Advanced thermal barrier coatings are essential to further increase the efficiency of gas turbine engines. One limiting factor of the TBC lifetime is the temperature dependent formation of the thermally grown oxide (TGO) during thermal exposure resulting in critical stress levels at the top coat -bond coat interface. Oxide dispersion strengthened (ODS) bond coats demonstrated slower oxygen scale growth during thermal exposure in comparison to standard bond coats.In this study for the first time TBC samples on single-crystal substrates (comparable to CMSX4) with thin ODS Co-based flash coats on the same Co-based bond coat (Amdry 995) and a porous atmospherically plasma sprayed (APS) yttria stabilized zirconia (YSZ) topcoat were manufactured by thermal spray techniques and evaluated with respect to their thermal cyclic behavior. As the major performance test cyclic burner rigs, which can establish thermal conditions similar to those in gas turbines, were applied.TBC samples with the new material combination show superior performance compared to previous samples. Cross sections of the samples were analyzed by scanning electron and laser scanning microscopy. Lifetime data and failure mode of the samples are discussed with respect to material properties such as thermal expansion coefficients, microstructural changes and TGO growth.
Thermal barrier coatings (TBCs) are commonly used to protect gas turbine components from high temperatures and oxidation. Such coatings consist of ceramic top coats and metallic bond coats. The mismatch in thermal expansion of the top coat, the bond coat and the component material is one main factor leading to the failure of the coating system. Columnar-structured top coats offer an enhanced tolerance to the strain during thermal cycling. On a flat bond coated surface, these TBCs reach higher thermal cycling performance. However, on rough surfaces, as used for thermal spray coatings, the performance of these thermal barrier coatings seems to be restricted or even stays below the performance of atmospheric-plasma-sprayed (APS) thermal barrier coatings. This low performance is linked to out-of-plane stresses at the interface between the top coat and the bond coat. In this study, a thin additional oxide-dispersion-strengthened (ODS) bond coat with high alumina content provides a reduced mismatch of the coefficient of thermal expansion (CTE) between the top coat and the bond coat. Columnar suspension plasma sprayed (SPS), yttria-stabilized zirconia (YSZ) TBCs were combined with low-CTE ODS bond coats. The behavior of these TBCs was characterized with respect to thermal cycling performance and degradation in a burner-rig facility. The comparison showed an up-to-four-fold increase in the performance of the new system.
Nine commercial and experimental powders from the MgO/Al2O3 system have been investigated in the present project. The composition ranged from MgO/MgAl2O4 composites with more than 70% MgO to an alumina-rich spinel powder (94% Al2O3). The powders were fused and crushed or agglomerated and sintered. The influence of the composition, the manufacturing route as well as the particle size distribution on the microstructure and the phases in the produced coatings have been investigated. For several of the powders, detailed design of experiment plans have been made and properties such as deposition efficiency, hardness and porosity were optimized. With optimized spray conditions coatings have been produced from all powders which were characterized in depth. Here, the results of microstructure, porosity values and thermal cyclic tests will be presented in more detail.
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