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Research Papers: Gas Turbines: Manufacturing, Materials, and Metallurgy

Extreme Temperature Coatings for Future Gas Turbine Engines

[+] Author and Article Information
M. A. Alvin

U.S. DOE National Energy,
Technology Laboratory,
Pittsburgh, PA 15236
e-mail: maryanne.alvin@netl.doe.gov

K. Klotz, B. McMordie

Coatings For Industry,
Souderton, PA 18964

D. Zhu

NASA Glenn Research Center,
Cleveland, OH 44135

B. Gleeson

University of Pittsburgh,
Pittsburgh, PA 15261

B. Warnes

Corrosion Control Consultants, Inc.,
Beaver, PA 15009

Contributed by the Turbomachinery Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received January 7, 2014; final manuscript received February 2, 2014; published online May 21, 2014. Editor: David Wisler.

J. Eng. Gas Turbines Power 136(11), 112102 (May 21, 2014) (8 pages) Paper No: GTP-14-1004; doi: 10.1115/1.4027186 History: Received January 07, 2014; Revised February 02, 2014; Accepted February 21, 2014

The National Energy Technology Laboratory-Regional University Alliance (NETL-RUA) has been developing extreme temperature coating systems that consist of a diffusion barrier coating (DBC), a low-cost wet slurry bond coat, a commercial yttria stabilized zirconia (YSZ) thermal barrier coating (TBC), and an extreme temperature external coating that are deposited along the surface of nickel-based superalloys and single crystal metal substrates. Thermal cyclic testing of these multilayer coatings was conducted in steam-containing environments at temperatures ranging between 1100 and 1550 °C. This paper discusses the response of these materials during bench-scale testing, and their potential use in advanced H- and J-class land-based gas turbine engines.

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References

Figures

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Fig. 1

Cross-sectional micrograph of the A1D bond coat system [1]

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Fig. 2

Comparison of NETL TBC composite architecture with current TBC technology

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Fig. 8

EB-PVD TBC coated coupons after laser thermal cyclic testing. (a) René N5/A1D/EB-PVD YSZ; steam at 1300 °C (∼2370 °F), 20, 1 h cycles (Test 2–4). (b) René N5/A1D/EB-PVD YSZ/EB-PVD ZrO2–2.8 wt. % Y2O3–3.3 wt. % Gd2O3–3.6 wt. % Yb2O3; steam at 1450–1460 °C (∼2640–2660 °F), 50, 1 h cycles (Test 2–5). (c) René N5/A1D/EB-PVD YSZ/EB-PVD HfO2–14 mol % Y2O3–3 mol % Gd2O3–3 mol % Yb2O3; steam at 1500–1520 °C (∼2730–2770 °F), 50, 1 h cycles (Test 2–3).

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Fig. 9

Cross-sectional micrographs of the René N5/A1D/EB-PVD YSZ coupon after 20 h of thermal cyclic testing in steam (Test 2–4)

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Fig. 10

(a) Surface and (b) cross-sectional micrographs of the René N5/A1D/EB-PVD YSZ/EB-PVD ZrO312 coupon after 50 h of thermal cyclic testing in steam (Test 2–5)

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Fig. 7

Cross-sectional micrograph of the René N5/A1D/APS YSZ/ZrO312 coupon after 50 h of thermal cyclic testing in steam (Test 1–5)

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Fig. 6

Cross-sectional micrograph of the René N5/A1D/APS YSZ/ZrO312 coupon after 50 h of thermal cyclic testing in air (Test 1–3)

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Fig. 5

René N5/LPPS NiCoCrAlY/APS YSZ ZrO312, air, 50 h thermal cyclic testing (Test 1–4)

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Fig. 4

APS TBC coated coupons after laser thermal cyclic testing. (a) René N5/LPPS MCrAlY/APS YSZ/ZrO312; air at ∼1482 °C (2700 °F), 50, 1 h cycles (Test 1–4). (b) René N5/A1D/APS YSZ/APS ZrO312; air at ∼1482 °C (2700 °F), 50, 1 h cycles (Test 1–3). (c) René N5/A1D/APS YSZ/ASP ZrO312; steam at ∼1482 °C (2700 °F), 49, 1 h cycles (Test 1–5).

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Fig. 3

Cross-sectional micrograph of René N/(Ni,Pt)Al after 50 h of thermal cyclic testing in steam

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Fig. 11

(a) Surface and (b) cross-sectional micrographs of the René N5/A1D/EB-PVD YSZ/EB-PVD HfO coupon after 50 h of thermal cyclic testing in steam (Test 2–3)

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Fig. 12

Cross-sectional micrograph of the Haynes 214/DBC/MCrAlY coupon after 50 h of thermal cyclic testing in steam at 1100 °C (∼2010 °F)

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Fig. 13

Future land-based engine turbine technology operating criteria [7]

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