Traditionally, thermal barrier coatings (TBCs) are used in gas turbine engines to create an insulation layer between the metallic components and the gases in the hot section. Atmospheric plasma spray (APS) is a common method used to produce TBCs. The goal of this study is to study the porosity and thermal cycling behavior of standard (STD) and vertically cracked (VC) thermal barrier coatings (TBCs) fabricated by Atmospheric Plasma Spray (APS) for two different thicknesses, 300 and 600 μm respectively. Electron Beam Physical Vapor Deposition (EBPVD) coatings with 300 micron thickness prepared under tumbled and non-tumbled conditions were studied. For this study, mercury porosimeter equipment (POREMASTER 33) by Quantachrome Instruments was used to measure porosity, and pore size distribution. Scanning Electron Microscopy (SEM) images were obtained for all the samples. The images showed clear microstructural difference between the APS and EBPVD coatings. All the coatings were thermal cycled to 1200°C and the conventional APS-STD (300μm) performed the best followed by APS-VC coatings and EBPVD coatings which performed similarly.
Thermal barrier coatings (TBCs) are used in gas turbine engines to achieve higher turbine inlet temperatures (TITs), improve turbine operating temperatures, reduce fuel consumption, increase components lives and thus lead to better turbine efficiency. Yttria-stabilized zirconia (YSZ), is an ideal candidate for TBCs as it has good thermal shock resistance, high thermal stability, low density, and low thermal conductivity. Traditionally, there are two main methods of fabricating TBCs: air plasma spray (APS) TBCs and electron beam physical vapor deposition (EBPVD) TBCs. It is the objective of this paper to study the effects of APS TBC microstructures in comparison with EBPVD TBCs deposited on NiCoCrAlYHf bond coated In738 substrate material for applications in advanced gas turbines. The bond coat NiCoCrAlY contains 0.25w% Hf which is expected to improve the reliability of standard (STD) and vertically cracked (VC) APS TBC material. TBC top coatings of 300 μm and 600 μm thickness for both standard and VC APS TBC and 300 μm EBPVD TBC were further investigated to determine the effect of coating thickness of TBC performance. Selected test specimens were evaluated for dry and wet thermal cyclic oxidation performance. Thermal property determination of select samples was achieved using a laser flash system that measures the thermal diffusivity and specific heat capacity from which the thermal conductivity is calculated. Lastly, select YSZ-Al2O3 composite structures were analyzed in addition to APS and EBPVD TBC microstructure, porosity, and thermal conductivity determination using a variety of analytical techniques. A laser flash system was used to measure the thermal diffusivity for all the samples. A POREMASTER 33 system was used to measure the porosity of the APS and EBPVD samples.
Thermal barrier coatings (TBCs) are used in gas turbine engines to achieve a higher working temperature, and thus lead to a better efficiency. Yttria-stabilized-zirconia (YSZ), a material with low thermal conductivity, is commonly used as the top coat layer to provide the thermal barrier effect. Recent studies demonstrated that YSZ-Al2O3 composite layer could reduce the oxygen diffusion through the TBC, thus YSZ-Al2O3 composite layer potentially could be used to mitigate the spalling induced failure of a TBC coating. The goal of this study is to investigate the effect of the addition of Al2O3 on the thermal properties of YSZ based TBCs. In this study, a stainless steel die was used to make disk shaped samples with 0, 1, 2, 3, 4 and 5 wt% Al2O3 /YSZ powder ratios under uniaxial pressure. A laser flash system was used to measure the thermal diffusivity for all samples and the porosity of the samples is measured using mercury porosimetry. It is found that adding Al2O3 to YSZ decreases the thermal conductivity and increases the porosity of the ceramic composites.
Yttria-Stabilized-Zirconia (YSZ) is the most common material used in the fabrication of Thermal Barrier Coatings (TBCs) for gas turbine applications. Due to the low thermal conductivity and a small mismatch of the thermal expansion coefficient to the high temperature alloy, YSZ is commonly used as the top coat layer to provide a thermal barrier effect. The aim of this work is to study the thermo-physical properties of standard (STD) and vertically cracked (VC) thermal barrier coatings fabricated by Atmospheric Plasma Spray (APS) for two different thicknesses, 400 and 600 μm respectively. This paper reports the thermal diffusivity, thermal conductivity, specific heat, porosity, and scanning electron microscope (SEM) images of STD-TBC samples and VC-TBC samples. In addition, a heat transfer model is presented for the STD-TBC and VC-TBC microstructures. The results show an increase in both thermal diffusivity and conductivity for the VC-TBC samples, compared to the STD-TBC sample over the temperature range tested (400°C to 800°C). In addition, there is a temperature dependence of the thermal diffusivity and the thermal conductivity for both VC-TBC and STD-TBC samples. The change of thermo-physical properties is directly linked to the microstructure of the samples, demonstrated by the porosity measurements, SEM images, and the heat transfer model.
Thermal barrier coatings (TBCs) are used in gas turbine engines to achieve a higher working temperature and thus lead to a better efficiency. Yttria-Stabilized-Zirconia (YSZ), a material with low thermal conductivity, is commonly used as the TBC top coat to provide the thermal barrier effect. In this paper, an analytical model is proposed to estimate the effective thermal conductivity of the TBCs based on the microstructures. This model includes the micro structure details, such as grain size, pore size, volume fraction of pores, and the interfacial resistance. To validate the model, two sets of TBC samples were fabricated and tested for thermal conductivity and associated microstructures. The first set of samples were disk shaped YSZ-Al2O3 samples fabricated using a pressing machine. The YSZ-Al2O3 powder mixture was 0, 1, 2, 3, 4 and 5 wt% Al2O3/YSZ powder ratio. The second set of samples were fabricated by Atmospheric Plasma Spray process for two different microstructure configurations, standard (STD) and vertically cracked (VC), at two different thicknesses, 400 and 700 urn respectively. A laser flash system was used to measure the thermal conductivity of the coatings. Experiments were performed over the temperature range from 100°C to 800°C. The porosity of the YSZ samples was measured using a mercury porosimetry analyzer, POREMASTER 33 system. A Scanning Electron Microscope (SEM) was used to study the microstructure of the samples. It is observed that the microstructure and the porosity are directly linked with the thermal conductivity values. The relationship of the properties to the real microstructure determines the validity of the proposed model.
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