfaces, due to such phenomena as asperity/debris contact induced cracking and splat pull-out bending during cycling, were observed especially for the combined LCF/HCF tests. It is found that the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. The failure associated with HCF process, however, is mainly associated with a surface wedging mechanism. The interaction between the LCF, HCF and ceramic coating creep, and the relative importance of LCF and HCF in crack propagation are also discussed based on the experimental evidence.

A study on thermal barrier coatings including thermal expansion mismatch and bond coat oxidation

NASA Technical Reports Server (NTRS)

Chang, George C.; Phucharoen, Woraphat; Miller, Robert A.

1986-01-01

The present investigation deals with a plasma-sprayed thermal barrier coating (TBC) intended for high temperature applications to advanced gas turbine blades. Typically, this type of coating system consists of a zirconia-yttria ceramic layer with a nickel-chromium-aluminum bond coat on a superalloy substrate. The problem on hand is a complex one due to the fact that bond coat oxidation and thermal mismatch occur in the TBC. Cracking in the TBC has also been experimentally illustrated. A clearer understanding of the mechanical behavior of the TBC is investigated. The stress states in a model thermal barrier coating as it cools down in air is studied. The powerful finite element method was utilized to model a coating cylindrical specimen. Four successively refined finite element models were developed. Some results obtained using the first two models have been reported previously. The major accomplishment is the successful development of an elastic TBC finite element model known as TBCG with interface geometry between the ceramic layer and the bond coat. An equally important milestone is the near-completion of the new elastic-plastic TBC finite element model called TBCGEP which yielded initial results. Representative results are presented.

Thermal barrier coating life prediction model development

NASA Technical Reports Server (NTRS)

Strangman, T. E.; Neumann, J. F.; Tasooji, A.

1985-01-01

This program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant thermal barrier coating (TBC) systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system is composed of a low pressure, plasma sprayed applied, oxidation resistant NiCrAlY bond coating. The other system is an air plasma sprayed yttria (8 percent) partially stabilized zirconia insulative layer.

Heterogeneous electrolyte (YSZ-Al 2O 3) based direct oxidation solid oxide fuel cell

NASA Astrophysics Data System (ADS)

Thokchom, J. S.; Xiao, H.; Rottmayer, M.; Reitz, T. L.; Kumar, B.

Bilayers comprised of dense and porous YSZ-Al 2O 3 (20 wt%) composite were tape cast, processed, and then fabricated into working solid oxide fuel cells (SOFCs). The porous part of the bilayer was converted into anode for direct oxidation of fuels by infiltrating CeO 2 and Cu. The cathode side of the bilayer was coated with an interlayer [YSZ-Al 2O 3 (20 wt%)]: LSM (1:1) and LSM as cathode. Several button cells were evaluated under hydrogen/air and propane/air atmospheres in intermediate temperature range and their performance data were analyzed. For the first time the feasibility of using YSZ-Al 2O 3 material for fabricating working SOFCs with high open circuit voltage (OCV) and power density is demonstrated. AC impedance spectroscopy and scanning electron microscopy (SEM) techniques were used to characterize the membrane and cell.

Thermal Properties of Oxides With Magnetoplumbite Structure for Advanced Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Thermal barrier coating life prediction model

NASA Technical Reports Server (NTRS)

Hillery, R. V.; Pilsner, B. H.

1985-01-01

This is the first report of the first phase of a 3-year program. Its objectives are to determine the predominant modes of degradation of a plasma sprayed thermal barrier coating system, then to develop and verify life prediction models accounting for these degradation modes. The first task (Task I) is to determine the major failure mechanisms. Presently, bond coat oxidation and bond coat creep are being evaluated as potential TBC failure mechanisms. The baseline TBC system consists of an air plasma sprayed ZrO2-Y2O3 top coat, a low pressure plasma sprayed NiCrAlY bond coat, and a Rene'80 substrate. Pre-exposures in air and argon combined with thermal cycle tests in air and argon are being utilized to evaluate bond coat oxidation as a failure mechanism. Unexpectedly, the specimens pre-exposed in argon failed before the specimens pre-exposed in air in subsequent thermal cycles testing in air. Four bond coats with different creep strengths are being utilized to evaluate the effect of bond coat creep on TBC degradation. These bond coats received an aluminide overcoat prior to application of the top coat to reduce the differences in bond coat oxidation behavior. Thermal cycle testing has been initiated. Methods have been selected for measuring tensile strength, Poisson's ratio, dynamic modulus and coefficient of thermal expansion both of the bond coat and top coat layers.

Controlling Microstructure of Yttria-Stabilized Zirconia Prepared from Suspensions and Solutions by Plasma Spraying with High Feed Rates

NASA Astrophysics Data System (ADS)

Musalek, Radek; Medricky, Jan; Tesar, Tomas; Kotlan, Jiri; Pala, Zdenek; Lukac, Frantisek; Illkova, Ksenia; Hlina, Michal; Chraska, Tomas; Sokolowski, Pawel; Curry, Nicholas

2017-12-01

Introduction of suspension and solution plasma spraying led to a breakthrough in the deposition of yttria-stabilized zirconia (YSZ) coatings and enabled preparation of new types of layers. However, their deposition with high feed rates needed, for example, for the deposition of thermal barrier coatings (TBCs) on large-scale components, is still challenging. In this study, possibility of high-throughput plasma spraying of YSZ coatings is demonstrated for the latest generation of high-enthalpy hybrid water-stabilized plasma (WSP-H) torch technology. The results show that microstructure of the coatings prepared by WSP-H may be tailored for specific applications by the choice of deposition conditions, in particular formulation of the liquid feedstock. Porous and columnar coatings with low thermal conductivity (0.5-0.6 W/mK) were prepared from commercial ethanol-based suspension. Dense vertically cracked coatings with higher thermal conductivity but also higher internal cohesion were deposited from suspension containing ethanol/water mixture and coarser YSZ particles. Spraying of solution formulated from diluted zirconium acetate and yttrium nitrate hexahydrate led also to the successful deposition of YSZ coating combining regions of porous and denser microstructure and providing both low thermal conductivity and improved cohesion of the coating. Enthalpy content, liquid-plasma interaction and coating buildup mechanisms are also discussed.

3D Microstructure Effects in Ni-YSZ Anodes: Influence of TPB Lengths on the Electrochemical Performance.

PubMed

Pecho, Omar M; Mai, Andreas; Münch, Beat; Hocker, Thomas; Flatt, Robert J; Holzer, Lorenz

2015-10-21

3D microstructure-performance relationships in Ni-YSZ anodes for electrolyte-supported cells are investigated in terms of the correlation between the triple phase boundary (TPB) length and polarization resistance ( R pol ). Three different Ni-YSZ anodes of varying microstructure are subjected to eight reduction-oxidation (redox) cycles at 950 °C. In general the TPB lengths correlate with anode performance . However, the quantitative results also show that there is no simplistic relationship between TPB and R pol . The degradation mechanism strongly depends on the initial microstructure. Finer microstructures exhibit lower degradation rates of TPB and R pol . In fine microstructures, TPB loss is found to be due to Ni coarsening, while in coarse microstructures reduction of active TPB results mainly from loss of YSZ percolation. The latter is attributed to weak bottlenecks associated with lower sintering activity of the coarse YSZ. The coarse anode suffers from complete loss of YSZ connectivity and associated drop of TPB active by 93%. Surprisingly, this severe microstructure degradation did not lead to electrochemical failure. Mechanistic scenarios are discussed for different anode microstructures. These scenarios are based on a model for coupled charge transfer and transport, which allows using TPB and effective properties as input. The mechanistic scenarios describe the microstructure influence on current distributions, which explains the observed complex relationship between TPB lengths and anode performances. The observed loss of YSZ percolation in the coarse anode is not detrimental because the electrochemical activity is concentrated in a narrow active layer. The anode performance can be predicted reliably if the volume-averaged properties (TPB active , effective ionic conductivity) are corrected for the so-called short-range effect, which is particularly important in cases with a narrow active layer.

3D Microstructure Effects in Ni-YSZ Anodes: Influence of TPB Lengths on the Electrochemical Performance

PubMed Central

Pecho, Omar M.; Mai, Andreas; Münch, Beat; Hocker, Thomas; Flatt, Robert J.; Holzer, Lorenz

2015-01-01

3D microstructure-performance relationships in Ni-YSZ anodes for electrolyte-supported cells are investigated in terms of the correlation between the triple phase boundary (TPB) length and polarization resistance (Rpol). Three different Ni-YSZ anodes of varying microstructure are subjected to eight reduction-oxidation (redox) cycles at 950 °C. In general the TPB lengths correlate with anode performance. However, the quantitative results also show that there is no simplistic relationship between TPB and Rpol. The degradation mechanism strongly depends on the initial microstructure. Finer microstructures exhibit lower degradation rates of TPB and Rpol. In fine microstructures, TPB loss is found to be due to Ni coarsening, while in coarse microstructures reduction of active TPB results mainly from loss of YSZ percolation. The latter is attributed to weak bottlenecks associated with lower sintering activity of the coarse YSZ. The coarse anode suffers from complete loss of YSZ connectivity and associated drop of TPBactive by 93%. Surprisingly, this severe microstructure degradation did not lead to electrochemical failure. Mechanistic scenarios are discussed for different anode microstructures. These scenarios are based on a model for coupled charge transfer and transport, which allows using TPB and effective properties as input. The mechanistic scenarios describe the microstructure influence on current distributions, which explains the observed complex relationship between TPB lengths and anode performances. The observed loss of YSZ percolation in the coarse anode is not detrimental because the electrochemical activity is concentrated in a narrow active layer. The anode performance can be predicted reliably if the volume-averaged properties (TPBactive, effective ionic conductivity) are corrected for the so-called short-range effect, which is particularly important in cases with a narrow active layer. PMID:28793624

Transient thermography testing of unpainted thermal barrier coating surfaces

NASA Astrophysics Data System (ADS)

Ptaszek, Grzegorz; Cawley, Peter; Almond, Darryl; Pickering, Simon

2013-01-01

This paper has investigated the effects of uneven surface discolouration of a thermal barrier coating (TBC) and of its IR translucency on the thermal responses observed by using mid and long wavelength IR cameras. It has been shown that unpainted blades can be tested satisfactorily by using a more powerful flash heating system and a long wavelength IR camera. The problem of uneven surface emissivity can be overcome by applying 2nd derivative processing of the log-log surface cooling curves.

Kinetic Monte Carlo Simulation of Oxygen and Cation Diffusion in Yttria-Stabilized Zirconia

NASA Technical Reports Server (NTRS)

Good, Brian

2011-01-01

Yttria-stabilized zirconia (YSZ) is of interest to the aerospace community, notably for its application as a thermal barrier coating for turbine engine components. In such an application, diffusion of both oxygen ions and cations is of concern. Oxygen diffusion can lead to deterioration of a coated part, and often necessitates an environmental barrier coating. Cation diffusion in YSZ is much slower than oxygen diffusion. However, such diffusion is a mechanism by which creep takes place, potentially affecting the mechanical integrity and phase stability of the coating. In other applications, the high oxygen diffusivity of YSZ is useful, and makes the material of interest for use as a solid-state electrolyte in fuel cells. The kinetic Monte Carlo (kMC) method offers a number of advantages compared with the more widely known molecular dynamics simulation method. In particular, kMC is much more efficient for the study of processes, such as diffusion, that involve infrequent events. We describe the results of kinetic Monte Carlo computer simulations of oxygen and cation diffusion in YSZ. Using diffusive energy barriers from ab initio calculations and from the literature, we present results on the temperature dependence of oxygen and cation diffusivity, and on the dependence of the diffusivities on yttria concentration and oxygen sublattice vacancy concentration. We also present results of the effect on diffusivity of oxygen vacancies in the vicinity of the barrier cations that determine the oxygen diffusion energy barriers.

Thermal Conductivity and Elastic Modulus Evolution of Thermal Barrier Coatings under High Heat Flux Conditions

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Miller, Robert A.

1999-01-01

Laser high heat flux test approaches have been established to obtain critical properties of ceramic thermal barrier coatings (TBCs) under near-realistic temperature and thermal gradients that may he encountered in advanced engine systems. Thermal conductivity change kinetics of a thin ceramic coating were continuously monitored in real time at various test temperatures. A significant thermal conductivity increase was observed during the laser simulated engine heat flux tests. For a 0.25 mm thick ZrO2-8%Y2O3 coating system, the overall thermal conductivity increased from the initial value of 1.0 W/m-K to 1. 15 W/m-K, 1. 19 W/m-K and 1.5 W/m-K after 30 hour testing at surface temperatures of 990C, 1100C, and 1320C. respectively. Hardness and modulus gradients across a 1.5 mm thick TBC system were also determined as a function of laser testing time using the laser sintering/creep and micro-indentation techniques. The coating Knoop hardness values increased from the initial hardness value of 4 GPa to 5 GPa near the ceramic/bond coat interface, and to 7.5 GPa at the ceramic coating surface after 120 hour testing. The ceramic surface modulus increased from an initial value of about 70 GPa to a final value of 125 GPa. The increase in thermal conductivity and the evolution of significant hardness and modulus gradients in the TBC systems are attributed to sintering-induced micro-porosity gradients under the laser-imposed high thermal gradient conditions. The test techniques provide a viable means for obtaining coating data for use in design, development, stress modeling, and life prediction for various thermal barrier coating applications.

Improved Thermal Cycling Durability of Thermal Barrier Coatings Manufactured by PS-PVD

NASA Astrophysics Data System (ADS)

Rezanka, S.; Mauer, G.; Vaßen, R.

2014-01-01

The plasma spray-physical vapor deposition (PS-PVD) process is a promising method to manufacture thermal barrier coatings (TBCs). It fills the gap between traditional thermal spray processes and electron beam physical vapor deposition (EB-PVD). The durability of PS-PVD manufactured columnar TBCs is strongly influenced by the compatibility of the metallic bondcoat (BC) and the ceramic TBC. Earlier investigations have shown that a smooth BC surface is beneficial for the durability during thermal cycling. Further improvements of the bonding between BC and TBC could be achieved by optimizing the formation of the thermally grown oxide (TGO) layer. In the present study, the parameters of pre-heating and deposition of the first coating layer were investigated in order to adjust the growth of the TGO. Finally, the durability of the PS-PVD coatings was improved while the main advantage of PS-PVD, i.e., much higher deposition rate in comparison to EB-PVD, could be maintained. For such coatings, improved thermal cycling lifetimes more than two times higher than conventionally sprayed TBCs, were measured in burner rigs at ~1250 °C/1050 °C surface/substrate exposure temperatures.

Defect Clustering and Nano-phase Structure Characterization of Multicomponent Rare Earth-Oxide-Doped Zirconia-Yttria Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Chen, Yuan L.; Miller, Robert A.

2004-01-01

Advanced thermal barrier coatings (TBCs) have been developed by incorporating multicomponent rare earth oxide dopants into zirconia-based thermal barrier coatings to promote the creation of the thermodynamically stable, immobile oxide defect clusters and/or nanophases within the coating systems. In this paper, the defect clusters, induced by Nd, Gd, and Yb rare earth dopants in the zirconia-yttria thermal barrier coatings, were characterized by high-resolution transmission electron microscopy (TEM). The TEM lattice imaging, selected area diffraction (SAD), and electron energy-loss spectroscopy (EELS) analyses demonstrated that the extensive nanoscale rare earth dopant segregation exists in the plasma-sprayed and electron-physical-vapor-deposited (EB PVD) thermal barrier coatings. The nanoscale concentration heterogeneity and the resulting large lattice distortion promoted the formation of parallel and rotational defective lattice clusters in the coating systems. The presence of the 5-to 100-nm-sized defect clusters and nanophases is believed to be responsible for the significant reduction of thermal conductivity, improved sintering resistance, and long-term high temperature stability of the advanced thermal barrier coating systems.

Chemical Vapor Deposition of Turbine Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Chip-carrier thermal barrier and its impact on lateral thermal lens profile and beam parameter product in high power broad area lasers

NASA Astrophysics Data System (ADS)

Rieprich, J.; Winterfeldt, M.; Kernke, R.; Tomm, J. W.; Crump, P.

2018-03-01

High power broad area diode lasers with high optical power density in a small focus spot are in strong commercial demand. For this purpose, the beam quality, quantified via the beam parameter product (BPP), has to be improved. Previous studies have shown that the BPP is strongly affected by current-induced heating and the associated thermal lens formed within the laser stripe. However, the chip structure and module-assembly related factors that regulate the size and the shape of the thermal lens are not well known. An experimental infrared thermographic technique is used to quantify the thermal lens profile in diode lasers operating at an emission wavelength of 910 nm, and the results are compared with finite element method simulations. The analysis indicates that the measured thermal profiles can best be explained when a thermal barrier is introduced between the chip and the carrier, which is shown to have a substantial impact on the BPP and the thermal resistance. Comparable results are observed in further measurements of samples from multiple vendors, and the barrier is only observed for junction-down (p-down) mounting, consistent with the barrier being associated with the GaAs-metal transition.

Electrophoretic deposition of bi-layered LSM/LSM-YSZ cathodes for solid oxide fuel cell

NASA Astrophysics Data System (ADS)

Itagaki, Yoshiteru; Watanabe, Shinji; Yamaji, Tsuyoshi; Asamoto, Makiko; Yahiro, Hidenori; Sadaoka, Yoshihiko

2012-09-01

Bi-layered cathodes with the LSM/LSM-YSZ structure for solid oxide fuel cells were successfully formed on the carbon-sputtered surface of a YSZ sheet by electrophoretic deposition (EPD). The thicknesses of the first layer of LSM-YSZ (LY) and the second layer of La0.8Sr0.2MnO3 (LSM) could be controlled by adjusting the deposition time in the EPD process. The cathodic properties of the bi-layered structures were superior to those of the mono-layered structures, and were dependent on the thickness of each layer. Decreasing the thickness of the first layer and increasing that of the second layer tended to reduce both polarization and ohmic resistances. The optimal thickness of the first layer at the operating temperature of 600 °C was 4 μm, suggesting that an effective three-phase boundary was extended from the interface between the electrolyte and cathode film to around 4 μm thickness.

Optimization of Heat Transfer on Thermal Barrier Coated Gas Turbine Blade

NASA Astrophysics Data System (ADS)

Aabid, Abdul; Khan, S. A.

2018-05-01

In the field of Aerospace Propulsion technology, material required to resist the maximum temperature. In this paper, using thermal barrier coatings (TBCs) method in gas turbine blade is used to protect hot section component from high-temperature effect to extend the service life and reduce the maintenance costs. The TBCs which include three layers of coating corresponding initial coat is super alloy-INCONEL 718 with 1 mm thickness, bond coat is Nano-structured ceramic-metallic composite-NiCoCrAIY with 0.15 mm thickness and top coat is ceramic composite-La2Ce2O7 with 0.09 mm thickness on the nickel alloy turbine blade which in turn increases the strength, efficiency and life span of the blades. Modeling a gas turbine blade using CATIA software and determining the amount of heat transfer on thermal barrier coated blade using ANSYS software has been performed. Thermal stresses and effects of different TBCs blade base alloys are considered using CATIA and ANSYS.

Residual Stresses Modeled in Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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

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

NASA Technical Reports Server (NTRS)

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.

Enhanced thermoelectric performance of Nb-doped SrTiO3 by nano-inclusion with low thermal conductivity

PubMed Central

Wang, Ning; Chen, Haijun; He, Hongcai; Norimatsu, Wataru; Kusunoki, Michiko; Koumoto, Kunihito

2013-01-01

Authors reported an effective path to increase the electrical conductivity while to decrease the thermal conductivity, and thus to enhance the ZT value by nano-inclusions. By this method, the ZT value of Nb-doped SrTiO3 was enhanced 9-fold by yttria stabilized zirconia (YSZ) nano-inclusions. YSZ inclusions, located inside grain and in triple junction, can reduce the thermal conductivity by effective interface phonon scattering, enhance the electrical conductivity by promoting the abnormal grain growth, and thus lead to the obvious enhancement of ZT value, which strongly suggests that, it is possible to not only reduce the thermal conductivity, but also increase the electrical conductivity by nano-inclusions with low thermal conductivity. This study will give some useful enlightenment to the preparation of high-performance oxide thermoelectric materials. PMID:24316665

Quantification of the degradation of Ni-YSZ anodes upon redox cycling

NASA Astrophysics Data System (ADS)

Song, Bowen; Ruiz-Trejo, Enrique; Bertei, Antonio; Brandon, Nigel P.

2018-01-01

Ni-YSZ anodes for Solid Oxide Fuel Cells are vulnerable to microstructural damage during redox cycling leading to a decrease in the electrochemical performance. This study quantifies the microstructural changes as a function of redox cycles at 800 °C and associates it to the deterioration of the mechanical properties and polarisation resistance. A physically-based model is used to estimate the triple-phase boundary (TPB) length from impedance spectra, and satisfactorily matches the TPB length quantified by FIB-SEM tomography: within 20 redox cycles, the TPB density decreases from 4.63 μm-2 to 1.06 μm-2. Although the polarisation resistance increases by an order of magnitude after 20 cycles, after each re-reduction the electrode polarisation improves consistently due to the transient generation of Ni nanoparticles around the TPBs. Nonetheless, the long-term degradation overshadows this transient improvement due to the nickel agglomeration. In addition, FIB-SEM tomography reveals fractures along YSZ grain boundaries, Ni-YSZ detachment and increased porosity in the composite that lead to irreversible mechanical damage: the elastic modulus diminishes from 36.4 GPa to 20.2 GPa and the hardness from 0.40 GPa to 0.15 GPa. These results suggest that microstructural, mechanical and electrochemical properties are strongly interdependent in determining the degradation caused by redox cycling.

Electron beam physical vapor deposition of YSZ electrolyte coatings for SOFCs

NASA Astrophysics Data System (ADS)

He, Xiaodong; Meng, Bin; Sun, Yue; Liu, Bochao; Li, Mingwei

2008-09-01

YSZ electrolyte coatings were prepared by electron beam physical vapor deposition (EB-PVD) at a high deposition rate of up to 1 μm/min. The YSZ coating consisted of a single cubic phase and no phase transformation occurred after annealing treatment at 1000 °C. A typical columnar structure was observed in this coating by SEM and feather-like characteristics appeared in every columnar grain. In columnar grain boundaries there were many micron-sized gaps and pores. In TEM image, many white lines were found, originating from the alignment of nanopores existing within feather-like columnar grains. The element distribution along the cross-section of the coating was homogeneous except Zr with a slight gradient. The coating exhibited a characteristic anisotropic behavior in electrical conductivity. In the direction perpendicular to coating surface the electrical conductivity was remarkably higher than that in the direction parallel to coating surface. This mainly attributed to the typical columnar structure for EB-PVD coating and the existence of many grain boundaries along the direction parallel to coating surface. For as-deposited coating, the gas permeability coefficient of 9.78 × 10 -5 cm 4 N -1 s -1 was obtained and this value was close to the critical value of YSZ electrolyte layer required for solid oxide fuel cell (SOFC) operation.

Energy efficient engine, high pressure turbine thermal barrier coating. Support technology report

NASA Technical Reports Server (NTRS)

Duderstadt, E. C.; Agarwal, P.

1983-01-01

This report describes the work performed on a thermal barrier coating support technology task of the Energy Efficient Engine Component Development Program. A thermal barrier coating (TBC) system consisting of a Ni-Cr-Al-Y bond cost layer and ZrO2-Y2O3 ceramic layer was selected from eight candidate coating systems on the basis of laboratory tests. The selection was based on coating microstructure, crystallographic phase composition, tensile bond and bend test results, erosion and impact test results, furnace exposure, thermal cycle, and high velocity dynamic oxidation test results. Procedures were developed for applying the selected TBC to CF6-50, high pressure turbine blades and vanes. Coated HPT components were tested in three kinds of tests. Stage 1 blades were tested in a cascade cyclic test rig, Stage 2 blades were component high cycle fatigue tested to qualify thermal barrier coated blades for engine testing, and Stage 2 blades and Stage 1 and 2 vanes were run in factory engine tests. After completion of the 1000 cycle engine test, the TBC on the blades was in excellent condition over all of the platform and airfoil except at the leading edge above midspan on the suction side of the airfoil. The coating damage appeared to be caused by particle impingement; adjacent blades without TBC also showed evidence of particle impingement.

Stator Blade with Thermal Barrier Testing on Hot Gas Rig

NASA Image and Video Library

1975-04-21

A 1-foot long stator blade with a thermal coating subjected to intense heat in order to test its strength at the National Aeronautics and Space Administration (NASA) Lewis Research Center. Lewis researchers sought to determine optimal types of ceramic coatings to increase the durability of metals. The research was primarily intended to support the design of stator blades for high-performance axial-flow compressor and turbofan engines. The coatings reduced the temperature of the metal and the amount of required cooling. As engines became more and more sophisticated, compressor blades were required to withstand higher and higher temperatures. Lewis researchers developed a dual-layer thermal-barrier coating that could be applied to turbine vanes and blades and combustion liners. This new sprayable thermal-barrier coating was evaluated for its durability, strength, fatigue, and aerodynamic penalties. This hot-gas rig fired the scorching gas at the leading edge of a test blade. The blade was cooled by an internal air flow. The blades were heated at two different velocities during the program. When using Mach 0.3 gases the entire heating and cooling cycle only lasted 30 seconds. The cycle lasted 60 minutes during tests at Mach 1.

Thermoelectric Properties of Silicon Germanium: An Investigation of the Reduction of Lattice Thermal Conductivity and Enhancement of Power Factor

NASA Astrophysics Data System (ADS)

Lahwal, Ali Sadek

Thermoelectric materials are of technological interest owing to their ability of direct thermal-to-electrical energy conversion. In thermoelectricity, thermal gradients can be used to generate an electrical power output. Recent efforts in thermoelectrics are focused on developing higher efficient power generation materials. In this dissertation, the overall goal is to investigate both the n-type and p-type of the state of the art thermoelectric material, silicon germanium (SiGe), for high temperature power generation. Further improvement of thermoelectric performance of Si-Ge alloys hinges upon how to significantly reduce the as yet large lattice thermal conductivity, and optimizing the thermoelectric power factor PF. Our methods, in this thesis, will be into two different approaches as follow: The first approach is manipulating the lattice thermal conductivity of n and p-type SiGe alloys via direct nanoparticle inclusion into the n-type SiGe matrix and, in a different process, using a core shell method for the p-type SiGe. This approach is in line with the process of in-situ nanocomposites. Nanocomposites have become a new paradigm for thermoelectric research in recent years and have resulted in the reduction of thermal conductivity via the nano-inclusion and grain boundary scattering of heat-carrying phonons. To this end, a promising choice of nano-particle to include by direct mixing into a SiGe matrix would be Yttria Stabilized Zirconia ( YSZ). In this work we report the preparation and thermoelectric study of n-type SiGe + YSZ nanocomposites prepared by direct mechanical mixing followed by Spark Plasma Sintering (SPS) processing. Specifically, we experimentally investigated the reduction of lattice thermal conductivity (kappaL) in the temperature range (30--800K) of n-type Si 80Ge20P2 alloys with the incorporation of YSZ nanoparticles (20 ˜ 40 nm diameter) into the Si-Ge matrix. These samples synthesized by SPS were found to have densities > 95% of the

Examination of charge transfer in Au/YSZ for high-temperature optical gas sensing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Baltrus, John P.; Ohodnicki, Paul R.

2014-01-01

Au-nanoparticle incorporated oxide thin film materials demonstrate significant promise as functionalsensor materials for high temperature optical gas sensing in severe environments relevant for fossil andnuclear based power generation. The Au/yttria-stabilized zirconia (YSZ) system has been extensivelystudied in the literature and serves as a model system for fundamental investigations that seek to betterunderstand the mechanistic origin of the plasmonic gas sensing response. In this work, X-ray photoelec-tron spectroscopy techniques are applied to Au/YSZ films in an attempt to provide further experimentalevidence for a proposed sensing mechanism involving a change in free carrier density of Au nanoparticles due to charge transfer.

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

NASA Technical Reports Server (NTRS)

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.

Thermal barrier coating life-prediction model development

NASA Technical Reports Server (NTRS)

Strangman, T. E.; Neumann, J.; Liu, A.

1986-01-01

The program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant thermal barrier coating (TBC) systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma-spray (LPPS) or an argon shrouded plasma-spray (ASPS) applied oxidation resistant NiCrAlY or (CoNiCrAlY) bond coating and an air-plasma-sprayed yttria partially stabilized zirconia insulative layer, is applied by both Chromalloy, Klock, and Union Carbide. The second type of TBS is applied by the electron beam-physical vapor deposition (EB-PVD) process by Temescal. The second year of the program was focused on specimen procurement, TMC system characterization, nondestructive evaluation methods, life prediction model development, and TFE731 engine testing of thermal barrier coated blades. Materials testing is approaching completion. Thermomechanical characterization of the TBC systems, with toughness, and spalling strain tests, was completed. Thermochemical testing is approximately two-thirds complete. Preliminary materials life models for the bond coating oxidation and zirconia sintering failure modes were developed. Integration of these life models with airfoil component analysis methods is in progress. Testing of high pressure turbine blades coated with the program TBS systems is in progress in a TFE731 turbofan engine. Eddy current technology feasibility was established with respect to nondestructively measuring zirconia layer thickness of a TBC system.

Thermal insulating barrier and neutron shield providing integrated protection for a nuclear reactor vessel

DOEpatents

Schreiber, R.B.; Fero, A.H.; Sejvar, J.

1997-12-16

The reactor vessel of a nuclear reactor installation which is suspended from the cold leg nozzles in a reactor cavity is provided with a lower thermal insulating barrier spaced from the reactor vessel to form a chamber which can be flooded with cooling water through passive valving to directly cool the reactor vessel in the event of a severe accident. The passive valving also includes bistable vents at the upper end of the thermal insulating barrier for releasing steam. A removable, modular neutron shield extending around the upper end of the reactor cavity below the nozzles forms with the upwardly and outwardly tapered transition on the outer surface of the reactor vessel, a labyrinthine channel which reduces neutron streaming while providing a passage for the escape of steam during a severe accident, and for the cooling air which is circulated along the reactor cavity walls outside the thermal insulating barrier during normal operation of the reactor. 8 figs.

Thermal insulating barrier and neutron shield providing integrated protection for a nuclear reactor vessel

DOEpatents

Schreiber, Roger B.; Fero, Arnold H.; Sejvar, James

1997-01-01

The reactor vessel of a nuclear reactor installation which is suspended from the cold leg nozzles in a reactor cavity is provided with a lower thermal insulating barrier spaced from the reactor vessel to form a chamber which can be flooded with cooling water through passive valving to directly cool the reactor vessel in the event of a severe accident. The passive valving also includes bistable vents at the upper end of the thermal insulating barrier for releasing steam. A removable, modular neutron shield extending around the upper end of the reactor cavity below the nozzles forms with the upwardly and outwardly tapered transition on the outer surface of the reactor vessel, a labyrinthine channel which reduces neutron streaming while providing a passage for the escape of steam during a severe accident, and for the cooling air which is circulated along the reactor cavity walls outside the thermal insulating barrier during normal operation of the reactor.

Preparation and Characterization of Anode-Supported YSZ Thin Film Electrolyte by Co-Tape Casting and Co-Sintering Process

NASA Astrophysics Data System (ADS)

Liu, Q. L.; Fu, C. J.; Chan, S. H.; Pasciak, G.

2011-06-01

In this study, a co-tape casting and co-sintering process has been developed to prepare yttria-stabilized zirconia (YSZ) electrolyte films supported on Ni-YSZ anode substrates in order to substantially reduce the fabrication cost of solid oxide fuel cells (SOFC). Through proper control of the process, the anode/electrolyte bilayer structures with a size of 7.8cm × 7.8cm were achieved with good flatness. Scanning electron microscopy (SEM) observation indicated that the YSZ electrolyte film was about 16 μm in thickness, highly dense, crack free and well-bonded to the anode support. The electrochemical properties of the prepared anode-supported electrolyte film was evaluated in a button cell mode incorporating a (LaSr)MnO3-YSZ composite cathode. With humidified hydrogen as the fuel and stationary air as the oxidant, the cell demonstrated an open-circuit voltage of 1.081 V and a maximum power density of 1.01 W/cm2 at 800°C. The obtained results represent the important progress in the development of anode-supported intermediate temperature SOFC with reduced fabrication cost.

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

NASA Technical Reports Server (NTRS)

Stecura, S.

1979-01-01

A cyclic furnace study was conducted between 990 - 280 C and 1095 - 280 C to evaluate the effects of yttrium, chromium, and aluminum concentrations in nickel base alloy bond coatings and also the effect of the bond coating thickness on the performance of yttria-stabilized zirconia thermal barrier coatings. The presence and the concentration of yttrium is very critical. Without yttrium, rapid oxidation of Ni-Al, Ni-Cr, and Ni-Cr-Al bond coatings causes zirconia thermal barrier coatings to fail very rapidly. Concentrations of chrominum and aluminum in Ni-Cr-Al-Y bond coating have a very significant effect on the thermal barrier coating life. This effect, however, is not as great as that due to yttrium. Furthermore, the thickness and the thickness uniformity also have a very significant effect on the life of the thermal barrier system.

Thermal and Environmental Barrier Coatings for Advanced Turbine Engine Applications

NASA Technical Reports Server (NTRS)

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.

Thermal Conductivity of Alumina-Toughened Zirconia Composites

NASA Technical Reports Server (NTRS)

Bansal, Narottam P.; Zhu, Dong-Ming

2003-01-01

10-mol% yttria-stabilized zirconia (10YSZ)-alumina composites containing 0 to 30 mol% alumina were fabricated by hot pressing at 1500 C in vacuum. Thermal conductivity of the composites, determined at various temperatures using a steady-state laser heat flux technique, increased with increase in alumina content. Composites containing 0, 5, and 10-mol% alumina did not show any change in thermal conductivity with temperature. However, those containing 20 and 30-mol% alumina showed a decrease in thermal conductivity with increase in temperature. The measured values of thermal conductivity were in good agreement with those calculated from simple rule of mixtures.

Thermal Barrier Coatings (les Revetements anti-mur de chaleur)

DTIC Science & Technology

1998-04-01

blades and vanes of advanced aircraft engines », 1992, Yokohama International Gas Turbine Congress... turbine blade and nozzle guide vane aerofoils for the aerogas turbine engine . Figure 9 Scanning electron micrograph of the surface of a plasma...2. Liebert C. H. et al, "Durability of zirconia thermal barrier coatings on air cooled turbine blades in cyclic jet engine operation", NASA

Thermal fluctuations enable rapid protein-protein associations in aqueous solution by lowering the reaction barrier

NASA Astrophysics Data System (ADS)

Sakaizawa, Honami; Watanabe, Hiroshi C.; Furuta, Tadaomi; Sakurai, Minoru

2016-01-01

In hydrophilic protein-protein associations, the dehydration penalty, which can cause the formation of a reaction barrier, must be canceled out; however, its mechanism has not been clarified. Here, we explored the possible mechanism through investigation of the dimerization of nucleotide binding domains (NBDs). We assessed the different dimerization processes by molecular dynamics simulations with and without thermal fluctuations in each NBD. Consequently, the reaction barriers of the former and latter were estimated to be ∼100 and ∼15 kcal/mol, respectively, suggesting that thermal fluctuations in the proteins facilitate the exclusion of water molecules from the interfacial region, thereby lowering the barrier.

A prefilter for mitigating PH 3 contamination of a Ni-YSZ anode

NASA Astrophysics Data System (ADS)

Xu, Chunchuan; Zondlo, John W.; Sabolsky, Edward M.

Ni-YSZ is used as the anode of a solid oxide fuel cell (SOFC) because it has excellent electrochemical performance for operation with coal-derived syngas. However, trace impurities, PH 3 H 2S AsH 3, and Sb in coal-syngas can cause SOFC degradation. Described here is a means of removing PH 3 impurity from syngas by using a Ni-based prefilter. In one test, a thin Ni-based filter was set upstream of a Ni-YSZ anode-supported SOFC. The SOFC was exposed to syngas with PH 3 under a constant current load at 800 °C. The filter decreased 20 ppm PH 3 in the feed to a level which did not degrade the SOFC for over 400 h until the filter became saturated. In another test, both H 2S and PH 3 were co-fed to the cell with Ni-based and Fe/Ni-based filters. The interaction between these two impurities did not significantly impact the filter performance with respect to PH 3 removal for both filter formulations. The cell performance was evaluated by current-voltage measurements and impedance spectroscopy. Post-mortem analyses of the cell and filter were performed by means of XRD, SEM/EDS and XPS. With proper filter design, the Ni-YSZ SOFC can operate on contaminated coal-syngas without degradation over a prescribed period of time.

Stabilization of metallic catalyst microstructures against high-temperature thermal coarsening

NASA Astrophysics Data System (ADS)

Driscoll, David Robert

The size and shape of metal particulate at high temperature is dictated by surface energy. In systems containing very small metal particles, smaller particles shrink and disappear as they grow into larger particles in a process referred to as coarsening. Coarsening causes irreversible degradation in a number of important systems including automotive catalytic converters and solid oxide fuel cells (SOFC) through a loss of catalyst (metal) surface area. This phenomenon is exemplified by nickel metal catalyst that is supported on ytrria-stabilized zirconia (YSZ) which represents a materials system critical to the function of SOFCs. It has been demonstrated that additions of aluminum titanate (ALT) to the Ni-YSZ system with subsequent thermal treatment can act to stabilize the geometry of Ni on YSZ. In demonstration SOFCs, ALT has increased the time required for the first 10% of degradation by a factor of 115. This work has sought to elucidate the mechanisms by which ALT imparts increased stability. The work contained here demonstrates that ALT easily decomposes to Al 2O3 and TiO2. During thermal treatment, the alumina reacts with NiO to form nickel aluminate and the titania interacts with the YSZ where it can form Zr5Ti7O24--a mixed ion electron conducting phase. In this way, the Al and Ti components of ALT have been determined to act independently where alumina appears to be dominant in microstructural stabilization. During cell operation, the nickel aluminate decomposes to nickel metal decorated with alumina nano-particulate. This geometry forms the basis of "diffusion caging" as a stabilization mechanism which is the subject of Chapter 8. The role of titania appears to be less important except when processing occurs in a way that facilitates formation of the MIEC phase. However, Ni-YSZ cermets have also shown a strength enhancement when doped with ALT. This strength enhancement is likely due to the influence of titania (Chapter 7). Future work has the potential to

Growth and micro structural studies on Yittria Stabilized Zirconia (YSZ) and Strontium Titanate (STO) buffer layers

NASA Technical Reports Server (NTRS)

Srinivas, S.; Pinto, R.; Pai, S. P.; Dsousa, D. P.; Apte, P. R.; Kumar, D.; Purandare, S. C.; Bhatnagar, A. K.

1995-01-01

Microstructure of Yittria Stabilized Zirconia (YSZ) and Strontium Titanate (STO) of radio frequency magnetron sputtered buffer layers was studied at various sputtering conditions on Si (100), Sapphire and LaAlO3 (100) substrates. The effect of substrate temperatures up to 800 C and sputtering gas pressures in the range of 50 mTorr. of growth conditions was studied. The buffer layers of YSZ and STO showed a strong tendency for columnar growth was observed above 15 mTorr sputtering gas pressure and at high substrate temperatures. Post annealing of these films in oxygen atmosphere reduced the oxygen deficiency and strain generated during growth of the films. Strong c-axis oriented superconducting YBa2Cu3O7-x (YBCO) thin films were obtained on these buffer layers using pulsed laser ablation technique. YBCO films deposited on multilayers of YSZ and STO were shown to have better superconducting properties.

New WC-Cu thermal barriers for fusion applications: High temperature mechanical behaviour

NASA Astrophysics Data System (ADS)

Tejado, E.; Dias, M.; Correia, J. B.; Palacios, T.; Carvalho, P. A.; Alves, E.; Pastor, J. Y.

2018-01-01

The combination of tungsten carbide and copper as a thermal barrier could effectively reduce the thermal mismatch between tungsten and copper alloy, which are proposed as base armour and heat sink, respectively, in the divertor of future fusion reactors. Furthermore, since the optimum operating temperature windows for these divertor materials do not overlap, a compatible thermal barrier interlayer between them is required to guarantee a smooth thermal transition, which in addition may mitigate radiation damage. The aim of this work is to study the thermo-mechanical properties of WC-Cu cermets fabricated by hot pressing. Focus is placed on the temperature effect and composition dependence, as the volume fraction of copper varies from 25 to 50 and 75 vol%. To explore this behaviour, fracture experiments are performed within a temperature range from room temperature to 800 °C under vacuum. In addition, elastic modulus and thermal expansion coefficient are estimated from these tests. Results reveal a strong dependence of the performance on temperature and on the volume fraction of copper and, surprisingly, a slight percent of Cu (25 vol%) can effectively reduce the large difference in thermal expansion between tungsten and copper alloy, which is a critical point for in service applications. The thermal performance of these materials, together with their mechanical properties could indeed reduce the heat transfer from the PFM to the underlying element while supporting the high thermal stresses of the joint. Thus, the presence of these cermets could allow the reactor to operate above the ductile to brittle transition temperature of tungsten, without compromising the underlying materials.

Life modeling of thermal barrier coatings for aircraft gas turbine engines

NASA Technical Reports Server (NTRS)

Miller, Robert A.

1988-01-01

Thermal barrier coating life models developed under the NASA Lewis Research Center's Hot Section Technology (HOST) program are summarized. An initial laboratory model and three design-capable models are discussed. Current understanding of coating failure mechanisms are also summarized.

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

NASA Technical Reports Server (NTRS)

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.

Thermal barrier coatings for turbine components

DOEpatents

Subramanian, Ramesh; Sabol, Stephen M.; Goedjen, John G.; Sloan, Kelly M.; Vance, Steven J.

2002-01-01

A turbine component, such as a turbine blade having a metal substrate (22) is coated with a metal MCrAlY alloy layer (24) and then a thermal barrier layer (20) selected from LaAlO.sub.3, NdAlO.sub.3, La.sub.2 Hf.sub.2 O.sub.7, Dy.sub.3 Al.sub.5 O.sub.12, HO.sub.3 Al.sub.3 O.sub.12, ErAlO.sub.3, GdAlO.sub.3, Yb.sub.2 Ti.sub.2 O.sub.7, LaYbO.sub.3, Gd.sub.2 Hf.sub.2 O.sub.7 or Y.sub.3 Al.sub.5 O.sub.12.

Air Plasma-Sprayed La2Zr2O7-SrZrO3 Composite Thermal Barrier Coating Subjected to CaO-MgO-Al2O3-SiO2 (CMAS)

NASA Astrophysics Data System (ADS)

Cai, Lili; Ma, Wen; Ma, Bole; Guo, Feng; Chen, Weidong; Dong, Hongying; Shuang, Yingchai

2017-08-01

La2Zr2O7-SrZrO3 composite thermal barrier coatings (TBCs) were prepared by air plasma spray (APS). The La2Zr2O7-SrZrO3 composite TBCs covered with calcium-magnesium-aluminum-silicate (CMAS) powder, as well as the powder mixture of CMAS and spray-dried La2Zr2O7-SrZrO3 composite powder, were heat-treated at 1250 °C in air for 1, 4, 8, and 12 h. The phase constituents and microstructures of the reaction products were characterized by x-ray diffraction, scanning electron microscopy, and energy-dispersive spectroscopy. Experimental results showed that the La2Zr2O7-SrZrO3 composite TBCs had higher CMAS resistance than 8YSZ coating. A dense new layer developed between CMAS and La2Zr2O7-SrZrO3 composite TBCs during interaction, and this new layer consisted mostly of apatite (Ca2La8(SiO4)6O2) and c-ZrO2. The newly developed layer effectively protected the La2Zr2O7-SrZrO3 composite TBCs from further CMAS attack.

Role of interfacial thermal barrier in the transverse thermal conductivity of uniaxial SiC fiber-reinforced reaction bonded silicon nitride

NASA Technical Reports Server (NTRS)

Bhatt, H.; Donaldson, K. Y.; Hasselman, D. P. H.; Bhatt, R. T.

1992-01-01

The transverse thermal conductivity of reaction-bonded Si3N4 is significantly affected by an interfacial barrier at the interface formed with SiC reinforcing fibers. A comparative study of composites with and without reinforcing-fiber carbon coatings found the coating to reduce effective thermal conductivity by a factor of about 2; this, however, is partially due to a thermal expansion-mismatch gap between fiber and matrix. HIPing of composites with coated fibers led to an enhancement of thermal conductivity via improved interfacial thermal contact and greater grain size and crystallinity of the fibers.

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

NASA Technical Reports Server (NTRS)

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.

Thermal barrier coatings for gas-turbine engine applications.

PubMed

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.

Optical Diagnostics for High-Temperature Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Effect of substrate preheating treatment on the microstructure and ultrasonic cavitation erosion behavior of plasma-sprayed YSZ coatings.

PubMed

Deng, Wen; An, Yulong; Hou, Guoliang; Li, Shuangjian; Zhou, Huidi; Chen, Jianmin

2018-09-01

Inconel 718 was used as the substrate and preheated at different temperatures to deposit yttrium stabilized zirconia (denoted as YSZ) coatings by atmospheric plasma spraying. The microstructure of the as-deposited YSZ coatings and those after cavitation-erosion tests were characterized by field emission scanning electron microscopy, Raman spectroscopy, and their hardness and toughness as well as cavitation-erosion resistance were evaluated in relation to the effect of substrate preheating temperature. Results indicate that the as-deposited YSZ coatings exhibit typical layered structure and consist of columnar crystals. With the increase of the substrate preheating temperature, the compactness and cohesion strength of coatings are obviously enhanced, which result in the increases in the hardness, elastic modulus and toughness as well as cavitation-erosion resistance of the ceramic coatings therewith. Particularly, the YSZ coating deposited at a substrate preheating temperature of 800 °C exhibits the highest hardness and toughness as well as the strongest lamellar interfacial bonding and cavitation-erosion resistance (its cavitation-erosion life is as much as 8 times than that of deposited at room temperature). Copyright © 2018 Elsevier B.V. All rights reserved.

Microstructural effect on radiative scattering coefficient and asymmetry factor of anisotropic thermal barrier coatings

NASA Astrophysics Data System (ADS)

Chen, X. W.; Zhao, C. Y.; Wang, B. X.

2018-05-01

Thermal barrier coatings are common porous materials coated on the surface of devices operating under high temperatures and designed for heat insulation. This study presents a comprehensive investigation on the microstructural effect on radiative scattering coefficient and asymmetry factor of anisotropic thermal barrier coatings. Based on the quartet structure generation set algorithm, the finite-difference-time-domain method is applied to calculate angular scattering intensity distribution of complicated random microstructure, which takes wave nature into account. Combining Monte Carlo method with Particle Swarm Optimization, asymmetry factor, scattering coefficient and absorption coefficient are retrieved simultaneously. The retrieved radiative properties are identified with the angular scattering intensity distribution under different pore shapes, which takes dependent scattering and anisotropic pore shape into account implicitly. It has been found that microstructure significantly affects the radiative properties in thermal barrier coatings. Compared with spherical shape, irregular anisotropic pore shape reduces the forward scattering peak. The method used in this paper can also be applied to other porous media, which designs a frame work for further quantitative study on porous media.

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

NASA Astrophysics Data System (ADS)

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.

Effects of Doping on Thermal Conductivity of Pyrochlore Oxides for Advanced Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Furnace Cyclic Behavior of Plasma-Sprayed Zirconia-Yttria and Multi-Component Rare Earth Oxide Doped Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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.

Thermal barrier coating life prediction model

NASA Technical Reports Server (NTRS)

Hillery, R. V.; Pilsner, B. H.; Cook, T. S.; Kim, K. S.

1986-01-01

This is the second annual report of the first 3-year phase of a 2-phase, 5-year program. The objectives of the first phase are to determine the predominant modes of degradation of a plasma sprayed thermal barrier coating system and to develop and verify life prediction models accounting for these degradation modes. The primary TBC system consists of an air plasma sprayed ZrO-Y2O3 top coat, a low pressure plasma sprayed NiCrAlY bond coat, and a Rene' 80 substrate. Task I was to evaluate TBC failure mechanisms. Both bond coat oxidation and bond coat creep have been identified as contributors to TBC failure. Key property determinations have also been made for the bond coat and the top coat, including tensile strength, Poisson's ratio, dynamic modulus, and coefficient of thermal expansion. Task II is to develop TBC life prediction models for the predominant failure modes. These models will be developed based on the results of thermmechanical experiments and finite element analysis. The thermomechanical experiments have been defined and testing initiated. Finite element models have also been developed to handle TBCs and are being utilized to evaluate different TBC failure regimes.

Rocket thrust chamber thermal barrier coatings

NASA Technical Reports Server (NTRS)

Batakis, A. P.; Vogan, J. W.

1985-01-01

A research program was conducted to generate data and develop analytical techniques to predict the performance and reliability of ceramic thermal barrier coatings in high heat flux environments. A finite element model was used to analyze the thermomechanical behavior of coating systems in rocket thrust chambers. Candidate coating systems (using a copper substrate, NiCrAlY bond coat and ZrO2.8Y2O3 ceramic overcoat) were selected for detailed study based on photomicrographic evaluations of experimental test specimens. The effects of plasma spray application parameters on the material properties of these coatings were measured and the effects on coating performance evaluated using the finite element model. Coating design curves which define acceptable operating envelopes for seleted coating systems were constructed based on temperature and strain limitations. Spray gun power levels was found to have the most significant effect on coating structure. Three coating systems were selected for study using different power levels. Thermal conductivity, strain tolerance, density, and residual stress were measured for these coatings. Analyses indicated that extremely thin coatings ( 0.02 mm) are required to accommodate the high heat flux of a rocket thrust chamber and ensure structural integrity.

Preconditioning of the YSZ-NiO Fuel Cell Anode in Hydrogenous Atmospheres Containing Water Vapor.

PubMed

Vasyliv, Bogdan; Podhurska, Viktoriya; Ostash, Orest

2017-12-01

The YSZ-NiO ceramics for solid oxide fuel cells (SOFCs) anode have been investigated. A series of specimens were singly reduced in a hydrogenous atmosphere (Ar-5 vol% H 2 mixture) at 600 °C under the pressure of 0.15 MPa or subjected to 'reduction in the mixture-oxidation in air' (redox) cycling at 600 °C. The YSZ-Ni cermets formed in both treatment conditions were then aged in 'water vapor in Ar-5 vol% H 2 mixture' atmosphere at 600 °C under the pressure of 0.15 MPa. Additionally, the behaviour of the as-received material in this atmosphere was studied. It was revealed that small amount of water vapor in Ar-5 vol% H 2 mixture (water vapor pressure below 0.03 MPa) does not affect the reduction of the nickel phase in the YSZ-NiO ceramics, but causes some changes in the YSZ-Ni cermet structure. In particular, nanopore growth in tiny Ni particles takes place. At higher concentration of water vapor in the mixture (water vapor pressure above 0.03-0.05 MPa), converse changes in the kinetics of reduction occur. The best physical and mechanical properties were revealed for the material treated by redox cycling after holding at 600 °C in water depleted gas mixture. The dual effect of water vapor on nickel-zirconia anode behaviour is discussed basing on scanning electron microscopy analysis data, material electrical conductivity, and strength.

Tests of NASA ceramic thermal barrier coating for gas-turbine engines

NASA Technical Reports Server (NTRS)

Liebert, C. H.

1979-01-01

A two-layer thermal barrier coating system with a bond coating of nickel-chromium-aluminum-yttrium and a ceramic coating of yttria-stabilized zirconia was tested for corrosion protection, thermal protection and durability. Full-scale gas-turbine engine tests demonstrated that this coating eliminated burning, melting, and warping of uncoated parts. During cyclic corrosion resistance tests made in marine diesel fuel products of combustion in a burner rig, the ceramic cracked on some specimens. Metallographic examination showed no base metal deterioration.

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

PubMed Central

Lu, Zhe; Myoung, Sang-Won; Jung, Yeon-Gil; Balakrishnan, Govindasamy; Lee, Jeongseung; Paik, Ungyu

2013-01-01

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. PMID:28811441

Cyclic Failure Mechanisms of Thermal and Environmental Barrier Coating Systems Under Thermal Gradient Test Conditions

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Lee, Kang N.; Miller, Robert A.

2002-01-01

Plasma-sprayed ZrO2-8wt%Y2O3 and mullite+BSAS/Si multilayer thermal and environmental barrier coating (TBC-EBC) systems on SiC/SiC ceramic matrix composite (CMC) substrates were thermally cyclic tested under high thermal gradients using a laser high-heat-flux rig in conjunction with furnace exposure in water-vapor environments. Coating sintering and interface damage were assessed by monitoring the real-time thermal conductivity changes during the laser heat-flux tests and by examining the microstructural changes after exposure. Sintering kinetics of the coating systems were also independently characterized using a dilatometer. It was found that the coating failure involved both the time-temperature dependent sintering and the cycle frequency dependent cyclic fatigue processes. The water vapor environments not only facilitated the initial coating conductivity increases due to enhanced sintering and interface reaction, but also promoted later conductivity reductions due to the accelerated coating cracking and delamination. The failure mechanisms of the coating systems are also discussed based on the cyclic test results and are correlated to the sintering and thermal stress behavior under the thermal gradient test conditions.

Wear behavior of carbide tool coated with Yttria-stabilized zirconia nano particles.

NASA Astrophysics Data System (ADS)

Jadhav, Pavandatta M.; Reddy, Narala Suresh Kumar

2018-04-01

Wear mechanism takes predominant role in reducing the tool life during machining of Titanium alloy. Challenges of wear mechanisms such as variation in chip, high pressure loads and spring back are responsible for tool wear. In addition, many tool materials are inapt for machining due to low thermal conductivity and volume specific heat of these materials results in high cutting temperature during machining. To confront this issue Electrostatic Spray Coating (ESC) coating technique is utilized to enhance the tool life to an acceptable level. The Yttria Stabilized Zirconia (YSZ) acts as a thermal barrier coating having high thermal expansion coefficient and thermal shock resistance. This investigation focuses on the influence of YSZ nanocoating on the tungsten carbide tool material and improve the machinability of Ti-6Al-4V alloy. YSZ nano powder was coated on the tungsten carbide pin by using ESC technique. The coatings have been tested for wear and friction behavior by using a pin-on-disc tribological tester. The dry sliding wear test was performed on Titanium alloy (Ti-6Al-4V) disc and YSZ coated tungsten carbide (pin) at ambient atmosphere. The performance parameters like wear rate and temperature rise were considered upon performing the dry sliding test on Ti-6Al-4V alloy disc. The performance parameters were calculated by using coefficient of friction and frictional force values which were obtained from the pin on disc test. Substantial resistance to wear was achieved by the coating.

Thermal barrier coating resistant to sintering

DOEpatents

Subramanian, Ramesh; Seth, Brig B.

2005-08-23

A device (10) is made, having a ceramic thermal barrier coating layer (16) characterized by a microstructure having gaps (18) with a sintering inhibiting material (22) disposed on the columns (20) within the gaps (18). The sintering resistant material (22) is stable over the range of operating temperatures of the device (10), is not soluble with the underlying ceramic layer (16) and is applied by a process that is not an electron beam physical vapor deposition process. The sintering inhibiting material (22) has a morphology adapted to improve the functionality of the sintering inhibiting material (22), characterized as continuous, nodule, rivulet, grain, crack, flake and combinations thereof and being disposed within at least some of the vertical and horizontal gaps.

Advanced Oxide Material Systems For 1650 C Thermal/Environmental Barrier Coating Applications

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Fox, Dennis S.; Bansal, Narottam P.; Miller, Robert A.

2004-01-01

Advanced thermal/environmental barrier coatings (T/EBCs) 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 1650 C T/EBC system is required to have better thermal stability, lower thermal conductivity, and improved sintering and thermal stress resistance than current coating systems. In this paper, the thermal conductivity, water vapor stability and cyclic durability of selected candidate zirconia-/hafnia-, pyrochlore- and magnetoplumbite-based T/EBC materials are evaluated. The test results have been used to downselect the T/EBC coating materials, and help demonstrate advanced 1650OC coatings feasibility with long-term cyclic durability.

Thermal Barrier/Seal for Extreme Temperature Applications

NASA Technical Reports Server (NTRS)

Steinetz, Bruce M.; Dunlap, Patrick H., Jr.; Phelps, Jack; Bauer, Paul; Bond, Bruce; McCool, Alex (Technical Monitor)

2002-01-01

Large solid rocket motors, as found on the Space Shuttle, are fabricated in segments for manufacturing considerations, bolted together, and sealed using conventional Viton O-ring seals. Similarly the nine large solid rocket motor nozzles are assembled from several different segments, bolted together, and sealed at six joint locations using conventional O-ring seals. The 5500 F combustion gases are generally kept a safe distance away from the seals by thick layers of phenolic or rubber insulation. Joint-fill compounds, including RTV (room temperature vulcanized compound) and polysulfide filler, are used to fill the joints in the insulation to prevent a direct flow-path to the O-rings. Normally these two stages of protection are enough to prevent a direct flow-path of the 900-psi hot gases from reaching the temperature-sensitive O-ring seals. However, in the current design 1 out of 15 Space Shuttle solid rocket motors experience hot gas effects on the Joint 6 wiper (sacrificial) O-rings. Also worrisome is the fact that joints have experienced heat effects on materials between the RTV and the O-rings, and in two cases O-rings have experienced heat effects. These conditions lead to extensive reviews of the post-flight conditions as part of the effort to monitor flight safety. We have developed a braided carbon fiber thermal barrier to replace the joint fill compounds in the Space Shuttle solid rocket motor nozzles to reduce the incoming 5500 F combustion gas temperature and permit only cool (approximately 100 F) gas to reach the temperature-sensitive O-ring seals. Implementation of this thermal barrier provides more robust, consistent operation with shorter turn around times between Shuttle launches.

Thermal Barriers Developed for Solid Rocket Motor Nozzle Joints

NASA Technical Reports Server (NTRS)

Steinetz, Bruce M.; Dunlap, Patrick H., Jr.

2000-01-01

Space shuttle solid rocket motor case assembly joints are sealed with conventional O-ring seals that are shielded from 5500 F combustion gases by thick layers of insulation and by special joint-fill compounds that fill assembly splitlines in the insulation. On a number of occasions, NASA has observed hot gas penetration through defects in the joint-fill compound of several of the rocket nozzle assembly joints. In the current nozzle-to-case joint, NASA has observed penetration of hot combustion gases through the joint-fill compound to the inboard wiper O-ring in one out of seven motors. Although this condition does not threaten motor safety, evidence of hot gas penetration to the wiper O-ring results in extensive reviews before resuming flight. The solid rocket motor manufacturer (Thiokol) approached the NASA Glenn Research Center at Lewis Field about the possibility of applying Glenn's braided fiber preform seal as a thermal barrier to protect the O-ring seals. Glenn and Thiokol are working to improve the nozzle-to-case joint design by implementing a more reliable J-leg design and by using a braided carbon fiber thermal barrier that would resist any hot gases that the J-leg does not block.

Development of Reliability Based Life Prediction Methods for Thermal and Environmental Barrier Coatings in Ceramic Matrix Composites

NASA Technical Reports Server (NTRS)

Shah, Ashwin

2001-01-01

Literature survey related to the EBC/TBC (environmental barrier coating/thermal barrier coating) fife models, failure mechanisms in EBC/TBC and the initial work plan for the proposed EBC/TBC life prediction methods development was developed as well as the finite element model for the thermal/stress analysis of the GRC-developed EBC system was prepared. Technical report for these activities is given in the subsequent sections.

Parametric Studies Of Failure Mechanisms In Thermal Barrier Coatings During Thermal Cycling Using FEM

NASA Astrophysics Data System (ADS)

Srivathsa, B.; Das, D. K.

2015-12-01

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.

Next Generation Thermal Barrier Coatings for the Gas Turbine Industry

NASA Astrophysics Data System (ADS)

Curry, Nicholas; Markocsan, Nicolaie; Li, Xin-Hai; Tricoire, Aurélien; Dorfman, Mitch

2011-01-01

The aim of this study is to develop the next generation of production ready air plasma sprayed thermal barrier coating with a low conductivity and long lifetime. A number of coating architectures were produced using commercially available plasma spray guns. Modifications were made to powder chemistry, including high purity powders, dysprosia stabilized zirconia powders, and powders containing porosity formers. Agglomerated & sintered and homogenized oven spheroidized powder morphologies were used to attain beneficial microstructures. Dual layer coatings were produced using the two powders. Laser flash technique was used to evaluate the thermal conductivity of the coating systems from room temperature to 1200 °C. Tests were performed on as-sprayed samples and samples were heat treated for 100 h at 1150 °C. Thermal conductivity results were correlated to the coating microstructure using image analysis of porosity and cracks. The results show the influence of beneficial porosity on reducing the thermal conductivity of the produced coatings.

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

NASA Technical Reports Server (NTRS)

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.

Phase analysis of plasma-sprayed zirconia-yttria coatings

NASA Technical Reports Server (NTRS)

Shankar, N. R.; Berndt, C. C.; Herman, H.

1983-01-01

Phase analysis of plasma-sprayed 8 wt pct-yttria-stabilized zirconia (YSZ) thermal barrier coatings and powders was carried out by X-ray diffraction. Step scanning was used for increased peak resolution. Plasma spraying of the YSZ powder into water or onto a steel substrate to form a coating reduced the cubic and monoclinic phases with a simultaneous increase in the tetragonal phase. Heat treatment of the coating at 1150 C for 10 h in an Ar atmosphere increased the amount of cubic and monoclinic phases. The implications of these transformations on coating performance and integrity are discussed.

Formulation of steam-methane reforming rate in Ni-YSZ porous anode of solid oxide fuel cells

NASA Astrophysics Data System (ADS)

Sugihara, Shinichi; Kawamura, Yusuke; Iwai, Hiroshi

2018-02-01

The steam-methane reforming reaction on a Ni-YSZ (yttria-stabilized zirconia) cermet was experimentally investigated under atmospheric pressure and in the temperature range from 650 to 750 °C. We examined the effects of the partial pressures of methane and steam in the supply gas on the reaction rate. The experiments were conducted with a low Ni contained Ni-YSZ cermet sheet of thickness 0.1 mm. Its porous microstructure and accompanied parameters were quantified using the FIB-SEM (focused ion beam scanning electron microscopy) technique. A power-law-type rate equation incorporating the reaction-rate-limiting conditions was obtained on the basis of the unit surface area of the Ni-pore contact surface in the cermet. The kinetics indicated a strong positive dependence on the methane partial pressure and a negative dependence on the steam partial pressure. The obtained rate equation successfully reproduced the experimental results for Ni-YSZ samples having different microstructures in the case of low methane consumption. The equation also reproduced the limiting-reaction behaviours at different temperatures.

Bilayer Suspension Plasma-Sprayed Thermal Barrier Coatings with Enhanced Thermal Cyclic Lifetime: Experiments and Modeling

NASA Astrophysics Data System (ADS)

Gupta, Mohit; Kumara, Chamara; Nylén, Per

2017-08-01

Suspension plasma spraying (SPS) has been shown as a promising process to produce porous columnar strain tolerant coatings for thermal barrier coatings (TBCs) in gas turbine engines. However, the highly porous structure is vulnerable to crack propagation, especially near the topcoat-bondcoat interface where high stresses are generated due to thermal cycling. A topcoat layer with high toughness near the topcoat-bondcoat interface could be beneficial to enhance thermal cyclic lifetime of SPS TBCs. In this work, a bilayer coating system consisting of first a dense layer near the topcoat-bondcoat interface followed by a porous columnar layer was fabricated by SPS using Yttria-stabilised zirconia suspension. The objective of this work was to investigate if the bilayer topcoat architecture could enhance the thermal cyclic lifetime of SPS TBCs through experiments and to understand the effect of the column gaps/vertical cracks and the dense layer on the generated stresses in the TBC during thermal cyclic loading through finite element modeling. The experimental results show that the bilayer TBC had significantly higher lifetime than the single-layer TBC. The modeling results show that the dense layer and vertical cracks are beneficial as they reduce the thermally induced stresses which thus increase the lifetime.

Plasma sprayed ceramic thermal barrier coating for NiAl-based intermetallic alloys

NASA Technical Reports Server (NTRS)

Miller, Robert A. (Inventor); Doychak, Joseph (Inventor)

1994-01-01

A thermal barrier coating system consists of two layers of a zirconia-yttria ceramic. The first layer is applied by low pressure plasma spraying. The second layer is applied by conventional atmospheric pressure plasma spraying. This facilitates the attachment of a durable thermally insulating ceramic coating directly to the surface of a highly oxidation resistant NiAl-based intermetallic alloy after the alloy has been preoxidized to promote the formation of a desirable Al2O3 scale.

MNASA as a Test for Carbon Fiber Thermal Barrier Development

NASA Technical Reports Server (NTRS)

Bauer, Paul; McCool, Alex (Technical Monitor)

2001-01-01

A carbon fiber rope thermal barrier is being evaluated as a replacement for the conventional room temperature vulcanizing (RTV) thermal barrier that is currently used to protect o-rings in Reusable Solid Rocket Motor (RSRM) nozzle joints. Performance requirements include its ability to cool any incoming, hot propellant gases that fill and pressurize the nozzle joints, filter slag and particulates, and to perform adequately in various joint assembly conditions as well as dynamic flight motion. Modified National Aeronautics and Space Administration (MNASA) motors, with their inherent and unique ability to replicate select RSRM internal environment features, were an integral step in the development path leading to full scale RSRM static test demonstration of the carbon fiber rope (CFR) joint concept. These 1/4 scale RSRM motors serve to bridge the gap between the other classes of subscale test motors (extremely small and moderate duration, or small scale and short duration) and the critical asset RSRM static test motors. A series of MNASA tests have been used to demonstrate carbon fiber rope performance and have provided rationale for implementation into a full-scale static motor and flight qualification.

Effect of thermal cycling on ZrO2-Y2O3 thermal barrier coatings

NASA Technical Reports Server (NTRS)

Mcdonald, G.; Hendricks, R. C.

1980-01-01

The paper studies the comparative life of plasma-sprayed ZrO2-Y2O3 thermal barrier coatings on NiCrAlY bond coats on Rene 41 in short (4 min) and long (57 min) thermal cycles at 1040 C in a 0.3-Mach flame. Attention is given to determining the effect of short- and long-duration cycles on ZrO2-Y2O3 coatings, the cause of any cycle frequency effects, and methods to improve tolerance to thermal stress. Short cycles greatly reduced the life of the ceramic coating in terms of time at temperatures as compared to longer cycles, the failed coating indicating compressive failure. The experiments and stress calculations show that repeatedly subjecting a ceramic coating to high rates of initial heating has a more destructive influence on the coating than sustained operation at temperature. The effect of such thermal compressive stresses might be minimized through coating deposition and thickness control and by turbine cycle measurement to keep starting heating rates below critical values.

In situ Van der Pauw measurements of the Ni/YSZ anode during exposure to syngas with phosphine contaminant

NASA Astrophysics Data System (ADS)

Demircan, Oktay; Xu, Chunchuan; Zondlo, John; Finklea, Harry O.

Solid oxide fuel cells (SOFCs) represent an option to provide a bridging technology for energy conversion (coal syngas) as well as a long-term technology (hydrogen from biomass). Whether the fuel is coal syngas or hydrogen from biomass, the effect of impurities on the performance of the anode is a vital question. The anode resistivity during SOFC operation with phosphine-contaminated syngas was studied using the in situ Van der Pauw method. Commercial anode-supported solid oxide fuel cells (Ni/YSZ composite anodes, YSZ electrolytes) were exposed to a synthetic coal syngas mixture (H 2, H 2O, CO, and CO 2) at a constant current and their performance evaluated periodically with electrochemical methods (cyclic voltammetry, impedance spectroscopy, and polarization curves). In one test, after 170 h of phosphine exposure, a significant degradation of cell performance (loss of cell voltage, increase of series resistance and increase of polarization resistance) was evident. The rate of voltage loss was 1.4 mV h -1. The resistivity measurements on Ni/YSZ anode by the in situ Van der Pauw method showed that there were no significant changes in anode resistivity both under clean syngas and syngas with 10 ppm PH 3. XRD analysis suggested that Ni 5P 2 and P 2O 5 are two compounds accumulated on the anode. XPS studies provided support for the presence of two phosphorus phases with different oxidation states on the external anode surface. Phosphorus, in a positive oxidation state, was observed in the anode active layer. Based on these observations, the effect of 10 ppm phosphine impurity (or its reaction products with coal syngas) is assigned to the loss of performance of the Ni/YSZ active layer next to the electrolyte, and not to any changes in the thick Ni/YSZ support layer.

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

NASA Technical Reports Server (NTRS)

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.

Thermal cycling and electrochemical characteristics of solid oxide fuel cell supported on stainless steel with a new 3-phase composite anode

NASA Astrophysics Data System (ADS)

Dayaghi, Amir Masoud; Kim, Kun Joong; Kim, Sun Jae; Kim, Sunwoong; Bae, Hongyeul; Choi, Gyeong Man

2017-06-01

We report design, fabrication method, and fast thermal-cycling ability of solid oxide fuel cells (SOFCs) that use stainless steel (STS) as a support, and a new 3-phase anode. La and Ni co-doped SrTiO3 (La0.2Sr0.8Ti0.9Ni0.1O3-d, LSTN), replaces some of the Ni in conventional Ni-yttria stabilized zirconia (YSZ) anode; the resultant LSTN-YSZ-Ni 3-phase-composite anode is tested as a new reduction (or decomposition)-resistant anode of STS-supported SOFCs that can be co-fired with STS. A multi-layered cell with YSZ electrolyte (thickness ∼5 μm), composite anode, STS-cermet contact-layer, and STS support is designed, then fabricated by tape casting, lamination, and co-firing at 1250 °C in reducing atmosphere. The maximum power density (MPD) is 325 mW cm-2 at 650 °C; this is one of the highest among STS-supported cells fabricated by co-firing. The cell also shows stable open-circuit voltage and Ohmic resistance during 100 rapid thermal cycles between 170 and 600 °C. STS support minimizes stress and avoids cracking of electrolyte during rapid thermal cycling. The excellent MPD and stability during thermal cycles, and promising characteristics of SOFC as a power source for vehicle or mobile devices that requires rapid thermal cycles, are attributed to the new design of the cell with new anode structure.

Molecular Dynamics Simulation of the Structure and Ion Transport in the Ce1 - x Gd x O2 - δ|YSZ Heterosystem

NASA Astrophysics Data System (ADS)

Galin, M. Z.; Ivanov-Schitz, A. K.; Mazo, G. N.

2018-01-01

Molecular dynamics simulation has been used to develop a realistic atomistic model of two-layer Ce1 - x Gd x O2 - δ|YSZ heterosystem. It is shown that Ce1 - x Gd x O2 - δ and YSZ layers (about 15 and 16 Å thick, respectively) retain their crystal structure on the whole. The main structural distortions are found to occur near the Ce1 - x Gd x O2 - δ|YSZ geometric interface, within a narrow interfacial region of few angstroms thick. Both the generalized diffusion characteristics of the system as a whole and the oxygen diffusion coefficients in the layers are calculated, and the diffusion activation energies are determined.

Delamination Mechanisms of Thermal and Environmental Barrier Coatings on SiC/SiC Ceramic Matrix Composites

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Choi, Sung R.; Lee, Kang N.; Miller, Robert A.

1990-01-01

Advanced ceramic thermal barrier coatings 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 issue remains a major concern with the ever-increasing temperature requirements. In this paper, thermal cyclic response and delamination failure modes of a ZrO2-8wt%Y2O3 and mullite/BSAS thermal/environmental barrier coating system on SiC/SiC ceramic matrix composites were investigated using a laser high-heat-flux technique. The coating degradation and delamination processes were monitored in real time by measuring coating apparent conductivity changes during the cyclic tests under realistic engine temperature and stress gradients, utilizing the fact that delamination cracking causes an apparent decrease in the measured thermal conductivity. The ceramic coating crack initiation and propagation driving forces under the cyclic thermal loads, in conjunction with the mechanical testing results, will be discussed.

Atomic-Level Properties of Thermal Barrier Coatings: Characterization of Metal-Ceramic Interfaces

DTIC Science & Technology

2001-01-01

these cases metal - metal bonds were stronger than metal - substrate bonds, thus predicting a 3D (cluster) growth mode as opposed to layer-by-layer...coat layer must be deposited. The top coat serves as the insulator and the bond coat mediates contact between the top coat and metal alloy substrate ...in thermomechanical properties between a YSZ top coat and a metal -alloy substrate is enough to require the introduction of an intermediate layer. This

In-situ formation of multiphase deposited thermal barrier coatings

DOEpatents

Subramanian, Ramesh

2004-01-13

A multiphase ceramic thermal barrier coating is provided. The coating is adapted for use in high temperature applications in excess of about 1200.degree. C., for coating superalloy components of a combustion turbine engine. The coating comprises a ceramic single or two oxide base layer disposed on the substrate surface; and a ceramic oxide reaction product material disposed on the base layer, the reaction product comprising the reaction product of the base layer with a ceramic single or two oxide overlay layer.

Enhanced Sintering of β"-Al2O3/YSZ with the Sintering Aids of TiO2 and MnO2

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lu, Xiaochuan; Li, Guosheng; Kim, Jin Yong

2015-07-11

β"-Al2O3 has been the dominated choice for the electrolyte materials of sodium batteries because of its high ionic conductivity, excellent stability with the electrode materials, satisfactory mechanical strength, and low material cost. To achieve adequate electrical and mechanical performance, sintering of β"-Al2O3 is typically carried out at temperatures above 1600oC with deliberate efforts on controlling the phase, composition, and microstructure. Here, we reported a simple method to fabricate β"-Al2O3/YSZ electrolyte at relatively lower temperatures. With the starting material of boehmite, single phase of β"-Al2O3 can be achieved at as low as 1200oC. It was found that TiO2 was extremely effectivemore » as a sintering aid for the densification of β"-Al2O3 and similar behavior was observed with MnO2 for YSZ. With the addition of 2 mol% TiO2 and 5 mol% MnO2, the β"-Al2O3/YSZ composite was able to be densified at as low as 1400oC with a fine microstructure and good electrical/mechanical performance. This study demonstrated a new approach of synthesis and sintering of β"-Al2O3/YSZ composite, which represented a simple and low-cost method for fabrication of high-performance β"-Al2O3/YSZ electrolyte.« less

Thermal barrier coatings on gas turbine blades: Chemical vapor deposition (Review)

NASA Astrophysics Data System (ADS)

Igumenov, I. K.; Aksenov, A. N.

2017-12-01

Schemes are presented for experimental setups (reactors) developed at leading scientific centers connected with the development of technologies for the deposition of coatings using the CVD method: at the Technical University of Braunschweig (Germany), the French Aerospace Research Center, the Materials Research Institute (Tohoku University, Japan) and the National Laboratory Oak Ridge (USA). Conditions and modes for obtaining the coatings with high operational parameters are considered. It is established that the formed thermal barrier coatings do not fundamentally differ in their properties (columnar microstructure, thermocyclic resistance, thermal conductivity coefficient) from standard electron-beam condensates, but the highest growth rates and the perfection of the crystal structure are achieved in the case of plasma-chemical processes and in reactors with additional laser or induction heating of a workpiece. It is shown that CVD reactors can serve as a basis for the development of rational and more advanced technologies for coating gas turbine blades that are not inferior to standard electron-beam plants in terms of the quality of produced coatings and have a much simpler and cheaper structure. The possibility of developing a new technology based on CVD processes for the formation of thermal barrier coatings with high operational parameters is discussed, including a set of requirements for industrial reactors, high-performance sources of vapor precursors, and promising new materials.

Thermal modelling of various thermal barrier coatings in a high heat flux rocket engine

NASA Technical Reports Server (NTRS)

Nesbitt, James A.

1989-01-01

Traditional Air Plasma Sprayed (APS) ZrO2-Y2O3 Thermal Barrier Coatings (TBC's) and Low Pressure Plasma Sprayed (LPPS) ZrO2-Y2O3/Ni-Cr-Al-Y cermet coatings were tested in a H2/O2 rocked engine. The traditional ZrO2-Y2O3 (TBC's) showed considerable metal temperature reductions during testing in the hydrogen-rich environment. A thermal model was developed to predict the thermal response of the tubes with the various coatings. Good agreement was observed between predicted temperatures and measured temperatures at the inner wall of the tube and in the metal near the coating/metal interface. The thermal model was also used to examine the effect of the differences in the reported values of the thermal conductivity of plasma sprayed ZrO2-Y2O3 ceramic coatings, the effect of 100 micron (0.004 in.) thick metallic bond coat, the effect of tangential heat transfer around the tube, and the effect or radiation from the surface of the ceramic coating. It was shown that for the short duration testing in the rocket engine, the most important of these considerations was the effect of the uncertainty in the thermal conductivity of temperatures (greater than 100 C) predicted in the tube. The thermal model was also used to predict the thermal response of the coated rod in order to quantify the difference in the metal temperatures between the two substrate geometries and to explain the previously-observed increased life of coatings on rods over that on tubes. A thermal model was also developed to predict heat transfer to the leading edge of High Pressure Fuel Turbopump (HPFTP) blades during start-up of the space shuttle main engines. The ability of various TBC's to reduce metal temperatures during the two thermal excursions occurring on start-up was predicted. Temperature reductions of 150 to 470 C were predicted for 165 micron (0.0065 in.) coatings for the greater of the two thermal excursions.

Fracture toughness improvements of dental ceramic through use of yttria-stabilized zirconia (YSZ) thin-film coatings.

PubMed

Chan, Ryan N; Stoner, Brian R; Thompson, Jeffrey Y; Scattergood, Ronald O; Piascik, Jeffrey R

2013-08-01

The aim of this study was to evaluate strengthening mechanisms of yttria-stabilized zirconia (YSZ) thin film coatings as a viable method for improving fracture toughness of all-ceramic dental restorations. Bars (2mm×2mm×15mm, n=12) were cut from porcelain (ProCAD, Ivoclar-Vivadent) blocks and wet-polished through 1200-grit using SiC abrasive. A Vickers indenter was used to induce flaws with controlled size and geometry. Depositions were performed via radio frequency magnetron sputtering (5mT, 25°C, 30:1 Ar/O2 gas ratio) with varying powers of substrate bias. Film and flaw properties were characterized by optical microscopy, scanning electron microscopy (SEM), and X-ray diffraction (XRD). Flexural strength was determined by three-point bending. Fracture toughness values were calculated from flaw size and fracture strength. Data show improvements in fracture strength of up to 57% over unmodified specimens. XRD analysis shows that films deposited with higher substrate bias displayed a high %monoclinic volume fraction (19%) compared to non-biased deposited films (87%), and resulted in increased film stresses and modified YSZ microstructures. SEM analysis shows critical flaw sizes of 67±1μm leading to fracture toughness improvements of 55% over unmodified specimens. Data support surface modification of dental ceramics with YSZ thin film coatings to improve fracture toughness. Increase in construct strength was attributed to increase in compressive film stresses and modified YSZ thin film microstructures. It is believed that this surface modification may lead to significant improvements and overall reliability of all-ceramic dental restorations. Copyright © 2013 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

Assessment of variations in thermal cycle life data of thermal barrier coated rods

NASA Astrophysics Data System (ADS)

Hendricks, R. C.; McDonald, G.

An analysis of thermal cycle life data for 22 thermal barrier coated (TBC) specimens was conducted. The Zr02-8Y203/NiCrAlY plasma spray coated Rene 41 rods were tested in a Mach 0.3 Jet A/air burner flame. All specimens were subjected to the same coating and subsequent test procedures in an effort to control three parametric groups; material properties, geometry and heat flux. Statistically, the data sample space had a mean of 1330 cycles with a standard deviation of 520 cycles. The data were described by normal or log-normal distributions, but other models could also apply; the sample size must be increased to clearly delineate a statistical failure model. The statistical methods were also applied to adhesive/cohesive strength data for 20 TBC discs of the same composition, with similar results. The sample space had a mean of 9 MPa with a standard deviation of 4.2 MPa.

Assessment of variations in thermal cycle life data of thermal barrier coated rods

NASA Technical Reports Server (NTRS)

Hendricks, R. C.; Mcdonald, G.

1981-01-01

An analysis of thermal cycle life data for 22 thermal barrier coated (TBC) specimens was conducted. The Zr02-8Y203/NiCrAlY plasma spray coated Rene 41 rods were tested in a Mach 0.3 Jet A/air burner flame. All specimens were subjected to the same coating and subsequent test procedures in an effort to control three parametric groups; material properties, geometry and heat flux. Statistically, the data sample space had a mean of 1330 cycles with a standard deviation of 520 cycles. The data were described by normal or log-normal distributions, but other models could also apply; the sample size must be increased to clearly delineate a statistical failure model. The statistical methods were also applied to adhesive/cohesive strength data for 20 TBC discs of the same composition, with similar results. The sample space had a mean of 9 MPa with a standard deviation of 4.2 MPa.

Thermal barrier coating life-prediction model development

NASA Technical Reports Server (NTRS)

Strangman, T. E.; Neumann, J.

1985-01-01

Life predictions are made for two types of strain-tolerant and oxidation-resistant Thermal Barrier Coating (TBC) systems produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma spray (LPPS) applied oxidation-resistant NiCrAlY bond coating and an air-plasma-sprayed yttria (8 percent) partially stabilized zirconia insulative layer, is applied by both Chromalloy and Klock. The second type of TBC is applied by the electron-beam/physical vapor deposition process by Temescal. Thermomechanical and thermochemical testing of the program TBCs is in progress. A number of the former tests has been completed. Fracture mechanics data for the Chromalloy plasma-sprayed TBC system indicate that the cohesive toughness of the zirconia layer is increased by thermal cycling and reduced by high temperature exposure at 1150 C. Eddy current technology feasibility has been established with respect to nondestructively measuring zirconia layer thickness of a TBC system. High pressure turbine blades have been coated with program TBC systems for a piggyback test in a TFE731-5 turbofan factory engine test. Data from this test will be used to validate the TBC life models.

Thermo-mechanical Fatigue Failure of Thermal Barrier Coated Superalloy Specimen

NASA Astrophysics Data System (ADS)

Subramanian, Rajivgandhi; Mori, Yuzuru; Yamagishi, Satoshi; Okazaki, Masakazu

2015-09-01

Failure behavior of thermal barrier coated (TBC) Ni-based superalloy specimens were studied from the aspect of the effect of bond coat material behavior on low cycle fatigue (LCF) and thermo-mechanical fatigue (TMF) at various temperatures and under various loading conditions. Initially, monotonic tensile tests were carried out on a MCrAlY alloy bond coat material in the temperature range of 298 K to 1273 K (25 °C to 1000 °C). Special attention was paid to understand the ductile to brittle transition temperature (DBTT). Next, LCF and TMF tests were carried out on the thermal barrier coated Ni-based alloy IN738 specimen. After these tests, the specimens were sectioned to understand their failure mechanisms on the basis of DBTT of the bond coat material. Experimental results demonstrated that the LCF and TMF lives of the TBC specimen were closely related to the DBTT of the bond coat material, and also the TMF lives were different from those of LCF tests. It has also been observed that the crack density in the bond coat in the TBC specimen was significantly dependent on the test conditions. More importantly, not only the number of cracks but also the crack penetration probability into substrate were shown to be sensitive to the DBTT.

Thermal Conductivity Change Kinetics of Ceramic Thermal Barrier Coatings Determined by the Steady-State Laser Heat Flux Technique

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Miller, Robert A.

2000-01-01

A steady-state laser heat flux technique has been developed at the NASA Glenn Research Center at Lewis Field to obtain critical thermal conductivity data of ceramic thermal barrier coatings under the temperature and thermal gradients that are realistically expected to be encountered in advanced engine systems. In this study, thermal conductivity change kinetics of a plasma-sprayed, 254-mm-thick ZrO2-8 wt % Y2O3 ceramic coating were obtained at high temperatures. During the testing, the temperature gradients across the coating system were carefully measured by the surface and back pyrometers and an embedded miniature thermocouple in the substrate. The actual heat flux passing through the coating system was determined from the metal substrate temperature drop (measured by the embedded miniature thermocouple and the back pyrometer) combined with one-dimensional heat transfer models.

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

NASA Technical Reports Server (NTRS)

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.

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

PubMed

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.

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

NASA Astrophysics Data System (ADS)

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.

Perspective on thermal barrier coatings for industrial gas turbine applications

NASA Technical Reports Server (NTRS)

Mutasim, Zaher; Brentnall, William

1995-01-01

Thermal barrier coatings (TBC's) have been used in high thrust aircraft engines for many years, and have proved to be very effective in providing thermal protection and increasing engine efficiencies. TBC life requirements for aircraft engines are typically less than those required for industrial gas turbines. This paper describes current and future applications of TBC's in industrial gas turbine engines. Early testing and applications of TBC's is reviewed. Areas of concern from the engine designer's and materials engineer's perspective are identified and evaluated. This paper focuses on the key factors that are expected to influence utilization of TBC's in advanced industrial gas turbine engines. It is anticipated that reliable, durable and highly effective coating systems will be produced that will ultimately improve engine efficiency and performance.

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

NASA Astrophysics Data System (ADS)

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.

Effect of thermal cycling on ZrO2-Y2O3 thermal barrier coatings

NASA Technical Reports Server (NTRS)

Mcdonald, G.; Hendricks, R. C.

1980-01-01

A study was made of the comparative life of plasma sprayed ZrO2-Y2O3 thermal barrier coatings on NiCrAlY bond coats on Rene 41 in short (4 min) and long (57 min) thermal cycles to 1040 C in a 0.3 Mach flame. Short cycles greatly reduced the life of the ceramic coating in terms of time at temperature as compared to longer cycles. Appearance of the failed coating indicated compressive failure. Failure occurred at the bond coat-ceramic coat junction. At heating rates greater than 550 kw/sq m, the calculated coating detachment stress was in the range of literature values of coating adhesive/cohesive strength. Methods are discussed for decreasing the effect of high heating rate by avoiding compressive stress.

PVD thermal barrier coating applications and process development for aircraft engines

NASA Astrophysics Data System (ADS)

Rigney, D. V.; Viguie, R.; Wortman, D. J.; Skelly, D. W.

1997-06-01

Thermal barrier coatings (TBCs) have been developed for application to aircraft engine components to improve service life in an increasingly hostile thermal environment. The choice of TBC type is related to the component, intended use, and economics. Selection of electron beam physical vapor deposition proc-essing for turbine blade is due in part to part size, surface finish requirements, thickness control needs, and hole closure issues. Process development of PVD TBCs has been carried out at several different sites, including GE Aircraft Engines (GEAE). The influence of processing variables on microstructure is dis-cussed, along with the GEAE development coater and initial experiences of pilot line operation.

Synthesis of nanocrystalline Ni/Ce-YSZ powder via a polymerization route

NASA Astrophysics Data System (ADS)

Abolghasemi, Z.; Tamizifar, M.; Arzani, K.; Nemati, A.; Khanfekr, A.; Bolandi, M.

2013-08-01

Pechini process was used for preparation of three kinds of nanocrystalline powders of yttria-stabilized zirconia (YSZ): doped with 1.5 mol% nickel oxide, doped with 15 mol% ceria, and doped with 1.5 mol% nickel oxide plus 15 mol% ceria. Zirconium chloride, yttrium nitrate, cerium nitrate, nickel nitrate, citric acid and ethylene glycol were polymerized at 80 °C to produce a gel. XRD, SEM and TEM analyses were used to investigate the crystalline phases and microstructures of obtained compounds. The results of XRD revealed the formation of nanocrystalline powder at 900 °C. Morphology of the powder calcined at 900 °C, examined with a scanning electron microscope, showed that the presence of nickel and cerium inhibited the grain growth in the system. The average crystallite size of the material doped with nickel oxide (9.33 nm) was bigger than the one doped with cerium oxide (9.29 nm), while the YSZ doping with the two oxides simultaneously promoted the grain growth with crystallite size of 11.37 nm. Yttria-stabilized zirconia powder with a mean crystallite size of 9.997 nm was prepared successfully by this method.

Tests of NASA ceramic thermal barrier coating for gas-turbine engines

NASA Technical Reports Server (NTRS)

Liebert, C. H.

1979-01-01

A NASA ceramic thermal barrier coating (TBC) system was tested by industrial and governmental organizations for a variety of aeronautical marine, and ground-based gas-turbine engine applications. This TBC is a two-layer system with a bond coating of nickel-chromium-aluminum-yttrium (Ni-16Cr-6Al-0.6Y, in wt %) and a ceramic coating of yttria stabilized zirconia (ZrO2-12Y2O3, in wt %). Tests (Liebert and Stenka, 1979) have been conducted to determine corrosion resistance, thermal protection, durability, thermal conductivity, and fatigue characteristics. The information presented covers some of the significant test results obtained on the first three items. The information also includes photographs of coated parts after tests, measurements of coating loss, amount of metal wall temperature reduction when the TBC is used, and extent of base metal corrosion.

Novel erbia-yttria co-doped zirconia fluorescent thermal history sensor

NASA Astrophysics Data System (ADS)

Copin, E. B.; Massol, X.; Amiel, S.; Sentenac, T.; Le Maoult, Y.; Lours, P.

2017-01-01

Thermochromic pigments are commonly used for off-line temperature mapping on components from systems operating at a temperature higher than 1073 K. However, their temperature resolution is often limited by the discrete number of color transitions they offer. This paper investigates the potential of erbia-yttria co-doped zirconia as a florescent thermal history sensor alternative to thermochromic pigments. Samples of yttria-stabilized zirconia powder (YSZ, 8.3 mol% YO1.5) doped with 1.5 mol% ErO1.5 and synthesized by a sol-gel route are calcined for 15 minutes under isothermal conditions between 1173 and 1423 K. The effects of temperature on their crystal structure and room temperature fluorescence properties are then studied. Results show a steady increase of the crystallinity of the powders with temperature, causing a significant and permanent increase of the emission intensity and fluorescence lifetime which could be used to determine temperature with a calculated theoretical resolution lower than 1 K for intensity. The intensity ratio obtained using a temperature insensitive YSZ:Eu3+ reference phosphor is proposed as a more robust parameter regarding experimental conditions for determining thermal history. Finally, the possibilities for integrating this fluorescent marker into sol-gel deposited coatings for future practical thermal history sensing applications is also discussed.

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

NASA Technical Reports Server (NTRS)

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.

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

NASA Astrophysics Data System (ADS)

Mei, Xianxiu; Liu, Xiaofei; Wang, Cunxia; Wang, Younian; Dong, Chuang

2012-12-01

In this paper, intense pulsed electron beam was used for the irradiation treatment of 6-8% Y2O3-stablized ZrO2 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 μs, electron voltage 15 kV, energy density 3, 5, 8, 15, 20 J/cm2, and pulsed numbers 30. 1050 °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/cm2, ZrO2 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/cm2, 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 insulation performance of irradiated coating was improved.

Thermochemistry of Calcium-Magnesium-Aluminum-Silicate (CMAS) and Components of Advanced Thermal and Environmental Barrier Coating Systems

NASA Technical Reports Server (NTRS)

Costa, Gustavo C. C.; Acosta, Waldo A.; Zhu, Dongming; Ghoshal, Anindya

2017-01-01

There is increasing interest in the degradation mechanism studies of thermal and environmental barrier coatings (TEBCs) of gas turbines by molten CaO-MgO-Al(exp. 2)O(exp. 3)-SiO(exp. 2) CMAS). CMAS minerals are usually referred as silicon-containing sand dust and volcano ash materials that are carried by the intake air into gas turbines, e.g. in aircraft engines, and their deposits often react at high temperatures (greater than 1200 degrees C) with the engine turbine coating systems and components. The high temperature reactions causes degradation and accelerated failure of the static and rotating components of the turbine engines. We discuss some results of the reactions between the CMAS and Rare-Earth (RE = Y, Yb, Dy, Gd, Nd and Sm) - oxide stabilized ZrO(exp. 2) or HfO(exp. 2) systems, and the stability of the resulting oxides and silicates. Plasma sprayed hollow tube samples (outside diameter = 4.7 mm, wall thickness = 0.76 mm and = 26 mm height) were half filled with CMAS powder, wrapped and sealed with platinum foil, and heat treated at 1310 degrees C for 5h. Samples were characterized by differential scanning calorimetry (DSC), X-ray diffraction, and cross-section electron microscopy analysis and energy dispersive X-ray spectroscopy. It was found that CMAS penetrated the samples at the grain boundaries and dissolved the TEBC materials to form silicate phases containing the rare-earth elements. Furthermore, it was found that apatite crystalline phases were formed in the samples with total rare-earth content higher than 12 mol% in the reaction zone for the ZrO(exp. 2) system. In general, samples with the nominal compositions (30YSZ), HfO(exp. 2)-7Dy(exp. 2)O(exp. 2) and ZrO(exp. 2)-9.5Y(exp. 2)O(exp. 3)-2.25Gd(exp. 2)O(exp. 3)-2.25Yb(exp. 2)O(exp. 3) exhibited lower reactivity or more resistance to CMAS than the other coating compositions of this work.

Flyweight 3D Graphene Scaffolds with Microinterface Barrier-Derived Tunable Thermal Insulation and Flame Retardancy.

PubMed

Zhang, Qiangqiang; Hao, Menglong; Xu, Xiang; Xiong, Guoping; Li, Hui; Fisher, Timothy S

2017-04-26

In this article, flyweight three-dimensional (3D) graphene scaffolds (GSs) have been demonstrated with a microinterface barrier-derived thermal insulation and flame retardancy characteristics. Such 3D GSs were fabricated by a modified hydrothermal method and a unidirectional freeze-casting process with hierarchical porous microstructures. Because of high porosity (99.9%), significant phonon scattering, and strong π-π interaction at the interface barriers of multilayer graphene cellular walls, the GSs demonstrate a sequence of multifunctional properties simultaneously, such as lightweight density, thermal insulating characteristics, and outstanding mechanical robustness. At 100 °C, oxidized GSs exhibit a thermal conductivity of 0.0126 ± 0.0010 W/(m K) in vacuum. The thermal conductivity of oxidized GSs remains relatively unaffected despite large-scale deformation-induced densification of the microstructures, as compared to the behavior of reduced GSs (rGSs) whose thermal conductivity increases dramatically under compression. The contrasting behavior of oxidized GSs and rGSs appears to derive from large differences in the intersheet contact resistance and varying intrinsic thermal conductivity between reduced and oxidized graphene sheets. The oxidized GSs also exhibit excellent flame retardant behavior and mechanical robustness, with only 2% strength decay after flame treatment. In a broader context, this work demonstrates a useful strategy to design porous nanomaterials with a tunable heat conduction behavior through interface engineering at the nanoscale.

Thermal Modelling of Various Thermal Barrier Coatings in a High Flux Rocket Engine

NASA Technical Reports Server (NTRS)

Nesbitt, James A.

1998-01-01

A thermal model was developed to predict the thermal response of coated and uncoated tubes tested in a H2/O2 rocket engine. Temperatures were predicted for traditional APS ZrO2-Y2O3 thermal barrier coatings, as well as APS and LPPS ZrO2-Y2O3/NiCrAlY cermet coatings. Good agreement was observed between predicted and measured metal temperatures at locations near the tube surface or at the inner tube wall. The thermal model was also used to quantitatively examine the effect of various coating system parameters on the temperatures in the substrate and coating. Accordingly, the effect of the presence a metallic bond coat and the effect of radiation from the surface of the ceramic layer were examined. In addition, the effect of a variation in the values of the thermal conductivity of the ceramic layer was also investigated. It was shown that a variation in the thermal conductivity of the ceramic layer, on the order of that reported in the literature for plasma sprayed ZrO2-Y2O3 coatings, can result in temperature differences in the substrate greater than 100 C, a much greater effect than that due to the presence of a bond coat or radiation from the ceramic layer. The thermal model was also used to predict the thermal response of a coated rod in order to quantify the difference in the metal temperatures between the two substrate geometries in order to explain the previously-observed increased life of coatings on rods over that on tubes. It was shown that for the short duration testing in the rocket engine, the temperature in a tube could exceed that in a rod by more than 100 C. Lastly, a two-dimensional model was developed to evaluate the effect of tangential heat transfer around the tube and its impact on reducing the stagnation point temperature. It was also shown that tangential heat transfer does not significantly reduce the stagnation point temperature, thus allowing application of a simpler, one-dimensional model for comparing measured and predicted stagnation point

Luminescence-Based Diagnostics of Thermal Barrier Coating Health and Performance

NASA Technical Reports Server (NTRS)

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.

Two-layer thermal barrier coating. I - Effects of composition and temperature on oxidation behavior and failure

NASA Technical Reports Server (NTRS)

Stecura, Stephan

1989-01-01

The effects of 21 bond and 2 ceramic coating compositions on the specific mass gain, internal crack location at failure, and life of a two-layer thermal barrier coating (TBC) were studied by cyclic testing in a furnace. MAR-M 200 + Hf alloy specimens were completely coated with bond and thermal barrier (ceramic) coatings. Both coatings were applied by air plasma spray deposition. Cyclic test data were obtained at 1110, 1160, and 1220 deg C. The data show that the specific mass gain and the TBC life are significantly affected by the composition of the bond coating and the temperature and only slightly affected by the composition of the ceramic coating.

Influence of High Cycle Thermal Loads on Thermal Fatigue Behavior of Thick Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Miller, Robert A.

1997-01-01

Thick thermal barrier coating systems in a diesel engine experience severe thermal Low Cycle Fatigue (LCF) and High Cycle Fatigue (HCF) during engine operation. In the present study, the mechanisms of fatigue crack initiation and propagation, as well as of coating failure, under thermal loads which simulate engine conditions, are investigated using a high power CO2 laser. In general, surface vertical cracks initiate early and grow continuously under LCF and HCF cyclic 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, which induce tensile stresses in the coating after cooling. Experiments show that the HCF cycles are very damaging to the coating systems. The combined LCF and HCF tests produced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. It is suggested that the HCF component cannot only accelerate the surface crack initiation, but also interact with the LCF by contributing to the crack growth at high temperatures. The increased LCF stress intensity at the crack tip due to the HCF component enhances the subsequent LCF crack growth. Conversely, since a faster HCF crack growth rate will be expected with lower effective compressive stresses in the coating, the LCF cycles also facilitate the HCF crack growth at high temperatures by stress relaxation process. A surface wedging model has been proposed to account for the HCF crack growth in the coating system. This mechanism predicts that HCF damage effect increases with increasing temperature swing, the thermal expansion coefficient and the elastic modulus of the ceramic coating, as well as the HCF interacting depth. A good agreement has been found between the analysis and experimental evidence.

Conjugate heat transfer investigation on the cooling performance of air cooled turbine blade with thermal barrier coating

NASA Astrophysics Data System (ADS)

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.

Emittance and absorptance of NASA ceramic thermal barrier coating system. [for turbine cooling

NASA Technical Reports Server (NTRS)

Liebert, C. H.

1978-01-01

Spectral emittance measurements were made on a two-layer ceramic thermal barrier coating system consisting of a metal substrate, a NiCrAly bond coating and a yttria-stabilized zirconia ceramic coating. Spectral emittance data were obtained for the coating system at temperatures of 300 to 1590 K, ceramic thickness of zero to 0.076 centimeter, and wavelengths of 0.4 to 14.6 micrometers. The data were transformed into total hemispherical emittance values and correlated with respect to ceramic coating thickness and temperature using multiple regression curve fitting techniques. The results show that the ceramic thermal barrier coating system is highly reflective and significantly reduces radiation heat loads on cooled gas turbine engine components. Calculation of the radiant heat transfer within the nonisothermal, translucent ceramic coating material shows that the gas-side ceramic coating surface temperature can be used in heat transfer analysis of radiation heat loads on the coating system.

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

NASA Technical Reports Server (NTRS)

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.

Adaptive Photothermal Emission Analysis Techniques for Robust Thermal Property Measurements of Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Valdes, Raymond

The characterization of thermal barrier coating (TBC) systems is increasingly important because they enable gas turbine engines to operate at high temperatures and efficiency. Phase of photothermal emission analysis (PopTea) has been developed to analyze the thermal behavior of the ceramic top-coat of TBCs, as a nondestructive and noncontact method for measuring thermal diffusivity and thermal conductivity. Most TBC allocations are on actively-cooled high temperature turbine blades, which makes it difficult to precisely model heat transfer in the metallic subsystem. This reduces the ability of rote thermal modeling to reflect the actual physical conditions of the system and can lead to higher uncertainty in measured thermal properties. This dissertation investigates fundamental issues underpinning robust thermal property measurements that are adaptive to non-specific, complex, and evolving system characteristics using the PopTea method. A generic and adaptive subsystem PopTea thermal model was developed to account for complex geometry beyond a well-defined coating and substrate system. Without a priori knowledge of the subsystem characteristics, two different measurement techniques were implemented using the subsystem model. In the first technique, the properties of the subsystem were resolved as part of the PopTea parameter estimation algorithm; and, the second technique independently resolved the subsystem properties using a differential "bare" subsystem. The confidence in thermal properties measured using the generic subsystem model is similar to that from a standard PopTea measurement on a "well-defined" TBC system. Non-systematic bias-error on experimental observations in PopTea measurements due to generic thermal model discrepancies was also mitigated using a regression-based sensitivity analysis. The sensitivity analysis reported measurement uncertainty and was developed into a data reduction method to filter out these "erroneous" observations. It was found

Thermal Shock Damage and Microstructure Evolution of Thermal Barrier Coatings on Mar-M247 Superalloy in a Combustion Gas Environment

NASA Astrophysics Data System (ADS)

Mei, Hui

2012-06-01

The effect of preoxidation on the thermal shock of air plasma sprayed thermal barrier coatings (TBCs) was completely investigated in a combustion gas environment by burning jet fuel with high speed air. Results show that with increasing cycles, the as-oxidized TBCs lost more weight and enlarged larger spallation area than the as-sprayed ones. Thermally grown oxide (TGO) growth and thermal mismatch stress were proven to play critical roles on the as-oxidized TBC failure. Two types of significant cracks were identified: the type I crack was vertical to the TGO interface and the type II crack was parallel to the TGO interface. The former accelerated the TGO growth to develop the latter as long as the oxidizing gas continuously diffused inward and then oxidized the more bond coat (BC). The preoxidation treatment directly increased the TGO thickness, formed the parallel cracks earlier in the TGO during the thermal shocks, and eventually resulted in the worse thermal shock resistance.

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

NASA Technical Reports Server (NTRS)

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.

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

NASA Technical Reports Server (NTRS)

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.

Industry tests of NASA ceramic thermal barrier coating. [for gas turbine engine applications

NASA Technical Reports Server (NTRS)

Liebert, C. H.; Stepka, F. S.

1979-01-01

Ceramic thermal barrier coating (TBC) system was tested by industrial and governmental organizations for a variety of aeronautical, marine, and ground-based gas turbine engine applications. This TBC is a two-layer system with a bond coating of nickel-chromium-aluminum-yttrium (Ni-16Cr-6Al-0.6Y, in wt. percent) and a ceramic coating of yttria-stabilized zirconia (ZrO2-12Y2O3, in wt. percent). Seven tests evaluated the system's thermal protection and durability. Five other tests determined thermal conductivity, vibratory fatigue characteristics, and corrosion resistance of the system. The information presented includes test results and photographs of the coated parts. Recommendations are made for improving the coating procedures.

Effect of Layer-Graded Bond Coats on Edge Stress Concentration and Oxidation Behavior of Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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

1998-01-01

Thermal barrier coating (TBC) durability is closely related to design, processing and microstructure of the coating Z, tn systems. Two important issues that must be considered during the design of a thermal barrier coating are thermal expansion and modulus mismatch between the substrate and the ceramic layer, and substrate oxidation. In many cases, both of these issues may be best addressed through the selection of an appropriate bond coat system. In this study, a low thermal expansion and layer-graded bond coat system, that consists of plasma-sprayed FeCoNiCrAl and FeCrAlY coatings, and a high velocity oxyfuel (HVOF) sprayed FeCrAlY coating, is developed to minimize the thermal stresses and provide oxidation resistance. The thermal expansion and oxidation behavior of the coating system are also characterized, and the strain isolation effect of the bond coat system is analyzed using the finite element method (FEM). Experiments and finite element results show that the layer-graded bond coat system possesses lower interfacial stresses. better strain isolation and excellent oxidation resistance. thus significantly improving the coating performance and durability.

Surface Modification of Thermal Barrier Coatings by Single-Shot Defocused Laser Treatments

NASA Astrophysics Data System (ADS)

Akdoğan, Vakur; Dokur, Mehmet M.; Göller, Gültekin; Keleş, Özgül

2013-09-01

Thermal barrier coatings (TBC) consisting of atmospheric plasma-sprayed ZrO2-8 wt.% Y2O3 and a high velocity oxygen fuel-sprayed metallic bond coat were subjected to CO2 continuous wave laser treatments. The effects of laser power on TBCs were investigated as was the thermally grown oxide (TGO) layer development of all as-sprayed and laser-treated coatings after thermal oxidation tests in air environment for 50, 100, and 200 h at 1100 °C. The effects of laser power on TBCs were investigated. TGO layer development was examined on all as-sprayed and laser-treated coatings after thermal oxidation tests in air environment for 50, 100, and 200 h at 1100 °C. Melted and heat-affected zone regions were observed in all the laser-treated samples. Oxidation tests showed a stable alumina layer and mixed spinel oxides in the TGO layers of the as-sprayed and laser-treated TBCs.

Strong Flux Pinning of Nano-Sized Ysz Particles in Ybco Films Prepared by Mod Method

NASA Astrophysics Data System (ADS)

Ye, S.; Suo, H. L.; Liu, M.; Tang, X.; Wu, Z. P.; Zhao, Y.; Zhou, M. L.

The YBCO films with doped YSZ nanoparticles have been prepared successfully by metal organic doepositon method using trifluoroacetates (TFA-MOD) through dissolving Zr organic salt into the YBCO precursor solution. The doped films have well in-plane and out-plane textures detected by both XRD Φ-scan and ω-scan. The YSZ nanoparticles with the size of about 5 ~ 15 nm were observed on the surface of the YBCO films using both FE-SEM and TEM. By comparing the superconducting properties, it was found that the doped YBCO films had lower Tc than that of undoped YBCO films. However, as increasing the applied magnetic field, Jc of the doped YBCO films were much better than that of undoped one. The Jc was as higher as 2.5 times than that of undoped YBCO film at 77 K and 1 T applied field.

Current status and future trends in turbine application of thermal barrier coatings

NASA Technical Reports Server (NTRS)

Sheffler, Keith D.; Gupta, Dinesh K.

1988-01-01

This paper provides an overview of the current status and future trends in application of thermal barrier coatings (TBC) to turbine components, and in particular to high turbine airfoils. Included are descriptions of the favorable results achieved to date with bill-of-material applications of plasma deposited TBC, and recent experience with developmental coatings applied by electron beam-physical vapor deposition.

Thermal Cycling and High-Temperature Corrosion Tests of Rare Earth Silicate Environmental Barrier Coatings

NASA Astrophysics Data System (ADS)

Darthout, Émilien; Gitzhofer, François

2017-12-01

Lutetium and yttrium silicates, enriched with an additional secondary zirconia phase, environmental barrier coatings were synthesized by the solution precursor plasma spraying process on silicon carbide substrates. A custom-made oven was designed for thermal cycling and water vapor corrosion testing. The oven can test four specimens simultaneously and allows to evaluate environmental barrier performances under similar corrosion kinetics compared to turbine engines. Coatings structural evolution has been observed by SEM on the polished cross sections, and phase composition has been analyzed by XRD. All coatings have been thermally cycled between 1300 °C and the ambient temperature, without spallation, due to their porosity and the presence of additional secondary phase which increases the thermal cycling resistance. During water vapor exposure at 1200 °C, rare earth disilicates showed a good stability, which is contradictory with the literature, due to impurities—such as Si- and Al-hydroxides—in the water vapor jets. The presence of vertical cracks allowed the water vapor to reach the substrate and then to corrode it. It has been observed that thin vertical cracks induced some spallation after 24 h of corrosion.

Surface Cracking and Interface Reaction Associated Delamination Failure of Thermal and Environmental Barrier Coatings

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Choi, Sung R.; Eldridge, Jeffrey I.; Lee, Kang N.; Miller, Robert A.

2003-01-01

In this paper, surface cracking and interface reactions of a BSAS coating and a multi-layer ZTO2-8wt%Y2O3 and mullite/BSAS/Si thermal and environmental barrier coating system on SiC/SiC ceramic matrix composites were characterized after long-term combined laser thermal gradient and furnace cyclic tests in a water vapor containing environment. The surface cracking was analyzed based on the coating thermal gradient sintering behavior and thermal expansion mismatch stress characteristics under the thermal cyclic conditions. The interface reactions, which were largely enhanced by the coating surface cracking in the water vapor environment, were investigated in detail, and the reaction phases were identified for the coating system after the long- term exposure. The accelerated coating delamination failure was attributed to the increased delamination driving force under the thermal gradient cyclic loading and the reduced interface adhesion due to the detrimental interface reactions.

Development of Thermal Barriers For Solid Rocket Motor Nozzle Joints

NASA Technical Reports Server (NTRS)

Steinetz, Bruce M.; Dunlap, Patrick H., Jr.

2000-01-01

Joints in the Space Shuttle solid rocket motors are sealed by O-rings to contain combustion gases inside the rocket that reach pressures of up to 900 psi and temperatures of up to 5500 F. To provide protection for the O-rings, the motors are insulated with either phenolic or rubber insulation. Gaps in the joints leading up to the O-rings are filled with polysulfide joint-fill compounds as an additional level of protection. The current RSRM nozzle-to-case joint design incorporating primary, secondary, and wiper O-rings experiences gas paths through the joint-fill compound to the innermost wiper O-ring in about one out of every seven motors. Although this does not pose a safety hazard to the motor, it is an undesirable condition that NASA and rocket manufacturer Thiokol want to eliminate. Each nozzle-to-case joint gas path results in extensive reviews and evaluation before flights can be resumed. Thiokol and NASA Marshall are currently working to improve the nozzle-to-case joint design by implementing a more reliable J-leg design that has been used successfully in the field and igniter joint. They are also planning to incorporate the NASA Glenn braided carbon fiber thermal barrier into the joint. The thermal barrier would act as an additional level of protection for the O-rings and allow the elimination of the joint-fill compound from the joint.

Plasma Spray-PVD: A New Thermal Spray Process to Deposit Out of the Vapor Phase

NASA Astrophysics Data System (ADS)

von Niessen, Konstantin; Gindrat, Malko

2011-06-01

Plasma spray-physical vapor deposition (PS-PVD) is a low pressure plasma spray technology recently developed by Sulzer Metco AG (Switzerland). Even though it is a thermal spray process, it can deposit coatings out of the vapor phase. The basis of PS-PVD is the low pressure plasma spraying (LPPS) technology that has been well established in industry for several years. In comparison to conventional vacuum plasma spraying (VPS) or low pressure plasma spraying (LPPS), the new proposed process uses a high energy plasma gun operated at a reduced work pressure of 0.1 kPa (1 mbar). Owing to the high energy plasma and further reduced work pressure, PS-PVD is able to deposit a coating not only by melting the feed stock material which builds up a layer from liquid splats but also by vaporizing the injected material. Therefore, the PS-PVD process fills the gap between the conventional physical vapor deposition (PVD) technologies and standard thermal spray processes. The possibility to vaporize feedstock material and to produce layers out of the vapor phase results in new and unique coating microstructures. The properties of such coatings are superior to those of thermal spray and electron beam-physical vapor deposition (EB-PVD) coatings. In contrast to EB-PVD, PS-PVD incorporates the vaporized coating material into a supersonic plasma plume. Owing to the forced gas stream of the plasma jet, complex shaped parts such as multi-airfoil turbine vanes can be coated with columnar thermal barrier coatings using PS-PVD. Even shadowed areas and areas which are not in the line of sight of the coating source can be coated homogeneously. This article reports on the progress made by Sulzer Metco in developing a thermal spray process to produce coatings out of the vapor phase. Columnar thermal barrier coatings made of Yttria-stabilized Zircona (YSZ) are optimized to serve in a turbine engine. This process includes not only preferable coating properties such as strain tolerance and erosion

Non-thermal dielectric barrier discharge plasma induces angiogenesis through reactive oxygen species.

PubMed

Arjunan, Krishna P; Clyne, Alisa Morss

2011-01-01

Vascularization plays a key role in processes such as wound healing and tissue engineering. Non-thermal plasma, which primarily produces reactive oxygen species (ROS), recently emerged as an efficient tool in medical applications. Liquids and endothelial cells were treated with a non-thermal dielectric barrier discharge plasma. Plasma treatment of phosphate buffered saline (PBS) and serum-free medium increased ROS concentration in a dose-dependent manner, with a higher concentration in serum-free medium. ROS concentration in cells peaked 1 hour after treatment. 4.2 J/cm(2) increased cell proliferation, 2D and 3D migration, as well as tube formation. A fibroblast growth factor-2 (FGF-2) neutralizing antibody and ROS scavengers for hydrogen peroxide and hydroxyl radicals abrogated these angiogenic effects. Non-thermal plasma may be a potential tool for applying ROS in precise doses to enhance vascularization.

Effect of Nano-Si3N4 Additives and Plasma Treatment on the Dry Sliding Wear Behavior of Plasma Sprayed Al2O3-8YSZ Ceramic Coatings

NASA Astrophysics Data System (ADS)

Gou, Junfeng; Zhang, Jian; Zhang, Qiwen; Wang, You; Wang, Chaohui

2017-04-01

In this paper, the effect of nano-Si3N4 additives and plasma treatment on the wear behavior of Al2O3-8YSZ ceramic coatings was studied. Nano-Al2O3, nano-8YSZ (8 wt.% Y2O3-stabilized ZrO2) and nano-Si3N4 powders were used as raw materials to fabricate four types of sprayable feedstocks. Plasma treatment was used to improve the properties of the feedstocks. The surface morphologies of the ceramic coatings were observed. The mechanical properties of the ceramic coatings were measured. The dry sliding wear behavior of the Al2O3-8YSZ coatings with and without Si3N4 additives was studied. Nano-Si3N4 additives and plasma treatment can improve the morphologies of the coatings by prohibiting the initiation of micro-cracks and reducing the unmelted particles. The hardness and bonding strength of AZSP (Al2O3-18 wt.% 8YSZ-10 wt.% Si3N4-plasma treatment) coating increased by 79.2 and 44% compared to those of AZ (Al2O3-20 wt.% 8YSZ) coating. The porosity of AZSP coating decreased by 85.4% compared to that of AZ coating. The wear test results showed that the addition of nano-Si3N4 and plasma treatment could improve the wear resistance of Al2O3-8YSZ coatings.

Parallel Large-Scale Molecular Dynamics Simulation Opens New Perspective to Clarify the Effect of a Porous Structure on the Sintering Process of Ni/YSZ Multiparticles.

PubMed

Xu, Jingxiang; Higuchi, Yuji; Ozawa, Nobuki; Sato, Kazuhisa; Hashida, Toshiyuki; Kubo, Momoji

2017-09-20

Ni sintering in the Ni/YSZ porous anode of a solid oxide fuel cell changes the porous structure, leading to degradation. Preventing sintering and degradation during operation is a great challenge. Usually, a sintering molecular dynamics (MD) simulation model consisting of two particles on a substrate is used; however, the model cannot reflect the porous structure effect on sintering. In our previous study, a multi-nanoparticle sintering modeling method with tens of thousands of atoms revealed the effect of the particle framework and porosity on sintering. However, the method cannot reveal the effect of the particle size on sintering and the effect of sintering on the change in the porous structure. In the present study, we report a strategy to reveal them in the porous structure by using our multi-nanoparticle modeling method and a parallel large-scale multimillion-atom MD simulator. We used this method to investigate the effect of YSZ particle size and tortuosity on sintering and degradation in the Ni/YSZ anodes. Our parallel large-scale MD simulation showed that the sintering degree decreased as the YSZ particle size decreased. The gas fuel diffusion path, which reflects the overpotential, was blocked by pore coalescence during sintering. The degradation of gas diffusion performance increased as the YSZ particle size increased. Furthermore, the gas diffusion performance was quantified by a tortuosity parameter and an optimal YSZ particle size, which is equal to that of Ni, was found for good diffusion after sintering. These findings cannot be obtained by previous MD sintering studies with tens of thousands of atoms. The present parallel large-scale multimillion-atom MD simulation makes it possible to clarify the effects of the particle size and tortuosity on sintering and degradation.

Dispersion of SiC nanoparticles in cellulose for study of tensile, thermal and oxygen barrier properties.

PubMed

Kisku, Sudhir K; Dash, Satyabrata; Swain, Sarat K

2014-01-01

Cellulose/silicon carbide (cellulose/SiC) nanobiocomposites were prepared by solution technique. The interaction of SiC nanoparticles with cellulose were confirmed by Fourier transformed infrared (FTIR) spectroscopy. The structure of cellulose/SiC nanobiocomposites was investigated by X-ray diffraction (XRD), and transmission electron microscopy (TEM). The tensile properties of the nanobiocomposites were improved as compared with virgin cellulose. Thermal stabilities of cellulose/SiC nanobiocomposites were studied by thermogravimetric analysis (TGA). The cellulose/SiC nanobiocomposites were thermally more stable than the raw cellulose. It may be due to the delamination of SiC with cellulose matrix. The oxygen barrier properties of cellulose composites were measured using gas permeameter. A substantial reduction in oxygen permeability was obtained with increase in silicon carbide concentrations. The thermally resistant and oxygen barrier properties of the prepared nanobiocomposites may enable the materials for the packaging applications. Copyright © 2013 Elsevier Ltd. All rights reserved.

Highly defective oxides as sinter resistant thermal barrier coating

DOEpatents

Subramanian, Ramesh

2005-08-16

A thermal barrier coating material formed of a highly defective cubic matrix structure having a concentration of a stabilizer sufficiently high that the oxygen vacancies created by the stabilizer interact within the matrix to form multi-vacancies, thereby improving the sintering resistance of the material. The concentration of stabilizer within the cubic matrix structure is greater than that concentration of stabilizer necessary to give the matrix a peak ionic conductivity value. The concentration of stabilizer may be at least 30 wt. %. Embodiments include a cubic matrix of zirconia stabilized by at least 30-50 wt. % yttria, and a cubic matrix of hafnia stabilized by at least 30-50 wt. % gadolinia.

Surface Cracking and Interface Reaction Associated Delamination Failure of Thermal and Environmental Barrier Coatings

NASA Technical Reports Server (NTRS)

Zhu, Dong-Ming; Choi, Sung R.; Eldridge, Jeffrey I.; Lee, Kang N.; Miller, Robert A.

2003-01-01

In this paper, surface cracking and interface reactions of a BSAS coating and a multi-layer ZrO2-8wt%Y2O3 and mullite/BSAS/Si thermal and environmental barrier coating system on SiC/SiC ceramic matrix composites were characterized after long-term combined laser thermal gradient and furnace cyclic tests in a water vapor containing environment. The surface cracking was analyzed based on the coating thermal gradient sintering behavior and thermal expansion mismatch stress characteristics under the thermal cyclic conditions. The interface reactions, which were largely enhanced by the coating surface cracking in the water vapor environment, were investigated in detail, and the reaction phases were identified for the coating system after the long-term exposure. The accelerated coating delamination failure was attributed to the increased delamination driving force under the thermal gradient cyclic loading and the reduced interface adhesion due to the detrimental interface reactions.

Evaluation of present thermal barrier coatings for potential service in electric utility gas turbines

NASA Technical Reports Server (NTRS)

Bratton, R. J.; Lau, S. K.; Lee, S. Y.

1982-01-01

The resistance of present-day thermal barrier coatings to combustion gases found in electric utility turbines was assessed. The plasma sprayed coatings, both duplex and graded types, were primarily zirconia-based, although a calcium silicate was also evaluated. Both atmospheric burner rig tests and high pressure tests (135 psig) showed that several present-day thermal barrier coatings have a high potential for service in gas turbines burning the relatively clean GT No. 2 fuel. However, coating improvements are needed for use in turbines burning lower grade fuel such as residual oil. The duplex ZrO2.8Y2O3/NiCrA1Y coating was ranked highest and selected for near-term field testing, with Ca2SiO4/NiCrA1Y ranked second. Graded coatings show potential for corrosive turbine operating conditions and warrant further development. The coating degradation mechanisms for each coating system subjected to the various environmental conditions are also described.

18O-tracer diffusion along nanoscaled Sc2O3/yttria stabilized zirconia (YSZ) multilayers: on the influence of strain.

PubMed

Aydin, Halit; Korte, Carsten; Janek, Jürgen

2013-06-01

The oxygen tracer diffusion coefficient describing transport along nano-/microscaled YSZ/Sc 2 O 3 multilayers as a function of the thick-ness of the ion-conducting YSZ layers has been measured by isotope exchange depth profiling (IEDP), using secondary ion mass spec-trometry (SIMS). The multilayer samples were prepared by pulsed laser deposition (PLD) on (0001) Al 2 O 3 single crystalline substrates. The values for the oxygen tracer diffusion coefficient were analyzed as a combination of contributions from bulk and interface contributions and compared with results from YSZ/Y 2 O 3 -multilayers with similar microstructure. Using the Nernst-Einstein equation as the relation between diffusivity and electrical conductivity we find very good agreement between conductivity and diffusion data, and we exclude substantial electronic conductivity in the multilayers. The effect of hetero-interface transport can be well explained by a simple interface strain model. As the multilayer samples consist of columnar film crystallites with a defined inter-face structure and texture, we also discuss the influence of this particular microstructure on the interfacial strain.

18O-tracer diffusion along nanoscaled Sc2O3/yttria stabilized zirconia (YSZ) multilayers: on the influence of strain

PubMed Central

Aydin, Halit; Korte, Carsten; Janek, Jürgen

2013-01-01

The oxygen tracer diffusion coefficient describing transport along nano-/microscaled YSZ/Sc2O3 multilayers as a function of the thick­ness of the ion-conducting YSZ layers has been measured by isotope exchange depth profiling (IEDP), using secondary ion mass spec­trometry (SIMS). The multilayer samples were prepared by pulsed laser deposition (PLD) on (0001) Al2O3 single crystalline substrates. The values for the oxygen tracer diffusion coefficient were analyzed as a combination of contributions from bulk and interface contributions and compared with results from YSZ/Y2O3-multilayers with similar microstructure. Using the Nernst–Einstein equation as the relation between diffusivity and electrical conductivity we find very good agreement between conductivity and diffusion data, and we exclude substantial electronic conductivity in the multilayers. The effect of hetero-interface transport can be well explained by a simple interface strain model. As the multilayer samples consist of columnar film crystallites with a defined inter­face structure and texture, we also discuss the influence of this particular microstructure on the interfacial strain. PMID:27877580

Effect of thermal barrier coating with various blends of pumpkin seed oil methyl ester in DI diesel engine

NASA Astrophysics Data System (ADS)

Karthickeyan, V.; Balamurugan, P.

2017-10-01

The rise in oil prices, dependency on fossil fuels, degradation of non-renewable energy resources and global warming strives to find a low-carbon content alternative fuel to the conventional fuel. In the present work, Partially Stabilized Zirconia (PSZ) was used as a thermal barrier coating in piston head, cylinder head and intake and exhaust valves using plasma spray technique, which provided a rise in combustion chamber temperature. With the present study, the effects of thermal barrier coating on the blends of Pumpkin Seed Oil Methyl Ester (PSOME) were observed in both the coated and uncoated engine. Performance and emission characteristics of the PSOME in coated and uncoated engines were observed and compared. Increased thermal efficiency and reduced fuel consumption were observed for B25 and diesel in coated and uncoated engine. On comparing with the other biodiesel samples, B25 exhibited lower HC, NOx and smoke emissions in thermally coated engine than uncoated engine. After 100 h of operation, no anamolies were found in the thermally coated components except minor cracks were identified in the edges of the piston head.

Effects of Thermal Barrier Coatings on Approaches to Turbine Blade Cooling

NASA Technical Reports Server (NTRS)

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.

Abradable dual-density ceramic turbine seal system

NASA Technical Reports Server (NTRS)

Clingman, D. L.; Schechter, B.; Cross, K. R.; Cavanagh, J. R.

1981-01-01

A plasma sprayed dual density ceramic abradable seal system for direct application to the HPT seal shroud of small gas turbine engines. The system concept is based on the thermal barrier coating and depends upon an additional layer of modified density ceramic material adjacent to the gas flow path to provide the desired abradability. This is achieved by codeposition of inert fillers with yttria stabilized zirconia (YSZ) to interrupt the continuity of the zirconia struture. The investigation of a variety of candidate fillers, with hardness values as low as 2 on Moh's scale, led to the conclusion that solid filler materials in combination with a YSZ matrix, regardless of their hardness values, have a propensity for compacting rather than shearing as originally expected. The observed compaction is accompanied by high energy dissipation in the rub interaction, usually resulting in the adhesive transfer of blade material to the stationary seal member. Two YSZ based coating systems which incorported hollow alumino silicate spheres as density reducing agents were surveyed over the entire range of compositions from 100 percent filler to 100 percent YSZ. Abradability and erosion characteristics were determined, hardness and permeability characterized, and engine experience acquired with several system configurations.

Effect of Sintering on Mechanical and Physical Properties of Plasma-Sprayed Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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

2004-01-01

The effect of sintering on mechanical and physical properties of free-standing plasma-sprayed ZrO2-8 wt% Y2O3 thermal barrier coatings (TBCs) was determined by annealing them at 1316 C in air. Mechanical and physical properties of the TBCs, including strength, modes I and II fracture toughness, elastic modulus, Poisson s response, density, microhardness, fractography, and phase stability, were determined at ambient temperature as a function of annealing time ranging from 0 to 500 h. All mechanical and physical properties, except for the amount of monoclinic phase, increased significantly in 5 to 100 h and then reached a plateau above 100 h. Annealing resulted in healing of microcracks and pores and in grain growth, accompanying densification of the TBC s body due to the sintering effect. However, an inevitable adverse effect also occurred such that the desired lower thermal conductivity and good expansivity, which makes the TBCs unique in thermal barrier applications, were degraded upon annealing. A model was proposed to assess and quantify all the property variables in response to annealing in a normalized scheme. Directionality of as-sprayed TBCs appeared to have an insignificant effect on their properties, as determined via fracture toughness, microhardness, and elastic modulus measurements.

Feasibility Assessment of Thermal Barrier Seals for Extreme Transient Temperatures

NASA Technical Reports Server (NTRS)

Steinetz, Bruce M.; Dunlap, Patrick H., Jr.

1998-01-01

The assembly joints of modem solid rocket motor cases are generally sealed using conventional O-ring type seals. The 5500+ F combustion gases produced by rocket motors are kept a safe distance away from the seals by thick layers of phenolic insulation. Special compounds are used to fill insulation gaps leading up to the seals to prevent a direct flowpath to them. Design criteria require that the seals should not experience torching or charring during operation, or their sealing ability would be compromised. On limited occasions, NASA has observed charring of the primary O-rings of the Space Shuttle solid rocket nozzle assembly joints due to parasitic leakage paths opening up in the gap-fill compounds during rocket operation. NASA is investigating different approaches for preventing torching or charring of the primary O-rings. One approach is to implement a braided rope seal upstream of the primary O-ring to serve as a thermal barrier that prevents the hot gases from impinging on the O-ring seals. This paper presents flow, resiliency, and thermal resistance for several types of NASA rope seals braided out of carbon fibers. Burn tests were performed to determine the time to burn through each of the seals when exposed to the flame of an oxyacetylene torch (5500 F), representative of the 5500 F solid rocket motor combustion temperatures. Rope seals braided out of carbon fibers endured the flame for over six minutes, three times longer than solid rocket motor burn time. Room and high temperature flow tests are presented for the carbon seals for different amounts of linear compression. Room temperature compression tests were performed to assess seal resiliency and unit preloads as a function of compression. The thermal barrier seal was tested in a subscale "char" motor test in which the seal sealed an intentional defect in the gap insulation. Temperature measurements indicated that the seal blocked 2500 F combustion gases on the upstream side with very little temperature

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

NASA Technical Reports Server (NTRS)

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.

Influence of Temperature on CaO-MgO-Al2O3-SiO2 (CMAS) Corrosion on Thermal Barrier Coatings

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wang, Honglong; Zhang, Xingxing; Agubra, Victor

2015-10-23

Higher operating temperature improves the energy efficiency in gas turbine engines and thermal barrier coatings are applied to protect the blades from high temperature and dust corrosion. Dust composed by CaO-MgO-Al2O3-SiO2 (CMAS) can melt and react with pyrochlore zirconates thermal barrier materials and degrade the performance or cause failure of the coatings. This paper discusses the relationship of the reaction product and corrosion temperature.

Thermal Conductivity and Stability of HfO2-Y2O3 and La2Zr2O7 Evaluated for 1650 Deg C Thermal/Environmental Barrier Coating Applications

NASA Technical Reports Server (NTRS)

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

2003-01-01

HfO2-Y2O3 and La2Zr2O7 are candidate thermal and environmental barrier coating (T/EBC) materials for gas turbine ceramic matrix composite (CMC) combustor applications because of their relatively low thermal conductivity and high temperature capability. In this paper, thermal conductivity and high temperature stability of hot-pressed and plasma sprayed specimens with representative partially-stabilized and fully-cubic HfO2-Y2O3 compositions and La2Zr2O7 were evaluated at temperatures up to 1700 C using a steady-state laser heat-flux technique. Sintering behavior of the plasmasprayed coatings was determined by monitoring the thermal conductivity increases during a 20-hour test period at various temperatures. Durability and failure mechanisms of the HfO2-Y2O3 and La2Zr2O7 coatings on mullite/SiC hexoloy or SiC/SiC CMC substrates were investigated at 1650 C under thermal gradient cyclic conditions. Coating design and testing issues for the 1650 C thermal/environmental barrier coating applications are also discussed.

Relation of Thermal Conductivity with Process Induced Anisotropic Void Systems in EB-PVD PYSZ Thermal Barrier Coatings

DOE Office of Scientific and Technical Information (OSTI.GOV)

Renteria, A. Flores; Saruhan-Brings, B.; Ilavsky, J.

2008-03-03

Thermal barrier coatings (TBCs) deposited by Electron-beam physical deposition (EB-PVD) protect the turbine blades situated at the high pressure sector of the aircraft and stationary turbines. It is an important task to uphold low thermal conductivity in TBCs during long-term service at elevated temperatures. One of the most promising methods to fulfil this task is to optimize the properties of PYSZ-based TBC by tailoring its microstructure. Thermal conductivity of the EB-PVD produced PYSZ TBCs is influenced mainly by the size, shape, orientation and volume of the various types of porosity present in the coatings. These pores can be classified asmore » open (inter-columnar and between feather arms gaps) and closed (intra-columnar pores). Since such pores are located within the three-dimensionally deposited columns and enclose large differences in their sizes, shapes, distribution and anisotropy, the accessibility for their characterization is very complex and requires the use of sophisticated methods. In this work, three different EB-PVD TBC microstructures were manufactured by varying the process parameters, yielding various characteristics of their pores. The corresponding thermal conductivities in as-coated state and after ageing at 11000C/1h and 100h were measured via Laser Flash Analysis Method (LFA). The pore characteristics and their individual effect on the thermal conductivity are analysed by USAXS which is supported by subsequent modelling and LFA methods, respectively. Evident differences in the thermal conductivity values of each microstructure were found in as-coated and aged conditions. In summary, broader columns introduce higher values in thermal conductivity. In general, thermal conductivity increases after ageing for all three investigated microstructures, although those with initial smaller pore surface area show smaller changes.« less

Relation of thermal conductivity with process induced anisotropic void system in EB-PVD PYSZ thermal barrier coatings.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Renteria, A. F.; Saruhan, B.; Ilavsky, J.

2007-01-01

Thermal barrier coatings (TBCs) deposited by Electron-beam physical deposition (EB-PVD) protect the turbine blades situated at the high pressure sector of the aircraft and stationary turbines. It is an important task to uphold low thermal conductivity in TBCs during long-term service at elevated temperatures. One of the most promising methods to fulfil this task is to optimize the properties of PYSZ-based ,TBC by tailoring its microstructure. Thermal conductivity of the EB-PVD produced PYSZ TBCs is influenced mainly by the size, shape, orientation and volume of the various types of porosity present in the coatings. These pores can be classified asmore » open (inter-columnar and between feather arms gaps) and closed (intra-columnar pores). Since such pores are located within the three-dimensionally deposited columns and enclose large differences in their sizes, shapes, distribution and anisotropy, the accessibility for their characterization is very complex and requires the use of sophisticated methods. In this work, three different EB-PVD TBC microstructures were manufactured by varying the process parameters, yielding various characteristics of their pores. The corresponding thermal conductivities in as-coated state and after ageing at 1100C/1h and 100h were measured via Laser Flash Analysis Method (LFA). The pore characteristics and their individual effect on the thermal conductivity are analysed by USAXS which is supported by subsequent modelling and LFA methods, respectively. Evident differences in the thermal conductivity values of each microstructure were found in as-coated and aged conditions. In summary, broader columns introduce higher values in thermal conductivity. In general, thermal conductivity increases after ageing for all three investigated microstructures, although those with initial smaller pore surface area show smaller changes.« less

Thermal barrier coating life-prediction model development. Annual report no. 2

DOE Office of Scientific and Technical Information (OSTI.GOV)

Strangman, T. E.; Neumann, J.; Liu, A.

1986-10-01

The program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant thermal barrier coating (TBC) systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma-spray (LPPS) or an argon shrouded plasma-spray (ASPS) applied oxidation resistant NiCrAlY or (CoNiCrAlY) bond coating and an air-plasma-sprayed yttria partially stabilized zirconia insulative layer, is applied by both Chromalloy, Klock, and Union Carbide. The second type of TBS is applied by the electron beam-physical vapor deposition (EB-PVD) process by Temescal. The second year of the program was focused on specimenmore » procurement, TMC system characterization, nondestructive evaluation methods, life prediction model development, and TFE731 engine testing of thermal barrier coated blades. Materials testing is approaching completion. Thermomechanical characterization of the TBC systems, with toughness, and spalling strain tests, was completed. Thermochemical testing is approximately two-thirds complete. Preliminary materials life models for the bond coating oxidation and zirconia sintering failure modes were developed. Integration of these life models with airfoil component analysis methods is in progress. Testing of high pressure turbine blades coated with the program TBS systems is in progress in a TFE731 turbofan engine. Eddy current technology feasibility was established with respect to nondestructively measuring zirconia layer thickness of a TBC system.« less

High temperature gradient cobalt based clad developed using microwave hybrid heating

NASA Astrophysics Data System (ADS)

Prasad, C. Durga; Joladarashi, Sharnappa; Ramesh, M. R.; Sarkar, Anunoy

2018-04-01

The development of cobalt based cladding on a titanium substrate using microwave cladding technique is benchmark in coating area. The developed cladding would serve the function of a corrosion resistant coating under high temperatures. Clads of thickness 500 µm have been developed by microwave hybrid heating. A microwave furnace of 2.45GHz frequency was used at a 900W power level for processing. Impact of processing time on melting and adhesion of clad has been discussed. The study also extended to static thermal analysis of simple parts with cladding using commercial Finite Element analysis (FEA) software. A comparative study is explored between four variants of the clad being developed. The analysis has been conducted using a square sample. Similar temperature gradient is also shown for a proposed multi-layer coating, which includes a thermal barrier coating yttria stabilized zirconia (YSZ) on top of the corrosion resistant clad. The YSZ coating would protect the corrosion resistant cladding and substrate from high temperatures.

Synthesis and Phase Stability of Scandia, Gadolinia, and Ytterbia Co-doped Zirconia for Thermal Barrier Coating Application

NASA Astrophysics Data System (ADS)

Li, Qi-Lian; Cui, Xiang-Zhong; Li, Shu-Qing; Yang, Wei-Hua; Wang, Chun; Cao, Qian

2015-01-01

Scandia, gadolinia, and ytterbia co-doped zirconia (SGYZ) ceramic powder was synthesized by chemical co-precipitation and calcination processes for application in thermal barrier coatings to promote the durability of gas turbines. The ceramic powder was agglomerated and sintered at 1150 °C for 2 h, and the powder exhibited good flowability and apparent density to be suitable for plasma spraying process. The microstructure, morphology and phase stability of the powder and plasma-sprayed SGYZ coatings were analyzed by means of scanning electron microscope and x-ray diffraction. Thermal conductivity of plasma-sprayed SGYZ coatings was measured. The results indicated that the SGYZ ceramic powder and the coating exhibit excellent stability to retain single non-transformable tetragonal zirconia even after high temperature (1400 °C) exposure for 500 h and do not undergo a tetragonal-to-monoclinic phase transition upon cooling. Furthermore, the plasma-sprayed SGYZ coating also exhibits lower thermal conductivity than yttria stabilized zirconia coating currently used in gas turbine engine industry. SGYZ can be explored as a candidate material of ultra-high temperature thermal barrier coating for advanced gas turbine engines.

High-temperature electrolysis of CO2-enriched mixtures by using fuel-electrode supported La0.6Sr0.4CoO3/YSZ/Ni-YSZ solid oxide cells

NASA Astrophysics Data System (ADS)

Kim, Si-Won; Bae, Yonggyun; Yoon, Kyung Joong; Lee, Jong-Ho; Lee, Jong-Heun; Hong, Jongsup

2018-02-01

To mitigate CO2 emissions, its reduction by high-temperature electrolysis using solid oxide cells is extensively investigated, for which excessive steam supply is assumed. However, such condition may degrade its feasibility due to massive energy required for generating hot steam, implying the needs for lowering steam demand. In this study, high-temperature electrolysis of CO2-enriched mixtures by using fuel-electrode supported La0.6Sr0.4CoO3/YSZ/Ni-YSZ solid oxide cells is considered to satisfy such needs. The effect of internal and external steam supply on its electrochemical performance and gas productivity is elucidated. It is shown that the steam produced in-situ inside the fuel-electrode by a reverse water gas shift reaction may decrease significantly the electrochemical resistance of dry CO2-fed operations, attributed to self-sustaining positive thermo-electrochemical reaction loop. This mechanism is conspicuous at low current density, whereas it is no longer effective at high current density in which total reactant concentrations for electrolysis is critical. To overcome such limitations, a small amount of external steam supply to the CO2-enriched feed stream may be needed, but this lowers the CO2 conversion and CO/H2 selectivity. Based on these results, it is discussed that there can be minimum steam supply sufficient for guaranteeing both low electrochemical resistance and high gas productivity.

Thermal barrier coating life prediction model development, phase 1

NASA Technical Reports Server (NTRS)

Demasi, Jeanine T.; Ortiz, Milton

1989-01-01

The objective of this program was to establish a methodology to predict thermal barrier coating (TBC) life on gas turbine engine components. The approach involved experimental life measurement coupled with analytical modeling of relevant degradation modes. Evaluation of experimental and flight service components indicate the predominant failure mode to be thermomechanical spallation of the ceramic coating layer resulting from propagation of a dominant near interface crack. Examination of fractionally exposed specimens indicated that dominant crack formation results from progressive structural damage in the form of subcritical microcrack link-up. Tests conducted to isolate important life drivers have shown MCrAlY oxidation to significantly affect the rate of damage accumulation. Mechanical property testing has shown the plasma deposited ceramic to exhibit a non-linear stress-strain response, creep and fatigue. The fatigue based life prediction model developed accounts for the unusual ceramic behavior and also incorporates an experimentally determined oxide rate model. The model predicts the growth of this oxide scale to influence the intensity of the mechanic driving force, resulting from cyclic strains and stresses caused by thermally induced and externally imposed mechanical loads.

A novel highly porous ceramic foam with efficient thermal insulation and high temperature resistance properties fabricated by gel-casting process

NASA Astrophysics Data System (ADS)

Yu, Jiahong; Wang, Guixiang; Tang, Di; Qiu, Ya; Sun, Nali; Liu, Wenqiao

2018-01-01

The design of super thermal insulation and high-temperature resistant materials for high temperature furnaces is crucial due to the energy crisis and the huge wasting. Although it is told that numerous studies have been reported about various of thermal insulation materials prepared by different methods, the applications of yttria-stabilized zirconia (YSZ) ceramic foams fabricated through tert-butyl alcohol (TBA)-based gel-casting process in bulk thermal isolators were barely to seen. In this paper, highly porous yttria-stabilized zirconia (YSZ) ceramic foams were fabricated by a novel gel-casting method using tert-butyl alcohol (TBA) as solvent and pore-forming agent. Different raw material ratio, sintering temperature and soaking time were all investigated to achieve optimal thermal insulation and mechanical properties. We can conclude that porosity drops gradually while compressive strength increases significantly with the rising temperature from 1000-1500°C. With prolonged soaking time, there is no obvious change in porosity but compressive strength increases gradually. All specimens have uniformly distributed pores with average size of 0.5-2μm and show good structural stability at high temperature. The final obtained ceramic foams displayed an outstanding ultra-low thermal conductivity property with only 200.6 °C in cold surface while the hot side was 1000 °C (hold 60 min to keep thermal balance before testing) at the thickness of 10 mm.

Optimization of High Porosity Thermal Barrier Coatings Generated with a Porosity Former

NASA Astrophysics Data System (ADS)

Medřický, Jan; Curry, Nicholas; Pala, Zdenek; Vilemova, Monika; Chraska, Tomas; Johansson, Jimmy; Markocsan, Nicolaie

2015-04-01

Yttria-stabilized zirconia thermal barrier coatings are extensively used in turbine industry; however, increasing performance requirements have begun to make conventional air plasma sprayed coatings insufficient for future needs. Since the thermal conductivity of bulk material cannot be lowered easily; the design of highly porous coatings may be the most efficient way to achieve coatings with low thermal conductivity. Thus the approach of fabrication of coatings with a high porosity level based on plasma spraying of ceramic particles of dysprosia-stabilized zirconia mixed with polymer particles, has been tested. Both polymer and ceramic particles melt in plasma and after impact onto a substrate they form a coating. When the coating is subjected to heat treatment, polymer burns out and a complex structure of pores and cracks is formed. In order to obtain desired porosity level and microstructural features in coatings; a design of experiments, based on changes in spray distance, powder feeding rate, and plasma-forming atmosphere, was performed. Acquired coatings were evaluated for thermal conductivity and thermo-cyclic fatigue, and their morphology was assessed using scanning electron microscopy. It was shown that porosity level can be controlled by appropriate changes in spraying parameters.

Ni-doped (CeO2- δ )-YSZ mesoarchitectured with nanocrystalline framework: the effect of thermal treatment on structure, surface chemistry and catalytic properties in the partial oxidation of methane (CPOM)

NASA Astrophysics Data System (ADS)

Somacescu, Simona; Florea, Mihaela; Osiceanu, Petre; Calderon-Moreno, Jose Maria; Ghica, Corneliu; Serra, Jose Manuel

2015-11-01

Ni-doped (CeO2- δ )-YSZ (5 mol% Ni oxide, 10 mol% ceria) mesoarchitectures (MA) with nanocrystalline framework have been synthesized by an original, facile and cheap approach based on Triton X100 nonionic surfactant as template and water as solvent at a strong basic pH value. Following the hydrothermal treatment under autogenous pressure ( 18 bars), Ni, Ce, Y, and Zr were well ordered as MA with nanocrystalline framework, assuring thermal stability. A comprehensive investigation of structure, texture, morphology, and surface chemistry was performed by means of a variety of complementary techniques (X-Ray Diffraction, XRD; Raman Spectroscopy, RS; Brunauer—Emmett—Teller, BET; Temperature—Programmed Reduction, TPR; Transmission Electron Microscopy, TEM and DF-STEM; X-ray Photoelectron Spectroscopy, XPS; Catalytic activity and selectivity). N2 sorption measurements highlighted that the mesoporous structure is formed at 600 °C and remains stable at 800 °C. At 900 °C, the MA collapses, favoring the formation of macropores. The XRD and Raman Spectroscopy of all samples showed the presence of a pure, single phase with fluorite-type structure. At 900 °C, an increased tetragonal distortion of the cubic lattice was observed. The surface chemistry probed by XPS exhibits a mixture of oxidation states (Ce3+ + Ce4+) with high percentage of Ce3+ valence state 35 % and (Ni3+ and Ni2+) oxidation states induced by the thermal treatment. These nanoparticles assembled into MA show high stability and selectivity over time in catalytic partial oxidation of methane (CPOM). These promising performances suggest an interesting prospect for introduction as anode within IT-SOFC assemblies.

Synthesis of thermal and chemical resistant oxygen barrier starch with reinforcement of nano silicon carbide.

PubMed

Dash, Satyabrata; Swain, Sarat K

2013-09-12

Starch/silicon carbide (starch/SiC) bionanocomposites were synthesized by solution method using different wt% of silicon carbide with starch matrix. The interaction between starch and silicon carbide was studied by Fourier transform infrared (FTIR) spectroscopy. The structure of the bionanocomposites was investigated by X-ray diffraction (XRD) and field emission scanning electron microscope (FESEM). Thermal property of starch/SiC bionanocomposites was measured and a significant enhancement of thermal resistance was noticed. The oxygen barrier property of the composites was studied and a substantial reduction in permeability was observed as compared to the virgin starch. The reduction of oxygen permeability with enhancement of thermal stability of prepared bionanocomposites may enable the materials suitable for thermal resistant packaging and adhesive applications. Copyright © 2013 Elsevier Ltd. All rights reserved.

Detection of thermally grown oxides in thermal barrier coatings by nondestructive evaluation

NASA Astrophysics Data System (ADS)

Fahr, A.; Rogé, B.; Thornton, J.

2006-03-01

The thermal-barrier coatings (TBC) sprayed on hot-section components of aircraft turbine engines commonly consist of a partially stabilized zirconia top-coat and an intermediate bond-coat applied on the metallic substrate. The bond-coat is made of an aluminide alloy that at high engine temperatures forms thermally grown oxides (TGO). Although formation of a thin layer of aluminum oxide at the interface between the ceramic top-coat and the bond-coat has the beneficial effect of protecting the metallic substrate from hot gases, oxide formation at splat boundaries or pores within the bond-coat is a source of weakness. In this study, plasma-sprayed TBC specimens are manufactured from two types of bond-coat powders and exposed to elevated temperatures to form oxides at the ceramic-bond-coat boundary and within the bond-coat. The specimens are then tested using nondestructive evaluation (NDE) and destructive metallography and compared with the as-manufactured samples. The objective is to determine if NDE can identify the oxidation within the bond-coat and give indication of its severity. While ultrasonic testing can provide some indication of the degree of bond-coat oxidation, the eddy current (EC) technique clearly identifies severe oxide formation within the bond-coat. Imaging of the EC signals as the function of probe location provides information on the spatial variations in the degree of oxidation, and thereby identifies which components or areas are prone to premature damage.

Environmental Barrier Coatings for Silicon-Based Ceramics

NASA Technical Reports Server (NTRS)

Lee, Kang N.; Fox, Dennis S.; Robinson, Raymond C.; Bansal, Narottam P.

2001-01-01

Silicon-based ceramics, such as SiC fiber-reinforced SiC (SiC/SiC ceramic matrix composites (CMC) and monolithic silicon nitride (Si3N4), are prime candidates for hot section structural components of next generation gas turbine engines. Silicon-based ceramics, however, suffer from rapid surface recession in combustion environments due to volatilization of the silica scale via reaction with water vapor, a major product of combustion. Therefore, application of silicon-based ceramic components in the hot section of advanced gas turbine engines requires development of a reliable method to protect the ceramic from environmental attack. An external environmental barrier coating (EBC) is considered a logical approach to achieve protection and CP long-term stability. The first generation EBC consisted of two layers, mullite (3Al2O3-2SiO2) bond coat and yttria-stabilized zirconia (YSZ, ZrO2-8 Wt.% Y2O3) top coat. Second generation EBCs, with substantially improved performance compared with the first generation EBC, were developed in the NASA High Speed Research-Enabling Propulsion Materials (HSR-EPM) Program. The first generation EBC consisted of two layers, mullite (3Al2O3-2SiO2) bond coat and yttria-stabilized zirconia (YSZ, ZrO2-8 wt.% Y2O3) top coat. Second generation EBCs, with substantially improved performance compared with the first generation EBC, were developed in the NASA High Speed Research-Enabling Propulsion Materials (HSR-EPM) Program (5). They consist of three layers, a silicon first bond coat, a mullite or a mullite + BSAS (BaO(1-x)-SrO(x)-Al2O3-2SiO2) second bond coat, and a BSAS top coat. The EPM EBCs were applied on SiC/SiC CMC combustor liners in three Solar Turbines (San Diego, CA) Centaur 50s gas turbine engines. The combined operation of the three engines has accumulated over 24,000 hours without failure (approximately 1,250 C maximum combustor liner temperature), with the engine in Texaco, Bakersfield, CA, accumulating about 14,000 hours. As the

Mechanical and thermal properties of SrO/BaO modified Y2O3-Al2O3-B2O3-SiO2 glasses and their compatibility with solid oxide fuel cell components

NASA Astrophysics Data System (ADS)

Kaur, Navdeep; Kaur, Gurbinder; Kumar, Devender; Singh, K.

2018-07-01

In this study, various compositions of (30-x) SrO-xBaO-10Al2O3-45SiO2-5B2O3-10Y2O3 (mol%) (5 ≤ x ≤ 25) were synthesized using the melt-quench technique. The as-prepared glasses were characterized by X-ray diffraction, micro-hardness testing, dilatometry, and scanning electron microscopy to determine their thermal and mechanical properties. Powders of the glasses were used to make diffusion couples with Crofer 22 APU (interconnect) and yttria stabilized zirconia (YSZ) for the interfacial study. Diffusion couples of the pre-oxidized Crofer 22 APU/glasses and YSZ/glasses were tested for 500 h at 850 °C. The coefficients of thermal expansion obtained for all the glasses were in the required range for applications in solid oxide fuel cells. The highest hardness and fracture toughness were obtained for the glass with x = 10 mol% due to the mixed modifier effect. However, the glass with x = 15 mol% exhibited better adhesion with YSZ and Crofer 22 APU.

High Temperature Properties of an Alumina Enhanced Thermal Barrier

NASA Technical Reports Server (NTRS)

Leiser, Daniel B.; Smith, Marnell; Keating, Elizabeth A.

1987-01-01

The heatshield material requirements for future space vehicles (Aerobraking Orbital Transfer Vehicle & National Aerospace Plane) will depend upon the desired flight capability, configuration and location on the vehicle. These requirements will be more demanding and different from those derived for the materials used in the Shuttle Orbiter thermal protection system. Research was therefore initiated into improving the thermal efficiency of this class of materials by first characterizing their thermal and structural capabilities. Alternate material systems have been developed, tested, and compared with the baseline Shuttle system. This research resulted in the development of several very low density, high porosity (80-90%) materials with enhanced durability and temperature capability. One of the developments was a family of materials referred to as Fibrous Refractory Composite Insulation (FRCI) utilizing a mixture of fibers, each serving a unique purpose. One composition of the FRCI family with two fibers was adopted as a baseline material for use on the third and fourth Orbiters in selected areas due to its strength at a lower density compared to earlier materials. A further improvement in the FRCI family of materials is the Alumina Enhanced Thermal Barrier (AETB), a three-fiber composite. It has a higher temperature capability (composition dependent) than the baseline FRCI as proven by convective heating tests of one composition. AETB was studied to better characterize its performance at high temperature and the mechanisms by which its properties change. In conclusion, the shrinkage of AETB is a factor of six better than baseline FRCI at 1260 C (2300 F) with about a 20% improvement in mechanical properties. This improvement could translate into a 110 C (200 F) higher temperature capability in use as a heat shield material, but further testing in a convective heating environment is required to determine the actual improvement attainable.

An Effective Electrical Resonance-Based Method to Detect Delamination in Thermal Barrier Coating

NASA Astrophysics Data System (ADS)

Kim, Jong Min; Park, Jae-Ha; Lee, Ho Girl; Kim, Hak-Joon; Song, Sung-Jin; Seok, Chang-Sung; Lee, Young-Ze

2017-12-01

This research proposes a simple yet highly sensitive method based on electrical resonance of an eddy-current probe to detect delamination of thermal barrier coating (TBC). This method can directly measure the mechanical characteristics of TBC compared to conventional ultrasonic testing and infrared thermography methods. The electrical resonance-based method can detect the delamination of TBC from the metallic bond coat by shifting the electrical impedance of eddy current testing (ECT) probe coupling with degraded TBC, and, due to this shift, the resonant frequencies near the peak impedance of ECT probe revealed high sensitivity to the delamination. In order to verify the performance of the proposed method, a simple experiment is performed with degraded TBC specimens by thermal cyclic exposure. Consequently, the delamination with growth of thermally grown oxide in a TBC system is experimentally identified. Additionally, the results are in good agreement with the results obtained from ultrasonic C-scanning.

An Effective Electrical Resonance-Based Method to Detect Delamination in Thermal Barrier Coating

NASA Astrophysics Data System (ADS)

Kim, Jong Min; Park, Jae-Ha; Lee, Ho Girl; Kim, Hak-Joon; Song, Sung-Jin; Seok, Chang-Sung; Lee, Young-Ze

2018-02-01

This research proposes a simple yet highly sensitive method based on electrical resonance of an eddy-current probe to detect delamination of thermal barrier coating (TBC). This method can directly measure the mechanical characteristics of TBC compared to conventional ultrasonic testing and infrared thermography methods. The electrical resonance-based method can detect the delamination of TBC from the metallic bond coat by shifting the electrical impedance of eddy current testing (ECT) probe coupling with degraded TBC, and, due to this shift, the resonant frequencies near the peak impedance of ECT probe revealed high sensitivity to the delamination. In order to verify the performance of the proposed method, a simple experiment is performed with degraded TBC specimens by thermal cyclic exposure. Consequently, the delamination with growth of thermally grown oxide in a TBC system is experimentally identified. Additionally, the results are in good agreement with the results obtained from ultrasonic C-scanning.

Depth-Selective Diagnostics of Thermal Barrier Coatings Incorporating Thermographic Phosphors

NASA Technical Reports Server (NTRS)

Eldridge, Jeffrey I.; Bencic, Timothy J.; Allison, Stephen W.; Beshears, David L.

2003-01-01

Thermographic phosphors have been previously demonstrated to provide effective non-contact, emissivity-independent surface temperature measurements. Because of the translucent nature of thermal barrier coatings (TBCs), thermographic-phosphor-based temperature measurements can be extended beyond the surface to provide depth-selective temperature measurements by incorporating the thermographic phosphor layer at the depth where the temperature measurement is desired. In this paper, thermographic phosphor (Y2O3:Eu) fluorescence decay time measurements are demonstrated for the first time to provide through-the-coating-thickness temperature readings up to 1000 C with the phosphor layer residing beneath a 100-Fm-thick TBC (plasma-sprayed 8wt% yttria-stabilized zirconia). With an appropriately chosen excitation wavelength and detection configuration, it is shown that sufficient phosphor emission is generated to provide effective temperature measurements, despite the attenuation of both the excitation and emission intensities by the overlying TBC. This depth-selective temperature measurement capability should prove particularly useful for TBC diagnostics, where a large thermal gradient is typically present across the TBC thickness.

Depth-Selective Diagnostics of Thermal Barrier Coatings Incorporating Thermographic Phosphors

NASA Technical Reports Server (NTRS)

Eldridge, J. I.; Bencic, T. J.; Allison, S. W.; Beshears, D. L.

2003-01-01

Thermographic phosphors have been previously demonstrated to provide effective non- contact, emissivity-independent surface temperature measurements. Because of the translucent nature of thermal barrier coatings (TBCs), thermographic-phosphor-based temperature measurements can be extended beyond the surface to provide depth-selective temperature measurements by incorporating the thermographic phosphor layer at the depth where the temperature measurement is desired. In this paper, the use of thermographic phosphor (Y2O3:Eu) luminescence decay time measurements is demonstrated for the first time for through-the-thickness temperature readings up to 1000 C with the phosphor placed beneath a 100-micron-thick TBC (plasma-sprayed 8wt% yttria-stabilized zirconia). With an appropriately chosen excitation wavelength and detection configuration, it is shown that sufficient phosphor emission is generated to provide effective temperature measurements, despite the attenuation of both the excitation and emission intensities by the overlying TBC. This depth-selective temperature measurement capability should prove particularly useful for TBC diagnostics, where a large thermal gradient is typically present across the TBC thickness.

Thermal barrier coating life prediction model development, phase 2

NASA Technical Reports Server (NTRS)

Meier, Susan Manning; Sheffler, Keith D.; Nissley, David M.

1991-01-01

The objective of this program was to generate a life prediction model for electron-beam-physical vapor deposited (EB-PVD) zirconia thermal barrier coating (TBC) on gas turbine engine components. Specific activities involved in development of the EB-PVD life prediction model included measurement of EB-PVD ceramic physical and mechanical properties and adherence strength, measurement of the thermally grown oxide (TGO) growth kinetics, generation of quantitative cyclic thermal spallation life data, and development of a spallation life prediction model. Life data useful for model development was obtained by exposing instrumented, EB-PVD ceramic coated cylindrical specimens in a jet fueled burner rig. Monotonic compression and tensile mechanical tests and physical property tests were conducted to obtain the EB-PVD ceramic behavior required for burner rig specimen analysis. As part of that effort, a nonlinear constitutive model was developed for the EB-PVD ceramic. Spallation failure of the EB-PVD TBC system consistently occurred at the TGO-metal interface. Calculated out-of-plane stresses were a small fraction of that required to statically fail the TGO. Thus, EB-PVD spallation was attributed to the interfacial cracking caused by in-plane TGO strains. Since TGO mechanical properties were not measured in this program, calculation of the burner rig specimen TGO in-plane strains was performed by using alumina properties. A life model based on maximum in-plane TGO tensile mechanical strain and TGO thickness correlated the burner rig specimen EB-PVD ceramic spallation lives within a factor of about plus or minus 2X.

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

NASA Technical Reports Server (NTRS)

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.

Evaluation of present-day thermal barrier coatings for industrial/utility applications

NASA Technical Reports Server (NTRS)

Bratton, R. J.; Lau, S. K.; Lee, S. Y.

1980-01-01

Atmospheric burner rig tests have been conducted to evaluate the corrosion resistance of present-day thermal barrier coatings. The coatings are primarily plasma-sprayed and zirconia-based. Both duplex and graded coating systems were tested at a gas temperature of 2100 F and metal temperatures that range from 1475 F to 1650 F. The fuels ranged from clean GT No. 2 to that doped with impurity levels which simulate water-washed residual fuels. Results to date suggest that liquid sulfate condensates play an important role in the coating degradation mechanisms, whereas the role of vanadium and its salts is less clear.

Thermal barrier coating life prediction model development

NASA Technical Reports Server (NTRS)

Hillery, R. V.; Pilsner, B. H.; Mcknight, R. L.; Cook, T. S.; Hartle, M. S.

1988-01-01

This report describes work performed to determine the predominat modes of degradation of a plasma sprayed thermal barrier coating system and to develop and verify life prediction models accounting for these degradation modes. The primary TBC system consisted of a low pressure plasma sprayed NiCrAlY bond coat, an air plasma sprayed ZrO2-Y2O3 top coat, and a Rene' 80 substrate. The work was divided into 3 technical tasks. The primary failure mode to be addressed was loss of the zirconia layer through spalling. Experiments showed that oxidation of the bond coat is a significant contributor to coating failure. It was evident from the test results that the species of oxide scale initially formed on the bond coat plays a role in coating degradation and failure. It was also shown that elevated temperature creep of the bond coat plays a role in coating failure. An empirical model was developed for predicting the test life of specimens with selected coating, specimen, and test condition variations. In the second task, a coating life prediction model was developed based on the data from Task 1 experiments, results from thermomechanical experiments performed as part of Task 2, and finite element analyses of the TBC system during thermal cycles. The third and final task attempted to verify the validity of the model developed in Task 2. This was done by using the model to predict the test lives of several coating variations and specimen geometries, then comparing these predicted lives to experimentally determined test lives. It was found that the model correctly predicts trends, but that additional refinement is needed to accurately predict coating life.

Deposition stress effects on thermal barrier coating burner rig life

NASA Technical Reports Server (NTRS)

Watson, J. W.; Levine, S. R.

1984-01-01

A study of the effect of plasma spray processing parameters on the life of a two layer thermal barrier coating was conducted. The ceramic layer was plasma sprayed at plasma arc currents of 900 and 600 amps onto uncooled tubes, cooled tubes, and solid bars of Waspalloy in a lathe with 1 or 8 passes of the plasma gun. These processing changes affected the residual stress state of the coating. When the specimens were tested in a Mach 0.3 cyclic burner rig at 1130 deg C, a wide range of coating lives resulted. Processing factors which reduced the residual stress state in the coating, such as reduced plasma temperature and increased heat dissipation, significantly increased coating life.

Thermal Analysis of a Carbon Fiber Rope Barrier for Use in the Reusable Solid Rocket Motor Nozzle Joint-2

NASA Technical Reports Server (NTRS)

Clayton, J. Louie

2002-01-01

This study provides development and verification of analysis methods used to assess performance of a carbon fiber rope (CFR) thermal barrier system that is currently being qualified for use in Reusable Solid Rocket Motor (RSRM) nozzle joint-2. Modeled geometry for flow calculations considers the joint to be vented with the porous CFR barriers placed in the 'open' assembly gap. Model development is based on a 1-D volume filling approach where flow resistances (assembly gap and CFRs) are defined by serially connected internal flow and the porous media 'Darcy' relationships. Combustion gas flow rates are computed using the volume filling code by assuming a lumped distribution total joint fill volume on a per linear circumferential inch basis. Gas compressibility, friction and heat transfer are included in the modeling. Gas-to-wall heat transfer is simulated by concurrent solution of the compressible flow equations and a large thermal 2-D finite element (FE) conduction grid. The derived numerical technique loosely couples the FE conduction matrix with the compressible gas flow equations. Free constants that appear in the governing equations are calibrated by parametric model comparison to hot fire subscale test results. The calibrated model is then used to make full-scale motor predictions using RSRM aft dome environments. Model results indicate that CFR thermal barrier systems will provide a thermally benign and controlled pressurization environment for the RSRM nozzle joint-2 primary seal activation.

Thermal Analysis of a Carbon Fiber Rope Barrier for Use in the Reusable Solid Rocket Motor Nozzle Joint-2

NASA Technical Reports Server (NTRS)

Clayton, J. Louie; Phelps, Lisa (Technical Monitor)

2001-01-01

This study provides for development and verification of analysis methods used to assess performance of a carbon fiber rope (CFR) thermal barrier system that is currently being qualified for use in Reusable Solid Rocket Motor (RSRM) nozzle joint-2. Modeled geometry for flow calculations considers the joint to be vented with the porous CFR barriers placed in the "open' assembly gap. Model development is based on a 1-D volume filling approach where flow resistances (assembly gap and CFRs) are defined by serially connected internal flow and the porous media "Darcy" relationships. Combustion gas flow rates are computed using the volume filling code by assuming a lumped distribution total joint fill volume on a per linear circumferential inch basis. Gas compressibility, friction and heat transfer are included in the modeling. Gas-to-wall heat transfer is simulated by concurrent solution of the compressible flow equations and a large thermal 2-D finite element (FE) conduction grid. The derived numerical technique loosely couples the FE conduction matrix with the compressible gas flow equations, Free constants that appear in the governing equations are calibrated by parametric model comparison to hot fire subscale test results. The calibrated model is then used to make full-scale motor predictions using RSRM aft dome environments. Model results indicate that CFR thermal barrier systems will provide a thermally benign and controlled pressurization environment for the RSRM nozzle joint-2 primary seal activation.

On the rumpling instability in thermal barrier systems

NASA Astrophysics Data System (ADS)

Panat, Rahul Padmakar

Thermal barrier coatings (TBCs) are protective multi-layered metal-ceramic coatings used in hot sections of jet engines and gas turbines. The TBCs are composed of a superalloy substrate, an intermediate metallic bond coat (BC) and a ceramic topcoat. The TBCs are beset by reliability problems arising from delamination of the ceramic topcoat due to various instabilities in the system. The present work examines one such instability of "rumpling", or progressive roughening of the BC surface in the BC-superalloy systems upon high temperature exposure. A combined experimental and analytical approach is taken to study the rumpling phenomenon. Thermal cycling and isothermal experiments are carried out in air and in vacuum to identify the driving force and the kinetics governing rumpling. The experiments show that a nominally flat BC surface rumples to a wavelength of about 60--100 mum, and an amplitude of about 4--8 mum. The rumpling is seen to be relatively insensitive to the initial BC surface morphology. Significant initial flaws are not necessary for rumpling to occur. Further, rumpling occurs even in absence of thermal cycling. To explain BC rumpling, we develop a linear stability model for surface evolution of BCs under a remote stress. The driving force for this process is the in-plane stress in the BC due to its thermal mismatch with the substrate as indicated by the experimental results. The BC volume and BC surface diffusion governs the deformation kinetics. A governing equation is derived that gives the amplitude evolution of BC surface perturbations as a function of time. The analysis establishes a range of wavelengths for which the perturbation amplitude increases at a significantly higher rate as compared with other wavelengths. At the dominant instability wavelength, under low-stress and high-temperature conditions, the model shows that the roughening is caused only by volume diffusion, while smoothing is caused only by surface diffusion. The results from

Thermal Cycling Behavior of Thermal Barrier Coatings with MCrAlY Bond Coat Irradiated by High-Current Pulsed Electron Beam.

PubMed

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 Al 2 O 3 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.

Temperature Mapping of Air Film-Cooled Thermal Barrier Coated Surfaces Using Phosphor Thermometry

NASA Technical Reports Server (NTRS)

Eldridge, Jeffrey I.

2016-01-01

While the effects of thermal barrier coating (TBC) thermal protection and air film cooling effectiveness for jet engine components are usually studied separately, their contributions to combined cooling effectiveness are interdependent and are not simply additive. Therefore, combined cooling effectiveness must be measured to achieve an optimum balance between TBC thermal protection and air film cooling. Phosphor thermometry offers several advantages for mapping temperatures of air film cooled surfaces. While infrared thermography has been typically applied to study air film cooling effectiveness, temperature accuracy depends on knowing surface emissivity (which may change) and correcting for effects of reflected radiation. Because decay time-based full-field phosphor thermometry is relatively immune to these effects, it can be applied advantageously to temperature mapping of air film-cooled TBC-coated surfaces. In this presentation, an overview will be given of efforts at NASA Glenn Research Center to perform temperature mapping of air film-cooled TBC-coated surfaces in a burner rig test environment. The effects of thermal background radiation and flame chemiluminescence on the measurements are investigated, and the strengths and limitations of this method for studying air film cooling effectiveness are discussed.

Performance of two-layer thermal barrier systems on directionally solidified Ni-Al-Mo and comparative effects of alloy thermal expansion on system life

NASA Technical Reports Server (NTRS)

Stecura, S.

1980-01-01

A promising two-layer thermal barrier coating system (TBS), Ni-16.4Cr-5.1A1-0.15Y/ZrO2-6.1Y2O3 (all in weight percent), was identified for directionally solidified Ni-Al-Mo (gamma/gamma' alpha). In cyclic furnace tests at 1095 C this system on gamma/gamma' alpha was better than Ni-16. 4Cr-5.1Al-0.15Y/ZrO2-7.8Y2O3 by about 50 percent. In natural gas - oxygen torch rig tests at 1250 C the ZrO2-6.1Y2O3 coating was better than the ZrO2-7.8Y2O3 coating by 95 percent, on MAR-M509 substrates and by 60 percent on gamma/gamma' alpha substrates. Decreasing the coefficient of thermal expansion of the substrate material from 17-18x10 to the -6 power/C (MAR-M200 + Hf and MAR-M509) to 11x10 to the -6 power/C (gamma/gamma' alpha) also resulted in improved TBS life. For example, in natural gas - oxygen torch rig tests at 1250 C, the life of Ni-16.4Cr-5.1Al-0.15Y/ZrO26.1Y2O3 was about 30 percent better on gamma/gamma' alpha than on MAR-M509 substrates. Thus compositional changes in the bond and thermal barrier coatings were shown to have a greater effect on TBS life than does the coefficient of thermal expansion.

Plasma sprayed metal supported YSZ/Ni-LSGM-LSCF ITSOFC with nanostructured anode

NASA Astrophysics Data System (ADS)

Hwang, Changsing; Tsai, Chun-Huang; Lo, Chih-Hung; Sun, Cha-Hong

Intermediate temperature solid oxide fuel cells (ITSOFCs) supported by a porous Ni-substrate and based on Sr and Mg doped lanthanum gallate (LSGM) electrolyte, lanthanum strontium cobalt ferrite (LSCF) cathode and nanostructured yttria stabilized zirconia-nickel (YSZ/Ni) cermet anode have been fabricated successfully by atmospheric plasma spraying (APS). From ac impedance analysis, the sprayed YSZ/Ni cermet anode with a novel nanostructure and advantageous triple phase boundaries after hydrogen reduction has a low resistance. It shows a good electrocatalytic activity for hydrogen oxidation reactions. The sprayed LSGM electrolyte with ∼60 μm in thickness and ∼0.054 S cm -1 conductivity at 800 °C shows a good gas tightness and gives an open circuit voltage (OCV) larger than 1 V. The sprayed LSCF cathode with ∼30 μm in thickness and ∼30% porosity has a minimum resistance after being heated at 1000 °C for 2 h. This cathode keeps right phase structure and good porous network microstructure for conducting electrons and negative oxygen ions. The APS sprayed cell after being heated at 1000 °C for 2 h has a minimum inherent resistance and achieves output power densities of ∼440 mW cm -2 at 800 °C, ∼275 mW cm -2 at 750 °C and ∼170 mW cm -2 at 700 °C. Results from SEM, XRD, ac impedance analysis and I- V- P measurements are presented here.

Technical and Economical Aspects of Current Thermal Barrier Coating Systems for Gas Turbine Engines by Thermal Spray and EBPVD: A Review

NASA Astrophysics Data System (ADS)

Feuerstein, Albert; Knapp, James; Taylor, Thomas; Ashary, Adil; Bolcavage, Ann; Hitchman, Neil

2008-06-01

The most advanced thermal barrier coating (TBC) systems for aircraft engine and power generation hot section components consist of electron beam physical vapor deposition (EBPVD) applied yttria-stabilized zirconia and platinum modified diffusion aluminide bond coating. Thermally sprayed ceramic and MCrAlY bond coatings, however, are still used extensively for combustors and power generation blades and vanes. This article highlights the key features of plasma spray and HVOF, diffusion aluminizing, and EBPVD coating processes. The coating characteristics of thermally sprayed MCrAlY bond coat as well as low density and dense vertically cracked (DVC) Zircoat TBC are described. Essential features of a typical EBPVD TBC coating system, consisting of a diffusion aluminide and a columnar TBC, are also presented. The major coating cost elements such as material, equipment and processing are explained for the different technologies, with a performance and cost comparison given for selected examples.

Thermal stability and formation barrier of a high-energetic material N8 polymer nitrogen encapsulated in (5,5) carbon nanotube

NASA Astrophysics Data System (ADS)

Ji, Wei; Timoshevskii, V.; Guo, H.; Abou-Rachid, Hakima; Lussier, Louis-Simon

2009-07-01

We report the density functional theory total energy calculations of thermal stability and formation barrier of polymer nitrogen confined in carbon nanotubes (CNT). The analysis suggests that N8 polymer nitrogen encapsulated in (5,5) carbon nanotube [N8@CNT(5,5)] is thermally (meta)stable at a finite temperature up to energy scale of at least 5000 K, similar to nitrogen molecule gas phase confined in CNT [N2@CNT(5,5)]. The energetic difference between these two phases of N does not significantly change with temperature. A barrier of 1.07 eV was found for the formation of N8@CNT(5,5) from N2@CNT(5,5), while the dissociation barrier was found to be 0.2 eV. Snapshots of the reaction pathway show that the transition state is composed by a N2 and a N6 inside a CNT(5,5).

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

NASA Technical Reports Server (NTRS)

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.

Thermal barrier and support for nuclear reactor fuel core

DOEpatents

Betts, Jr., William S.; Pickering, J. Larry; Black, William E.

1987-01-01

A thermal barrier/core support for the fuel core of a nuclear reactor having a metallic cylinder secured to the reactor vessel liner and surrounded by fibrous insulation material. A top cap is secured to the upper end of the metallic cylinder that locates and orients a cover block and post seat. Under normal operating conditions, the metallic cylinder supports the entire load exerted by its associated fuel core post. Disposed within the metallic cylinder is a column of ceramic material, the height of which is less than that of the metallic cylinder, and thus is not normally load bearing. In the event of a temperature excursion beyond the design limits of the metallic cylinder and resulting in deformation of the cylinder, the ceramic column will abut the top cap to support the fuel core post.

Performance and emission characteristics of the thermal barrier coated SI engine by adding argon inert gas to intake mixture.

PubMed

Karthikeya Sharma, T

2015-11-01

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.

Performance and emission characteristics of the thermal barrier coated SI engine by adding argon inert gas to intake mixture

PubMed Central

Karthikeya Sharma, T.

2014-01-01

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. PMID:26644918

Investigation of failure mechanism of thermal barrier coatings (TBCs) deposited by EB-PVD technique

NASA Astrophysics Data System (ADS)

Shahid, M. R.; Abbas, Musharaf

2013-06-01

Failure mechanism of thermal barrier coatings (TBCs) prepared by electron beam physical vapor deposition (EB-PVD) technique owing to formation of micro cracks was investigated. The TBCs were deposited on the Ni-based super alloy IN-100 and the micro cracks were observed within the top ceramic coat of thermally cycled TBCs at 1050°C. It was observed that these cracks propagate in the ceramic coat in the direction normal to interface while no cracks were observed in the bond coat. SEM/EDS studies revealed that some non-uniform oxides were formed on the interface between ceramic top and metallic bond coat just below the cracks. Study proposed that the cracks were initiated due to stress owing to big difference in Pilling-Bed worth ratio of non-uniform oxides as well as thermal stress, which caused the formation of cracks in top ceramic coat leading to failure of TBCs

Micro heat barrier

DOEpatents

Marshall, Albert C.; Kravitz, Stanley H.; Tigges, Chris P.; Vawter, Gregory A.

2003-08-12

A highly effective, micron-scale micro heat barrier structure and process for manufacturing a micro heat barrier based on semiconductor and/or MEMS fabrication techniques. The micro heat barrier has an array of non-metallic, freestanding microsupports with a height less than 100 microns, attached to a substrate. An infrared reflective membrane (e.g., 1 micron gold) can be supported by the array of microsupports to provide radiation shielding. The micro heat barrier can be evacuated to eliminate gas phase heat conduction and convection. Semi-isotropic, reactive ion plasma etching can be used to create a microspike having a cusp-like shape with a sharp, pointed tip (<0.1 micron), to minimize the tip's contact area. A heat source can be placed directly on the microspikes. The micro heat barrier can have an apparent thermal conductivity in the range of 10.sup.-6 to 10.sup.-7 W/m-K. Multiple layers of reflective membranes can be used to increase thermal resistance.

Synthesis and Characterization of Yttria-Stabilized Zirconia Nanoparticles Doped with Ytterbium and Gadolinium: ZrO2 9.5Y2O3 5.6Yb2O3 5.2Gd2O3

NASA Astrophysics Data System (ADS)

Bahamirian, M.; Hadavi, S. M. M.; Rahimipour, M. R.; Farvizi, M.; Keyvani, A.

2018-03-01

Defect cluster thermal barrier coatings (TBCs) are attractive alternatives to Yttria-stabilized zirconia (YSZ) in advanced applications. In this study, YSZ nanoparticles doped with ytterbium and gadolinium (ZrO2 9.5Y2O3 5.6Yb2O3 5.2Gd2O3 (ZGYbY)) were synthesized through a chemical co-precipitation and calcination method, and characterized by in situ high-temperature X-ray diffraction analysis in the temperature range of 25 °C to 1000 °C (HTK-XRD), thermogravimetric analysis, differential thermal analysis, Fourier transform infrared spectroscopy, Raman spectroscopy, and field emission scanning electron microscopy (FE-SEM). Precise cell parameters of t-prime phase and the best zirconia phase for TBC applications were calculated by Cohen's and Rietveld refinement methods. Optimum crystallization temperature of the precursor powder was found to be 1000 °C. Furthermore, FE-SEM results for the calcined ZGYbY powders indicated orderly particles of uniform shape and size with a small tendency toward agglomeration. Average lattice thermal expansion coefficient in the temperature range of 25 °C to 1000 °C was determined to be 31.71 × 10-6 K-1.

Synthesis and Characterization of Yttria-Stabilized Zirconia Nanoparticles Doped with Ytterbium and Gadolinium: ZrO2 9.5Y2O3 5.6Yb2O3 5.2Gd2O3

NASA Astrophysics Data System (ADS)

Bahamirian, M.; Hadavi, S. M. M.; Rahimipour, M. R.; Farvizi, M.; Keyvani, A.

2018-06-01

Defect cluster thermal barrier coatings (TBCs) are attractive alternatives to Yttria-stabilized zirconia (YSZ) in advanced applications. In this study, YSZ nanoparticles doped with ytterbium and gadolinium (ZrO2 9.5Y2O3 5.6Yb2O3 5.2Gd2O3 (ZGYbY)) were synthesized through a chemical co-precipitation and calcination method, and characterized by in situ high-temperature X-ray diffraction analysis in the temperature range of 25 °C to 1000 °C (HTK-XRD), thermogravimetric analysis, differential thermal analysis, Fourier transform infrared spectroscopy, Raman spectroscopy, and field emission scanning electron microscopy (FE-SEM). Precise cell parameters of t-prime phase and the best zirconia phase for TBC applications were calculated by Cohen's and Rietveld refinement methods. Optimum crystallization temperature of the precursor powder was found to be 1000 °C. Furthermore, FE-SEM results for the calcined ZGYbY powders indicated orderly particles of uniform shape and size with a small tendency toward agglomeration. Average lattice thermal expansion coefficient in the temperature range of 25 °C to 1000 °C was determined to be 31.71 × 10-6 K-1.

Oxidation of Alumina-Forming MAX Phases in Turbine Environments

NASA Technical Reports Server (NTRS)

Smialek, James; Garg, Anita; Harder, Bryan; Nesbitt, James; Gabb, Timothy; Gray, SImon

2017-01-01

Protective coatings for high temperature turbine components are based on YSZ thermal barriers and oxidation resistant, alumina-forming NiAl or NiCoCrAlY bond coats. Ti2AlC and Cr2AlC MAX phases are thus of special interest because of good oxidation resistance and CTE that can match Al2O3 and YSZ. Their alumina scales grow according to cubic kinetics due to grain growth in the scale, with initial heating dominated by fast TiO2 growth. Protective cubic kinetics are also found in high pressure burner rig tests of MAXthal 211 Ti2AlC, but with reduced rates due to volatile TiO(OH)2 formation in water vapor. YSZ-coatings on bulk Ti2AlC exhibit remarkable durability up to 1300C in furnace tests and at least a 25x life advantage compared to superalloys. At another extreme, Cr2AlC is resistant to low temperature Na2SO4 hot corrosion and exhibits thermal cycling stability bonded to a superalloy disk material. Accordingly, sputtered Cr2AlC coatings on disk specimens prevented hot corrosion detriments on LCF. Breakaway oxidation (Ti2AlC), scale spallation (Cr2AlC), interdiffusion, and processing as coatings still present serious challenges. However the basic properties of MAX phases provide some unusual opportunities for use in high temperature turbines.

Structural evolution of plasma-sprayed nanoscale 3 mol% and 5 mol% yttria-stabilized zirconia coatings during sintering

NASA Astrophysics Data System (ADS)

Zhao, Yan; Gao, Yang

2017-12-01

The microstructure of plasma-sprayed nanostructured yttria-stabilized zirconia (YSZ) coatings may change during high-temperature exposure, which would influence the coating performance and service lifetime. In this study, the phase structure and the microstructural evolution of 3YSZ (zirconia-3 mol% yttria) and 5YSZ (zirconia-5 mol% yttria) nanostructured coatings were investigated by means of sintering at 1400 °C for 50-100 h. The microhardness, elastic moduli, and thermal shock cycles of the 3YSZ and 5YSZ nanostructured coatings were also investigated. The results showed that the redistribution of yttrium ions at 1400 °C caused the continuous increase of monoclinic-phase zirconia, but no obvious inter-splat cracking formed at the cross-sections, even after 100 h. Large voids appeared around the nanoporous zone because of the sintering of nanoscale granules upon high-temperature exposure. The microhardness and elastic moduli of the nanostructured coatings first increased and then decreased with increasing sintering times. The growth rate of the nanograins in the 3YSZ coating was lower than that in 5YSZ, which slowed the changes in 3YSZ coating porosity during sintering. Although the 3YSZ coating was prone to monoclinic phase transition, the experimental results showed that the thermal shock resistance of the 3YSZ coating was better than that of the 5YSZ coating.

Scandia-and-Yttria-Stabilized Zirconia for Thermal Barriers

NASA Technical Reports Server (NTRS)

Mess, Derek

2003-01-01

yttria in suitable proportions has shown promise of being a superior thermal- barrier coating (TBC) material, relative to zirconia stabilized with yttria only. More specifically, a range of compositions in the zirconia/scandia/yttria material system has been found to afford increased resistance to deleterious phase transformations at temperatures high enough to cause deterioration of yttria-stabilized zirconia. Yttria-stabilized zirconia TBCs have been applied to metallic substrates in gas turbine and jet engines to protect the substrates against high operating temperatures. These coatings have porous and microcracked structures, which can accommodate strains induced by thermal-expansion mismatch and thermal shock. The longevity of such a coating depends upon yttria as a stabilizing additive that helps to maintain the zirconia in an yttria-rich, socalled non-transformable tetragonal crystallographic phase, thus preventing transformation to the monoclinic phase with an associated deleterious volume change. However, at a temperature greater than about 1,200 C, there is sufficient atomic mobility that the equilibrium, transformable zirconia phase is formed. Upon subsequent cooling, this phase transforms to the monoclinic phase, with an associated volume change that adversely affects the integrity of the coating. Recently, scandia was identified as a stabilizer that could be used instead of, or in addition to, yttria. Of particular interest are scandia-and-yttria-stabilized zirconia (SYSZ) compositions of about 6 mole percent scandia and 1 mole percent yttria, which have been found to exhibit remarkable phase stability at a temperature of 1,400 C in simple aging tests. Unfortunately, scandia is expensive, so that the problem becomes one of determining whether there are compositions with smaller proportions of scandia that afford the required high-temperature stability. In an attempt to solve this problem, experiments were performed on specimens made with reduced

Furnace Cyclic Oxidation Behavior of Multicomponent Low Conductivity Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Zhu, Dongming; Nesbitt, James A.; Barrett, Charles A.; McCue, Terry R.; Miller, Robert A.

2004-03-01

Ceramic thermal barrier coatings (TBCs) will play an increasingly important role in advanced gas turbine engines due to their ability to further increase engine operating temperatures and reduce cooling, thus helping achieve future engine low emission, high efficiency, and improved reliability goals. Advanced multicomponent zirconia (ZrO2)-based TBCs are being developed using an oxide defect clustering design approach to achieve the required coating low thermal conductivity and high-temperature stability. Although the new composition coatings were not yet optimized for cyclic durability, an initial durability screening of the candidate coating materials was conducted using conventional furnace cyclic oxidation tests. In this paper, furnace cyclic oxidation behavior of plasma-sprayed ZrO2-based defect cluster TBCs was investigated at 1163°C using 45 min hot-time cycles. The ceramic coating failure mechanisms were studied using scanning electron microscopy (SEM) combined with x-ray diffraction (XRD) phase analysis after the furnace tests. The coating cyclic lifetime is also discussed in relation to coating processing, phase structures, dopant concentration, and other thermo-physical properties.

Combined Mode I and Mode II Fracture of Plasma-Sprayed Thermal Barrier Coatings at Ambient and Elevated Temperatures

NASA Technical Reports Server (NTRS)

Choi, Sung R.; Zhu, Dongming; Miller, Robert A.

2003-01-01

The mode I, mode II, and combined mode I-mode II fracture behavior of ZrO2 - 8wt%Y2O3 thermal barrier coatings was determined in asymmetric flexure loading at both ambient and elevated temperatures. Precracks were introduced in test specimens using the single-edge-v-notched beam (SEVNB) method incorporated with final diamond polishing to achieve sharp crack tips. 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 behaviors of the coating material were compared with those of monolithic advanced ceramics determined previously. The mixed-mode fracture behavior of the plasma- sprayed thermal barrier coating material was predicted in terms of fracture envelope and propagation angle using mixed-mode fracture theories.

Mid-Infrared Reflectance Imaging of Thermal-Barrier Coatings

NASA Technical Reports Server (NTRS)

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

Liquid Feedstock Plasma Spraying: An Emerging Process for Advanced Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Markocsan, Nicolaie; Gupta, Mohit; Joshi, Shrikant; Nylén, Per; Li, Xin-Hai; Wigren, Jan

2017-08-01

Liquid feedstock plasma spraying (LFPS) involves deposition of ultrafine droplets of suspensions or solution precursors (typically ranging from nano- to submicron size) and permits production of coatings with unique microstructures that are promising for advanced thermal barrier coating (TBC) applications. This paper reviews the recent progress arising from efforts devoted to development of high-performance TBCs using the LFPS approach. Advancements in both suspension plasma spraying and solution precursor plasma spraying, which constitute the two main variants of LFPS, are presented. Results illustrating the different types of the microstructures that can be realized in LFPS through appropriate process parameter control, model-assisted assessment of influence of coating defects on thermo-mechanical properties and the complex interplay between pore coarsening, sintering and crystallite growth in governing thermal conductivity are summarized. The enhancement in functional performances/lifetime possible in LFPS TBCs with multilayered architectures and by incorporating new pyrochlore chemistries such as gadolinium zirconate, besides the conventional single 8 wt.% yttria-stabilized zirconia insulating ceramic layer, is specifically highlighted.

Novel thermal barrier coatings (TBCs) that are resistant to high temperature attack by calcium oxide-magnesium oxide-silicon oxide-aluminum oxide (CMAS) glassy deposits

NASA Astrophysics Data System (ADS)

Aygun, Aysegul

2008-10-01

Higher performance and durability requirements of gas-turbine engines will require a new generation of thermal barrier coatings (TBCs). This is particularly true of engines operated at higher temperatures, where TBCs are subjected to attack by CaO-MgO-Al2O3-SiO 2 (CMAS) glassy deposits. In this work, a new approach for mitigating CMAS attack on TBCs is introduced, where up to 20 mol% Al2O 3 and 5 mol% TiO2 in the form of a solid solution is incorporated into Y2O3-stabilized ZrO2 (YSZ) TBCs. The fabrication of such TBCs with engineered chemistries is made possible by the solution-precursor plasma spray (SPPS) process, which is uniquely suited for depositing coatings of metastable ceramics with extended solid-solubilities. In the current work, the TBC serves as a reservoir of Al and Ti solutes, which are incorporated into the molten CMAS glass that is in contact with the TBC. An accumulation of Al concentration in the CMAS glass as it penetrates the TBC shifts the glass composition from the difficult-to-crystallize psuedowollastonite field to the easy-to-crystallize anorthite field. The incorporation of Ti in the glass promotes crystallization of the CMAS glass by serving as a nucleating agent. This combined effect results in the near-complete crystallization of the leading edge of the CMAS front into anorthite, essentially arresting the front. Both of these phenomena will help crystallize the CMAS glass, making it immobile and ineffective in penetrating the TBC. It is shown that incorporation of both Al and Ti in the CMAS glass is essential for this approach to be effective. Additionally, incorporation of Al and Ti as solutes is expected to alleviate thermal-expansion and thermal-conductivity issues associated with crystalline second phases used before. Moreover, the metastable nature of the Al and Ti solutes will make them more readily available for incorporation in the molten CMAS glass. CMAS interactions with SPPS TBCs of various metastable compositions are

Developing Cost-Effective Dense Continuous SDC Barrier Layers for SOFCs

DOE Office of Scientific and Technical Information (OSTI.GOV)

Nguyen, Hoang Viet P.; Hardy, John S.; Coyle, Christopher A.

Significantly improved performance during electrochemical testing of a cell with a dense continuous pulsed laser deposited (PLD) samarium doped ceria (SDC) layer spurred investigations into the fabrication of dense continuous SDC barrier layers by means of cost-effective deposition using screen printing which is amenable to industrial production of SOFCs. Many approaches to improve the SDC density have been explored including the use of powder with reduced particle sizes, inks with increased solids loading, and doping with sintering aids (1). In terms of sintering aids, dopants like Mo or binary systems of Mo+Cu or Fe+Co greatly enhance SDC sinterability. In fact,more » adding dopants to a screen printed, prefired, porous SDC layer made it possible to achieve a dense continuous barrier layer atop the YSZ electrolyte without sintering above 1200°C. Although the objective of fabricating a dense continuous layer was achieved, additional studies have been initiated to improve the cell performance. Underlying issues with constrained sintering and dopant-enhanced ceria-zirconia solid solubility are also addressed in this paper.« less

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

NASA Technical Reports Server (NTRS)

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.

Perspective on thermal barrier coatings for industrial gas turbine applications

NASA Technical Reports Server (NTRS)

Mutasim, Z. Z.; Hsu, L. L.; Brentnall, W. D.

1995-01-01

Thermal Barrier Coatings (TBC's) have been used in high thrust aircraft engines for many years, and have proved to be very effective in allowing higher turbine inlet temperatures. TBC life requirements for aircraft engines are typically less than those required in industrial gas turbines. The use of TBC's for industrial gas turbines can increase if durability and longer service life can be successfully demonstrated. This paper will describe current and future applications of TBC's in industrial gas turbine engines. Early testing and applications of TBC's will also be reviewed. This paper focuses on the key factors that are expected to influence utilization of TBC's in advanced industrial gas turbine engines. It is anticipated that reliable, durable and high effective coating systems will be produced that will ultimately improve engine efficiency and performance.

Oxidation behavior of a thermal barrier coating

NASA Technical Reports Server (NTRS)

Miller, R. A.

1984-01-01

Thermal barrier coatings, consisting of a plasma sprayed calcium silicate ceramic layer and a CoCrAlY or NiCrAlY bond coat, were applied on B-1900 coupons and cycled hourly in air in a rapid-response furnace to maximum temperatures of 1030, 1100, or 1160 C. Eight specimens were tested for each of the six conditions of bond-coat composition and temperature. Specimens were removed from test at the onset of failure, which was taken to be the formation of a fine surface crack visible at 10X magnification. Specimens were weighed periodically, and plots of weight gain vs time indicate that weight is gained at a parabolic rate after an initial period where weight was gained at a much greater rate. The high initial oxidation rate is thought to arise from the initially high surface area in the porous bond coat. Specimen life (time to first crack) was found to be a strong function of temperature. However, while test lives varied greatly with time, the weight gain at the time of specimen failure was quite insensitive to temperature. This indicates that there is a critical weight gain at which the coating fails when subjected to this test.

Combined Mode I and Mode II Fracture of Plasma-Sprayed Thermal Barrier Coatings at Ambient and Elevated Temperatures

NASA Technical Reports Server (NTRS)

Choi, Sung R.; Zhu, Dongming; Miller, Robert A.

2003-01-01

The mode I, mode II, and combined mode I-mode II fracture behavior of ZrO2- 8wt%Y2O3 thermal barrier coatings was determined in asymmetric flexure loading at both ambient and elevated temperatures. Precracks were introduced in test specimens using the single-edge-v-notched beam (SEVNB) method incorporated with final diamond polishing to achieve sharp crack tips. 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 K(sub I)/K(sub II) were also determined. The mixed-mode fracture behaviors of the coating material were compared with those of monolithic advanced ceramics determined previously. The mixed-mode fracture behavior of the plasma-sprayed thermal barrier coating material was predicted in terms of fracture envelope and propagation angle using mixed-mode fracture theories.

The impact of steam and current density on carbon formation from biomass gasification tar on Ni/YSZ, and Ni/CGO solid oxide fuel cell anodes

NASA Astrophysics Data System (ADS)

Mermelstein, Joshua; Millan, Marcos; Brandon, Nigel

The combination of solid oxide fuel cells (SOFCs) and biomass gasification has the potential to become an attractive technology for the production of clean renewable energy. However the impact of tars, formed during biomass gasification, on the performance and durability of SOFC anodes has not been well established experimentally. This paper reports an experimental study on the mitigation of carbon formation arising from the exposure of the commonly used Ni/YSZ (yttria stabilized zirconia) and Ni/CGO (gadolinium-doped ceria) SOFC anodes to biomass gasification tars. Carbon formation and cell degradation was reduced through means of steam reforming of the tar over the nickel anode, and partial oxidation of benzene model tar via the transport of oxygen ions to the anode while operating the fuel cell under load. Thermodynamic calculations suggest that a threshold current density of 365 mA cm -2 was required to suppress carbon formation in dry conditions, which was consistent with the results of experiments conducted in this study. The importance of both anode microstructure and composition towards carbon deposition was seen in the comparison of Ni/YSZ and Ni/CGO anodes exposed to the biomass gasification tar. Under steam concentrations greater than the thermodynamic threshold for carbon deposition, Ni/YSZ anodes still exhibited cell degradation, as shown by increased polarization resistances, and carbon formation was seen using SEM imaging. Ni/CGO anodes were found to be more resilient to carbon formation than Ni/YSZ anodes, and displayed increased performance after each subsequent exposure to tar, likely due to continued reforming of condensed tar on the anode.

Ionic conductivity and thermal stability of magnetron-sputtered nanocrystalline yttria-stabilized zirconia

NASA Astrophysics Data System (ADS)

Sillassen, M.; Eklund, P.; Sridharan, M.; Pryds, N.; Bonanos, N.; Bøttiger, J.

2009-05-01

Thermally stable, stoichiometric, cubic yttria-stabilized zirconia (YSZ) thin-film electrolytes have been synthesized by reactive pulsed dc magnetron sputtering from a Zr-Y (80/20 at. %) alloy target. Films deposited at floating potential had a ⟨111⟩ texture. Single-line profile analysis of the 111 x-ray diffraction peak yielded a grain size of ˜20 nm and a microstrain of ˜2% regardless of deposition temperature. Films deposited at 400 °C and selected bias voltages in the range from -70 to -200 V showed a reduced grain size for higher bias voltages, yielding a grain size of ˜6 nm and a microstrain of ˜2.5% at bias voltages of -175 and -200 V with additional incorporation of argon. The films were thermally stable; very limited grain coarsening was observed up to an annealing temperature of 800 °C. Temperature-dependent impedance spectroscopy analysis of the YSZ films with Ag electrodes showed that the in-plane ionic conductivity was within one order of magnitude higher in films deposited with substrate bias corresponding to a decrease in grain size compared to films deposited at floating potential. This suggests that there is a significant contribution to the ionic conductivity from grain boundaries. The activation energy for oxygen ion migration was determined to be between 1.14 and 1.30 eV.

YSZ-based sensor using Cr-Fe-based spinel-oxide electrodes for selective detection of CO.

PubMed

Anggraini, Sri Ayu; Fujio, Yuki; Ikeda, Hiroshi; Miura, Norio

2017-08-22

A selective carbon monoxide (CO) sensor was developed by the use of both of CuCrFeO 4 and CoCrFeO 4 as the sensing electrode (SE) for yttria-stabilized zirconia (YSZ)-based potentiometric sensor. The sensing-characteristic examinations of the YSZ-based sensors using each of spinel oxides as the single-SE sensor showed that CuCrFeO 4 -SE had the ability to detect CO, hydrocarbons and NO x gases, while CoCrFeO 4 -SE was sensitive to hydrocarbons and NO x gases. Thus, when both SEs were paired as a combined-SEs sensor, the resulting sensor could generate a selective response to CO at 450 °C under humid conditions. The sensor was also capable of detecting CO in the concentration range of 20-700 ppm. Its sensing mechanism that was examined via polarization-curve measurements was confirmed to be based on mixed-potential model. The CO response generated by the combined-SEs sensor was unaffected by the change of water vapor concentration in the range of 1.3-11.5 vol% H 2 O. Additionally, the sensing performance was stable during 13 days tested. Copyright © 2017 Elsevier B.V. All rights reserved.

Delamination Mechanisms of Thermal and Environmental Barrier Coatings on SiC/SiC Ceramic Matrix Composites