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Research Papers

The Effect of Coating Composition and Geometry on Thermal Barrier Coatings Lifetime

[+] Author and Article Information
Bruce A. Pint

Oak Ridge National Laboratory,
Materials Science and Technology Division,
Oak Ridge, TN 37831-6156
e-mail: pintba@ornl.gov

Michael J. Lance, J. Allen Haynes

Oak Ridge National Laboratory,
Materials Science and Technology Division,
Oak Ridge, TN 37831-6156

Manuscript received June 28, 2018; final manuscript received August 10, 2018; published online October 4, 2018. Editor: Jerzy T. Sawicki. The United States Government retains, and by accepting the article for publication, the publisher acknowledges that the United States Government retains, a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this work, or allow others to do so, for United States government purposes.

J. Eng. Gas Turbines Power 141(3), 031004 (Oct 04, 2018) (7 pages) Paper No: GTP-18-1397; doi: 10.1115/1.4041309 History: Received June 28, 2018; Revised August 10, 2018

Several factors are being investigated that affect the performance of thermal barrier coatings (TBC) for use in land-based gas turbines where coatings are mainly thermally sprayed. This study examined high velocity oxygen fuel (HVOF), air plasma-sprayed (APS), and vacuum plasma-sprayed (VPS) MCrAlYHfSi bond coatings with APS YSZ top coatings at 900–1100 °C. For superalloy 247 substrates and VPS coatings tested in 1 h cycles at 1100 °C, removing 0.6 wt %Si had no effect on average lifetime in 1 h cycles at 1100 °C, but adding 0.3%Ti had a negative effect. Rod specimens were coated with APS, HVOF, and HVOF with an outer APS layer bond coating and tested in 100 h cycles in air + 10%H2O at 1100 °C. With an HVOF bond coating, initial results indicate that 12.5 mm diameter rod specimens have much shorter 100 h cycle lifetimes than disk specimens. Much longer lifetimes were obtained when the bond coating had an inner HVOF layer and outer APS layer.

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Figures

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Fig. 1

Comparison of different specimen geometries ranging from flat disks to a specimen with a blade-like cross section

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Fig. 2

Average lifetime for five different process combinations on alloy 247 substrates exposed in 1 h cycles at 1100 °C in air + 10%H2O

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Fig. 3

Light microscopy of polished cross section of failed VPS NiCoCrAlYHfSi bond coatings after 1 h cycles at 1100 °C in wet air (a) batch 1, 640 cycles and (b) batch 2, 600 cycles

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Fig. 4

Specimen mass gain during 500 h cycles at 900 °C in laboratory air and air + 10%H2O for specimens with different bond coatings and APS YSZ top coatings

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Fig. 5

Light microscopy of polished cross section of specimens exposed 5000 h at 900 °C in dry air ((a) and (c)) and air + 10%H2O ((b) and (d)) for HVOF MCrAlYHfSi on 1483 ((a) and (b)) and VPS MCrAlYHfSi on 247 ((c) and (d)), all with APS YSZ

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Fig. 6

Comparison of coating lifetimes (cumulative time in 100 h cycles to failure) for disk specimens (average of five specimens with HVOF MCrAlYHfSi bond coating) and rod specimens with MCrAlYHfSi bond coatings made by APS or HVOF

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Fig. 7

Light microscopy of polished cross section of coated 247 rods after APS YSZ failure in 100 h cycles at 1100 °C in air + 10%H2O (a) APS MCrAlYHfSi bond coating after 700 h and (b) HVOF MCrAlYHfSi after 400 h

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Fig. 8

Light microscopy of polished cross section of coated 247 rods with APS YSZ top coatings exposed for 5000 h in 500 h cycles in air + 10%H2O (a) HVOF MCrAlYHfSi at 900 °C and APS MCrAlYHfSi at (b) 900 °C and (c) 1000 °C

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Fig. 9

Average coating lifetimes (cumulative time in 100 h cycles to failure) for rod specimens with two different bond coatings and three different top coatings. Whiskers note a standard deviation for three specimens of each type.

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Fig. 10

Light microscopy of polished cross section of HVOF MCrAlYHfSi coated 247 rods after APS YSZ failure in 100 h cycles at 1100 °C in air + 10%H2O (a) high porosity YSZ after 400 h and (b) bi-layer YSZ after 300 h

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Fig. 11

Light microscopy of polished cross section of an as-received HVOF+APS MCrAlYHfSi coated 247 rod with a porous single layer APS YSZ top coating

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Fig. 12

Histograms of the Al2O3 scale residual stress following 2 × 100 h cycles at 1100 °C in wet air by PLPS. The measured stresses were binned into groups of 100 MPa for bi-layer (Bi) and single-layer porous (Por) YSZ.

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