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 processing for turbine blade is due in part to part size, surface finish requirements, thickness control needs, and hole closure issues. Process development ofPVD TBCs has been carried out at several different sites, including GE Aircraft Engines (GEAE). The influence of processing variables on microstructure is discussed, along with the GEAE development coater and initial experiences of pilot line operation.
The higher performance levels of modem gas turbine engines present significant challenges in the reliability of materials in the turbine. The increased engine temperatures required to achieve the higher performance levels reduce the strength of the materials used in the turbine sections of the engine. Various forms of Thermal Barrier Coatings (rBCs) have been used for many years to increase the reliability of gas turbine engine components.Recent experience with the Physical Vapor Deposition (PVD) process using ceramic material has demonstrated success in extending the service life of turbine blades and nozzles. Engine testing has also revealed the TBC is susceptible to high angle particle impact damage.Sand particles and other engine debris impact the TBC surface at the leading edge of airfoils and fracture the PVD columns. As the impacting continues the TBC erodes away in local areas. Analysis of the eroded areas has shown a slight increase in temperature over a fully coated area, however, a significant temperature reduction was realized over an airfoil without any TBC.
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