0
Research Papers: Gas Turbines: Combustion, Fuels, and Emissions

Prediction and Analysis of Impact of Thermal Barrier Coating Oxidation on Gas Turbine Creep Life

[+] Author and Article Information
E. A. Ogiriki

School of Aerospace, Transport
and Manufacturing,
Cranfield University,
Bedford, Cranfield MK43 0AL, UK
e-mail: ebitoski@yahoo.com

Y. G. Li

School of Aerospace, Transport
and Manufacturing,
Cranfield University, Bedford,
Cranfield MK43 0AL, UK
e-mail: i.y.li@cranfield.ac.uk

Th. Nikolaidis

School of Aerospace, Transport
and Manufacturing,
Cranfield University,
Bedford, Cranfield MK43 0AL, UK
e-mail: t.nikolaidis@cranfield.ac.uk

Contributed by the Combustion and Fuels Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received February 19, 2016; final manuscript received June 26, 2016; published online August 2, 2016. Editor: David Wisler.

J. Eng. Gas Turbines Power 138(12), 121501 (Aug 02, 2016) (9 pages) Paper No: GTP-16-1081; doi: 10.1115/1.4034020 History: Received February 19, 2016; Revised June 26, 2016

Thermal barrier coatings (TBCs) have been widely used in the power generation industry to protect turbine blades from damage in hostile operating environment. This allows either a high turbine entry temperature (TET) to be employed or a low percentage of cooling air to be used, both of which will improve the performance and efficiency of gas turbine engines. However, with continuous increases in TET aimed at improving the performance and efficiency of gas turbines, TBCs have become more susceptible to oxidation. Such oxidation has been largely responsible for the premature failure of most TBCs. Nevertheless, existing creep life prediction models that give adequate considerations to the effects of TBC oxidation on creep life are rare. The implication is that the creep life of gas turbines may be estimated more accurately if TBC oxidation is considered. In this paper, a performance-based integrated creep life model has been introduced with the capability of assessing the impact of TBC oxidation on the creep life and performance of gas turbines. The model comprises of a thermal, stress, oxidation, performance, and life estimation models. High pressure turbine (HPT) blades are selected as the life limiting component of gas turbines. Therefore, the integrated model was employed to investigate the effect of several operating conditions on the HPT blades of a model gas turbine engine using a creep factor (CF) approach. The results show that different operating conditions can significantly affect the oxidation rates of TBCs which in turn affect the creep life of HPT blades. For instance, TBC oxidation can speed up the overall life usage of a gas turbine engine from 4.22% to 6.35% within a one-year operation. It is the objective of this research that the developed method may assist gas turbine users in selecting the best mission profile that will minimize maintenance and operating costs while giving the best engine availability.

Copyright © 2016 by ASME
Your Session has timed out. Please sign back in to continue.

References

Schlachter, W. , and Gessinger, G. , 1990, “ Innovation in Power Engineering—Role of Materials,” High Temperature Materials for Power Engineering, Kluwer Academic Publishers, Liege, Belgium.
Kilgallon, P. , Simms, N. J. , and Oakey, J. E. , 2002, “ Fate of Trace Contaminants from Biomass Fuels in Gasification System,” 7th Liege Conference Materials for Advanced Power Engineering, J. Lecomte-Beckers, M. Carton, F. Schubert, and P. J. Ennis, eds., Liege, Belgium, p. 903.
Allen, D. H. , Oakey, J. E. , and Scarlin, B. , 1998, Materials for Advanced Power Engineering, J. Lecomte-Beckers, ed., Springer, Berlin, p. 1825.
Jansohn, P. , 2013, Modern Gas Turbine Systems: High Efficiency, Low Emission, Fuel Flexible Power Generation, Elsevier, Oxford, UK.
Miller, R. A. , 1997, “ Thermal Barrier Coatings for Aircraft Engines: History and Directions,” J. Therm. Spray Technol., 6(1), pp. 35–42. [CrossRef]
Roy, N. , Ghosh, R. N. , and Pandey, M. C. , 2001, “ Modelling of Interaction Between Creep and Oxidation Behavior for Engineering Materials,” ISIJ Int., 41(8), pp. 915–921. [CrossRef]
Eriksson, R. , Brodin, H. , Johansson, S. , Östergren, L. , and Li, X. , 2011, “ Influence of Isothermal and Cyclic Heat Treatments on the Adhesion of Plasma Sprayed Thermal Barrier Coatings,” Surf. Coat. Technol., 205(23), pp. 5422–5429. [CrossRef]
Chen, L. , 2006, “ Yttria-Stabilized Zirconia Thermal Barrier Coatings—A Review,” Surf. Rev. Lett., 13(05), pp. 535–544. [CrossRef]
Ghafir, M. A. , Li, Y. , Singh, R. , Huang, K. , and Feng, X. , 2010, “ Impact of Operating and Health Conditions on Aero Gas Turbine: Hot Section Creep Life Using a Creep Factor Approach,” ASME Paper No. GT2010-22332.
MacMillan, W. L. , 1974, Development of a Modular-Type Computer Program for the Calculation of Gas Turbine Off-Design Performance, Cranfield Institute of Technology, Cranfield, UK.
Meier, S. , Nissley, D. , Sheffler, K. , and Cruse, T. A. , 1992, “ Thermal Barrier Coating Life Prediction Model Development,” ASME J. Turbomach., 114(2), pp. 258–263.
Miller, R. A. , and Lowell, C. E. , 1982, “ Failure Mechanisms of Thermal Barrier Coatings Exposed to Elevated Temperatures,” Thin Solid Films, 95(3), pp. 265–273. [CrossRef]
Berndt, C. C. , and Herman, H. , 1983, “ Failure During Thermal Cycling of Plasma-Sprayed Thermal Barrier Coatings,” Thin Solid Films, 108(4), pp. 427–437. [CrossRef]
Tsai, H. , and Tsai, P. , 1995, “ Microstructures and Properties of Laser-Glazed Plasma-Sprayed ZrO2-YO1. 5/Ni-22Cr-10AI-1Y Thermal Barrier Coatings,” J. Mater. Eng. Perform., 4(6), pp. 689–696. [CrossRef]
Kuroda, S. , and Clyne, T. , 1991, “ The Quenching Stress in Thermally Sprayed Coatings,” Thin Solid Films, 200(1), pp. 49–66. [CrossRef]
Lee, J. , Ra, H. , Hong, K. , and Hur, S. , 1992, “ Analysis of Deposition Phenomena and Residual Stress in Plasma Spray Coatings,” Surf. Coat. Technol., 56(1), pp. 27–37. [CrossRef]
Martena, M. , Botto, D. , Fino, P. , Sabbadini, S. , Gola, M. , and Badini, C. , 2006, “ Modelling of TBC System Failure: Stress Distribution as a Function of TGO Thickness and Thermal Expansion Mismatch,” Eng. Failure Anal., 13(3), pp. 409–426. [CrossRef]
Busso, E. , Lin, J. , Sakurai, S. , and Nakayama, M. , 2001, “ A Mechanistic Study of Oxidation-Induced Degradation in a Plasma-Sprayed Thermal Barrier Coating System—Part I: Model Formulation,” Acta Mater., 49(9), pp. 1515–1528. [CrossRef]
Eshati, S. , 2011, “ An Evaluation of Operation and Creep Life of Stationary Gas Turbine Engine,” Ph.D. thesis, School of Engineering, Cranfield University, Cranfield, UK.
Cookson and Haslam, A. , 2011, “ Mechanical Design of Turbomachinery (Lecture Note),” Department of Power and Propulsion, School of Engineering, Cranfield University, Cranfield, UK.
Walsh, P. P. , and Fletcher, P. , 2004, Gas Turbine Performance, Blackwell Publishing, Oxford, UK.
Horlock, J. , and Torbidoni, L. , 2006, “ Turbine Blade Cooling: The Blade Temperature Distribution,” Proc. Inst. Mech. Eng., Part A, 220(4), pp. 343–353. [CrossRef]
Rubini , 2013, “ Turbine Blade Cooling,” M.Sc. Course Note, School of Engineering, University of Hull, East Riding of Yorkshire, UK.
Larson, F. , and Miller, J. , 1952, “ A Time-Temperature Relationship for Rupture and Creep Stresses,” Trans ASME, 74(5), pp. 765–775.
Badeer, G. , 2000, “ GE Aeroderivative Gas Turbines-Design and Operating Features,” GE Power Systems, Evendale, OH, Report No. GER-3695E.
MacManus, 2012, “ Turbomachinery Course Notes—Turbines,” M.Sc. Course Note, School of Engineering, Cranfield University, Cranfield, UK.
Saravanamuttoo, H. I. H. , Cohen, H. , Rogers, G. F. C. , and Straznicky, P. V. , 2009, Gas Turbine Theory, 6th ed., Pearson Prentice-Hall, Harlow, Essex, UK.
Wright, P. , and Evans, A. , 1999, “ Mechanisms Governing the Performance of Thermal Barrier Coatings,” Curr. Opin. Solid State Mater. Sci., 4(3), pp. 255–265. [CrossRef]

Figures

Grahic Jump Location
Fig. 1

Integrated creep life assessment model

Grahic Jump Location
Fig. 2

Schematic diagram of the blade and gas directions

Grahic Jump Location
Fig. 3

Average radial temperature distribution profile at the inlet of a turbine rotor blade

Grahic Jump Location
Fig. 4

Blade centrifugal forces

Grahic Jump Location
Fig. 5

Temperature profile of a blade with TBC and film cooling

Grahic Jump Location
Fig. 6

Layout of two-shaft aeroderivative engine

Grahic Jump Location
Fig. 7

Strain effects on TBC life at different TBCs

Grahic Jump Location
Fig. 8

Effect of TET on TBC life at different PCN

Grahic Jump Location
Fig. 9

Ambient temperature effects on TBC life at different strain

Grahic Jump Location
Fig. 10

Effect of TBC failure on blade temperature

Grahic Jump Location
Fig. 11

Blade metal temperature deviation due to different TETs

Grahic Jump Location
Fig. 12

TBC oxidation on blade creep life at different TETs and strain levels

Grahic Jump Location
Fig. 13

Day temperature profile

Grahic Jump Location
Fig. 14

PCN variation for different ambient conditions at constant power

Grahic Jump Location
Fig. 15

TET variation for different ambient temperature at constant power

Grahic Jump Location
Fig. 16

Creep variation during winter

Grahic Jump Location
Fig. 17

Creep variation during summer

Grahic Jump Location
Fig. 18

Creep and oxidation effects

Grahic Jump Location
Fig. 19

Impact of TBC oxidation on the overall life usage

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In