Thermal barrier coatings (TBCs) using yttria‐stabilized zirconium dioxide (YSZ) are widely used in gas turbines to protect metal components against the high combustion product temperature. Increasing combustion temperature and pressure, radiative heat transfer becomes an essential portion of the overall heat transfer in TBCs. This necessitates a greater understanding of the thermal radiative properties of YSZ films, especially in the near‐infrared wavelength range. The commonly used Kubelka–Munk (KM) method in the radiative property reduction from the measured transmittance and reflectance spectra of YSZ films can incur inaccurate results when the coating optical thickness is not sufficiently large. The discrete ordinates method with the asymmetric spherical ring angular quadrature can solve the radiative transfer equation with good accuracy in optically thin media. Considering the solution accuracy and computational efficiency, a hybrid approach of combining the KM and discrete ordinate methods is used to invert radiative properties. The absorption and scattering coefficients of air plasma sprayed YSZ films are determined over the wavelength range from 1 to 2.6 μm at room temperature. Over this near‐infrared wavelength range, the scattering coefficient decreases with the increasing wavelength, and the absorption coefficient is very small overall.
Air plasma sprayed (APS) thermal barrier coatings (TBCs) are a widely used technology in the gas turbine industry to thermally insulate and protect underlying metallic superalloy components. These TBCs are designed to have intrinsically low thermal conductivity while also being structurally compliant to withstand cyclic thermal excursions in a turbine environment. This study examines yttria-stabilized zirconia (YSZ) TBCs of varying architecture: porous and dense vertically cracked (DVC), which were deposited onto bond-coated superalloys and tested in a novel CO 2 laser rig. Additionally, multilayered TBCs: a two-layered YSZ (dense + porous) and a multi-material YSZ/GZO TBC were evaluated using the same laser rig. Cyclic exposure under simulative thermal gradients was carried out using the laser rig to evaluate the microstructural change of these different TBCs over time. During the test, real-time calculations of the normalized thermal conductivity of the TBCs were also evaluated to elucidate information about the nature of the microstructural change in relation to the starting microstructure and composition. It was determined that porous TBCs undergo steady increases in conductivity, whereas DVC and YSZ/GZO systems experience an initial increase followed by a monotonic decrease in conductivity.Microstructural studies confirmed the difference in coating evolution due to the cycling.
Thermal barrier coatings (TBC) are used to protect the hot components of gas turbine engines to enhance thermal efficiency and component service life. It is critical for TBC development that a testing method be used to understand the potential and limitation of coating’s durability and integrity under the gas turbine engine operation conditions. In this paper, laser high heat flux testing with an applied temperature gradient across TBC coated buttons is presented. The ceramic coating is ZrO2-8 wt.% Y2O3 applied via the air plasma spraying process on top of a NiCoCrAlY bond coating and an Inconel alloy substrate button of 25.4 mm diameter. The coated button is subject to precisely-controlled laser heating on the top side (1150°C) and temperature gradient of 63.9°C/mm through the button overall thickness. The TBC button lasts 160.9 hr or 570 cycles of laser heating. Analysis of void fraction change before and after the test, thermal conductivity change during the laser test, and failure assessment are presented. After the test, the top coating has cracks in vertical or oblique directions and significant horizontal cracks near the top coating and bond coating interface. Significant horizontal top coating cracks close to the interface between the top coating and bond coating appear near the button center. Although the coating delamination has not occurred yet, at the end of the laser testing the button is close to delamination. Based on the horizontal cracks and the thermally grown oxide layer geometry, a finite element analysis is conducted to calculate the residual stress and the strain energy release rate. A possible approach to combine laser rig test result and finite element computation for developing a TBC service life model is discussed.
Thermal barrier coatings are widely used in gas turbines to protect the gas turbine metal components against very high combustion product temperature. To improve energy efficiency, higher combustion temperatures are needed. A limiting factor at present is the stability under extreme and prolonged heating of thermal barrier coatings. The coatings are typically made by the air plasma sprayed process in which fine particles of yttria-stabilized zirconia (YSZ) are melted or partially melted and ejected from plasma jet at high speed onto the bond coated substrate metal. With increasing combustion temperature and pressure in the modern gas turbine engines radiative heat transfer is becoming an important portion of the overall heat transfer in the thermal barrier coating. This study has demonstrated that the commonly used Kubelka-Munk method in the radiative property reduction from the measured transmittance and reflectance spectra of YSZ coatings will incur inaccurate result when the coating optical thickness is not sufficiently large. An alternative method — the discrete ordinates method with the asymmetric spherical ring angular quadrature — is used instead. The absorption and scattering coefficients of air plasma sprayed YSZ films are determined over the wavelength range from 1 to 2.6 μm at room temperature. Over this near infrared wavelength range, the scattering coefficient decreases with the increasing wavelength and the absorption coefficient is very small overall. The pore size distributions before and after the 50-hr temperature gradient, thermal cycling are compared. The sintering effect as well as the crack growth will impact the coating radiative properties. These results point to a clear need for better understanding of the radiative heat transfer process, which includes the microstructure-property relationship, progressive changes of the radiative properties with the operation condition and time.
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