Cyclic behavior of EB-PVD thermal barrier coating systems with modified bond coats

Schulz, Uwe; Fritscher, K.; Ebach-Stahl, Andrea

doi:10.1016/j.surfcoat.2008.08.056

Cited by 77 publications

(34 citation statements)

References 18 publications

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“…Similar failure times (not shown) were reported for CMSX-4, TMS 138A, and TMS 82, substrates, which were all measurably higher than those for SRR99 substrates. Other substrates, tested at 1100°C and 1150°C, include Rene′142, IN100, and AM1 (as reported by Lau, Schulz, SaintRamond, and co-workers) [38,[44][45][46]. While these alloys are not single crystals, they exhibited lives comparable to the overall population.…”

Section: Temperature Effects Of Compiled Fct Livesmentioning

confidence: 95%

Compiled furnace cyclic lives of EB-PVD thermal barrier coatings

Smialek

2015

Surface and Coatings Technology

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a b s t r a c t a r t i c l e i n f oFurnace cycling has been widely used to study the failure of EB-PVD thermal barrier coatings. This contribution compiles TBC furnace cyclic lives over a broad literature base to highlight optimum systems and generalized trends not always apparent in one study. Systems included typical bond coats (Pt-modified aluminides, diffused Pt-only γ/γ′, and NiCoCrAlY (± Pt, Hf) overlays) and superalloy substrates (1st, 2nd, 3rd generation single crystals, directionally solidified, or conventionally cast). Pretreatments included controlled low p(O 2 ) bond coat pre-oxidation and grit blasting (or none). The aggregate lives (~70) suggest a general trend with temperature,~10-fold decrease for every 100°C increase. Measured alumina scale thicknesses (~30) were, on average, 6.1 ± 1.8 μm at failure and independent of temperature for conventional systems. Most failures thus occurred in less time than that predicted to grow 7 μm of alumina scale (as estimated from separate TGA studies of a Ptmodified aluminide coated 2nd generation single crystal superalloy). A tentative activation energy indicated from the broad distribution of failure times was~280 kJ/mol, while that from homogeneous TGA testing was 380 kJ/mol, with regression coefficients of r 2 = 0.57 and 0.98, respectively. Published by Elsevier B.V.

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Section: Temperature Effects Of Compiled Fct Livesmentioning

confidence: 95%

Compiled furnace cyclic lives of EB-PVD thermal barrier coatings

Smialek

2015

Surface and Coatings Technology

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“…12)14) Some studies have shown that a TBC deposited by electron beam physical vapor deposition (EB-PVD) exhibits better durability in comparison to a TBC deposited by APS. 15) 17) Those TBCs deposited by EB-PVD coating and featuring singular columns and coarse grain sizes exhibit better mechanical properties. 18)20) Another method for increasing the TBC durability involves selecting a new material and then redesigning the double layer according to the new selection.…”

Section: )10)mentioning

confidence: 99%

Microstructure controls in Gadolinium Zirconate/YSZ double layers and their properties

Lee

Kim

2014

J. Ceram. Soc. Japan

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In this study, a double-layer thermal barrier coating was designed and deposited by an electron beam physical vapor deposition technique. The microstructure was controlled by using different target ingots during the electron beam physical vapor deposition process. The double layer coating consists of Gd 2 Zr 2 O 7 for the top layer and YSZ for the bottom layer. The microstructure, hardness, and thermal shock properties of the double layer deposited using a single-ingot process were compared with the results obtained with the two-ingot process. The single-ingot process involves forming the Gd 2 Zr 2 O 7 /YSZ double layer using a single YSZ/Gd 2 Zr 2 O 7 double-layered ingot. The two-ingot process involves coating with each of the YSZ and Gd 2 Zr 2 O 7 ingots. While the XRD results indicated that the same pyrochlore-fluorite structures are formed in those ingots, differences in the microstructure and composition were observed by FE-SEM and EDS analyses. These differences influence the hardness and thermal shock resistance of the coating. The results indicate that the finer singular columns produced by the two-ingot process do not improve the hardness, but delay the delamination of the top layer during thermal shock tests due to residual compressive stress and strain tolerance.

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“…The blades in modern aero, marine, and industrial gas turbines are manufactured exclusively from nickel-based super alloys and operate under the most arduous conditions of temperature and stress of any component in the engine (Huda 2009(Huda , 1995. These conditions are further complicated for turbine installations in marine (corrosive) environments, which include sulfur and sodium from the fuel and various halides contained in seawater (Schulz et al 2008;Braue et al 2007). These features are known to drastically reduce the superalloy component life and reliability by consuming the material at an unpredictably rapid rate, thereby reducing the load-carrying capacity and potentially leading to catastrophic failure of components.…”

Section: Enhancing Profitability In Power Generationmentioning

confidence: 99%

“…Nye Thermodynamics Corporation (NTC) 2011; Zeren 1982;Schulz et al 2008;Braue et al 2007;Huda et al 2011;Jianting 2011;Cao and Loria 2005;Sajjadi and Nategh 2001;Sajjadi et al 2002;Zickler et al 2009;Perepezko 2009;Todd 1989;Kansai Electric Power Company (KEPCO) 2011;Diologent and Caron 2004;Kennedy 2005;Kitazawa et al 2010;Pint et al 1998;Wright and Gibbons 2007;Choi et al 2010;Walston 2004;Troczynski et al 1996;DeMasi-Marcinand and Gupta 1994;Movchan 1996;Schulz et al 1997;Padture et al 2002;Boccaccini and Zhitomirsky 2002;Boccaccini et al 2006;Besra and Liu 2007;Corni et al 2008;Dusoulier et al 2011;Doungdaw et al 2005;Mohanty et al 2008;Put et al 2003 Use TBC using EPD/EBPVD MHI, J-series engine operating at TIT = 1,600°C has achieved efficiency exceeding 60%…”

Section: A New Chart For Gt Researchers Designers and Manufacturersmentioning

confidence: 99%

Enhancing power output and profitability through energy-efficiency techniques and advanced materials in today’s industrial gas turbines

Huda

Zaharinie

Al-Ansary

2014

Int J Mech Mater Eng

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This paper reviews and integrates the latest energy-efficiency improvement techniques to recently developed superalloys and coatings for enhancing power output and profitability in today's industrial gas turbines (GTs). It has been shown that the retrofitting of inlet air cooling and steam injected gas technology technologies in simple turbines can boost power output from 30 to 48.25 MW and improve generation efficiency from 29.9% to 33.4%. It has been reviewed that for improving efficiency of power plants beyond 60%, it is important to use higher turbine inlet temperature (TIT) in combined cycle gas turbine by applying single-crystal nickel-based superalloys and thermal barrier coating involving closed-loop steam cooling. It has been shown that an increase of the TIT by 56°C can result in increased revenue of US$8/kW to the manufacturer of the original rating, provided the GT is sold for US$200/kW. In view of the latest development in GT technology, which enables them to be operated at TIT = 1,600°C, it is recommended to develop superalloys based on higher-melting temperatures (Mo-based superalloys). A new chart for increasing power output has been developed so as to enable the GT designers to manufacture GT engines with enhanced profitability.

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Cyclic behavior of EB-PVD thermal barrier coating systems with modified bond coats

Cited by 77 publications

References 18 publications

Compiled furnace cyclic lives of EB-PVD thermal barrier coatings

Compiled furnace cyclic lives of EB-PVD thermal barrier coatings

Microstructure controls in Gadolinium Zirconate/YSZ double layers and their properties

Enhancing power output and profitability through energy-efficiency techniques and advanced materials in today’s industrial gas turbines

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