Effects of Interface Roughness on Residual Stresses in Thermal Barrier Coatings

Using a newly developed object-oriented finite-element analysis method, both an actual microstructure and model microstructures of a plasma-sprayed thermal barrier coating system were numerically simulated to analyze the full-field residual stresses of this coating system. Residual stresses in the actual microstructure were influenced by both the irregular top-coat/bond-coat interface and cracks in the top coat. By treating the microcracked top coat as a more-compliant solid microstructure, the effects of the irregular interface on residual stresses were examined. These results then could be compared to results that have been obtained by analyzing a model microstructure with a sinusoidal interface, which has been considered by some earlier investigators.     

Erosion-Indicating Thermal Barrier Coatings Using Luminescent Sublayers

A successful approach to producing thermal barrier coatings (TBCs) that are self-indicating for location and depth of erosion is presented. Erosion indication is demonstrated in electron-beam physical vapor-deposited (EB-PVD) TBCs consisting of 7 wt% yttria-stabilized zirconia (7YSZ) with europium-doped and terbium-doped sublayers. Multiple-ingot deposition was utilized to deposit doped layers with sharp boundaries in dopant concentration without disrupting the columnar growth that gives EB-PVD TBCs their desirable strain tolerance. TBC-coated specimens were subjected to alumina-particle-jet erosion, and the erosion depth was indicated under ultraviolet illumination by the luminescence associated with the sublayers exposed by erosion. Sufficiently distinct luminescent sublayer boundaries were retained to maintain an effective erosion-indicating capability even after annealing free-standing TBCs at 1400°C for 100 h.     

Thermomechanical Analysis of Functionally Graded Thermal Barrier Coatings with Different Microstructural Scales

The recently developed two-dimensional version of the higher-order theory for functionally graded materials (denoted as HOTFGM-2D in previous communications) has been used to investigate the effects of microstructural architectures in graded thermal barrier coatings (TBCs) on stress distributions in the presence of a through-thickness temperature gradient. In particular, the response of TBCs with different levels of functionally graded microstructural refinement and different arrangements has been investigated, and the results for the through-thickness stress distributions are compared with those based on the standard micromechanical homogenization scheme. The examples presented illustrate the shortcomings of the standard micromechanics-based approach that is applied to the analysis of functionally graded TBCs, particularly if the presence of creep effects is included in the analysis.     

陶瓷热障涂层在化工过程装备中的应用

针对化工生产中的易氧化、高温腐蚀和易磨损等因素,提出适用于化工过程装备的材料体系设计方案。在方案中将材料设计思路创造性地应用到陶瓷热障涂层,提出了对其进行结构设计的总体思路,并对主要设计参数的设计方法进行了初步研究。     

Nondestructive Evaluation of Thermal Barrier Coatings Using Impedance Spectroscopy

This article reviews previous studies on nondestructive evaluation of thermal barrier coatings (TBCs) using impedance spectroscopy (IS). IS or electrochemical impedance spectroscopy has been widely used to measure the electrical properties of materials and electrochemical behavior at electrode/electrolyte interfaces. TBCs, which comprise metallic and ceramic multilayers, have been widely used in the hot section of aeroturbine engines to increase turbine efficiency and to extend the life of metallic components. Since 1999, IS has been developed to examine degradation of the TBCs as a nondestructive evaluation tool, which is critical for prediction of TBCs lifetime during service. IS has been used both at high temperature in dry environments and in aqueous solutions. Impedance spectra of TBCs reflect change in TBC thickness, porosity, cracks, sintering, and yttria-stabilized zirconia phase transformation. Meanwhile, impedance measurements indicate the thermally grown oxide growth and the failure in TBCs. In addition, the thermal conductivity of TBCs can be correlated to impedance measurement results.     

Development of Advanced Low Conductivity Thermal Barrier Coatings

Advanced multi-component, low-conductivity oxide thermal barrier coatings have been developed using an approach that emphasizes real-time monitoring of thermal conductivity under conditions that are engine-like in terms of temperatures and heat fluxes. This is in contrast to the traditional approach where coatings are initially optimized in terms of furnace and burner rig durability with subsequent measurement in the as-processed or furnace-sintered condition. The present work establishes a laser high-heat-flux test as the basis for evaluating advanced plasma-sprayed and electron beam-physical vapor deposited (EBPVD) thermal barrier coatings under the NASA Ultra-Efficient Engine Technology (UEET) Program. The candidate coating materials for this program are novel thermal barrier coatings that are found to have significantly reduced thermal conductivities and improved thermal stability due to an oxide defect-cluster design. Critical issues for designing advanced low-conductivity coatings with improved coating durability are also discussed.     

Delamination-Indicating Thermal Barrier Coatings Using YSZ:Eu Sublayers

Nondestructive diagnostic tools that can reliably assess thermal barrier coating (TBC) delamination are needed to provide protection against premature TBC failure as well as to reduce the costs associated with unnecessary TBC replacement. A coating design for a TBC that is self-indicating for delamination has been successfully implemented by incorporating a europium-doped yttria-stabilized zirconia (YSZ) luminescent sublayer beneath the overlying undoped YSZ TBC. It was demonstrated that incorporation of the europium-doped YSZ layer could be achieved without disrupting TBC columnar growth by using multiple ingot electron beam physical vapor deposition. Both scanning luminescence mapping as well as luminescence imaging revealed greatly enhanced detected luminescence from scratch-induced delaminated regions. This enhanced detected luminescence arises due to high internal reflectivity of both excitation and emission wavelengths at the interface between the luminescent sublayer and the delamination crack. In particular, imaging of the enhanced luminescence associated with TBC delamination was fast and simple to implement, therefore showing great promise as a practical tool for inspecting for TBC delamination.     

Alumina/Epoxy Interpenetrating Phase Composite Coatings: I, Processing and Microstructural Development

Interpenetrating phase composite (IPC) coatings consisting of continuously connected Al₂O₃ and epoxy phases were fabricated. The ceramic phase was prepared by depositing an aqueous dispersion of Al₂O₃ (0.3 μm) containing orthophosphoric acid, H₃PO₄, (1–9.6 wt%, solid basis) and heating to create phosphate bonds between particles. The resulting ceramic coating was porous, which allowed the infiltration and curing of a second-phase epoxy resin. The effect of dispersion composition and thermal processing conditions on the phosphate bonding and ceramic microstructure was investigated. Reaction between Al₂O₃ and H₃PO₄ generated an aluminum phosphate layer on particle surfaces and between particles; this bonding phase was initially amorphous, but partially crystallized upon heating to 500°C. Flexural modulus measurements verified the formation of bonds between particles. The coating porosity (and hence epoxy content in the final IPC coating) decreased from ∼50% to 30% with increased H₃PO₄ loading. The addition of aluminum chloride, AlCl₃, enhanced bonding at low temperatures but did not change the porosity. Diffuse reflectance FTIR showed that a combination of UV and thermal curing steps was necessary for complete curing of the infiltrated epoxy phase. Al₂O₃/epoxy IPC coatings prepared by this method can range in thickness from 1 to 100 μm and have potential applications in wear resistance.     

Topographical and Microstructural Property Evolution of Air Plasma‐Sprayed Zirconia Thermal Barrier Coatings

The effects of process parameters on thermal barrier coating (TBC) formation and microstructural properties have been studied. Further understanding of the evolution of properties such as porosity and hardness is an important aspect in the design of efficient TBCs. Plasma‐sprayed yttria‐stabilized zirconia was coated onto mild steel substrates. The torch was held perpendicular to the substrate to form cone‐shaped deposits. Standoff distance (SOD) (80, 90, and 120 mm) and time (15, 30, and 60 s) were altered to investigate the microstructural property relationships of the coatings. Shape characteristics of the coatings were measured via a coordinate measuring machine, and surface roughness measurements were acquired using a 3D optical profiler. The deposition efficiency and coating roughness were affected by SOD and the evolving contour of the underlying surface. Hardness and porosity profiles were mapped to display the effect of process parameters. Dynamic parameters such as particle trajectory, evolving impact angle and dwell time affected changes in porosity, hardness, and density for each coating profile.     

Depth-Resolved Porosity Investigation of EB-PVD Thermal Barrier Coatings Using High-Energy X-rays

Demands for designing prime reliant, energy-efficient, and high-performance thermal barrier coatings (TBCs) in gas turbines have led to a growing interest toward comprehensive microstructural characterization. Here we investigate the novel use of high-energy X-rays for small-angle X-ray scattering (SAXS), together with wide-angle scattering and radiography, for the depth-resolved characterization of TBCs grown by electron beam physical vapor deposition (EB-PVD). The coating microstructure is found to consist of columns perpendicular to the substrate, extending through the thickness, with a [001] growth texture and significant intercolumnar porosity. In addition, overshadowing effects during deposition together with gas entrapment give rise to nanoscale intracolumnar porosity consisting of featherlike and globular pores. Radiography showed an increase in the total porosity, from 15% near the substrate to 25% near the coating surface, which is ascribed to an increase in the intercolumnar spacing at the top of the coating. By contrast, the small-angle scattering studies, which are sensitive to fine features, showed the pore internal surface area to be greatest near the substrate.     

Fatigue of Thick Thermal Barrier Coatings

Thick thermal barrier coatings (TTBCs) of plasma-sprayed 8% Y₂O₃–ZrO₂ were fatigued in compression as part of a reliability and durability study to evaluate their potential use in high-performance diesel engines. Test specimens were designed to test the bulk ceramic uniaxialiy, independent of the substrate. A test machine was designed to alleviate the mechanical gripping and alignment difficulties associated with cyclically stressing brittle ceramics in compression. Higher fatigue limits, 375 vs 200 MPa, were observed at 800°C than at room temperature. Specimens tested at room temperature after high-temperature com-pressive cycling also had higher fatigue limits, indicating that the strengthening was permanent. At temperatures of 800°C, the coatings showed evidence of low-temperature, pressure-induced sintering. The extent to which sintering occurred was determined by studying the change in the elastic modulus as a result of the application of varying temperatures and static stresses.     

热障涂层材料研究进展

热障涂层材料广泛应用于发动机热端部件的热防护,能有效提高航空发动机热端 部件的工作温度和使用寿命。目前商用的热障涂层材料为氧化钇部分稳定氧化锆,但其在服役 温度高于 1200?C 时会发生相变而失效,难以满足新一代航空发动机对热障涂层的性能要求。因 此,寻找新型热障涂层材料及其服役性能研究一直是近年来的热点。本文综述了近年来氧化钇 稳定氧化锆、钙钛矿氧化物、烧绿石氧化物以及稀土硅酸盐材料的研究进展,并展望了热障涂 层材料的未来发展趋势。     

Characterization of Electron Beam Physical Vapor-Deposited Thermal Barrier Coatings Using Diffuse Optical Reflectance

The use of diffuse optical spectral reflectance as a nondestructive tool to characterize the microstructure of electron beam physical vapor deposition (EB-PVD) thermal barrier coatings (TBCs) has been investigated and the contributions of intercolumnar gaps and intracolumnar pores distinguished. It is shown that the reflectance is controlled by the refractive index mismatch and that the optical scattering coefficient depends on the thickness of the TBC due to the porosity distribution through the thickness of the coating. The sensitivity of the reflectance to the porosity suggests that optical reflectance can be used to characterize the microstructure of EB-PVD TBC for both quality control and nondestructive evaluation purposes.     

The Measurement of Residual Strains Within Thermal Barrier Coatings Using High-Energy X-Ray Diffraction

The residual strains through the entire thickness of the zirconia layer of pristine and heat-treated thermal barrier coatings (TBCs) were mapped to help elucidate the failure mechanisms of TBCs. The strains were measured using 80.72 keV synchrotron radiation and a transmission geometry. The heat-treated TBC showed that a compressive strain formed in the zirconia layer of the TBC on cooling but this strain was diluted and reversed by the oxidation-driven expansion of the underlying metals. It also showed large (0.0024) out-of-plane tensile strains in the zirconia layer just above its interface with a thick underlying oxide layer.     

CMAS-Resistant Thermal Barrier Coatings (TBC)

Electron beam-physical vapor-deposited thermal barrier coatings (TBC) are susceptible to damage due to environmental contaminants such as calcium–magnesium–aluminum–silicon oxide systems (CMAS). This paper discusses various approaches of modifying TBC for enhanced protection against CMAS attack. Methodologies were explored with various coating systems maintaining functionality as nonwetting, sacrificial, and impervious to CMAS attack. In the brief isothermal (1260°C/10 min) tests, a nearly crack-free and reglazed Pd coating provided substantial protection from the CMAS attack. Approaches that provided some minor improvements need further optimization to better assess their viability.     

New Thermal Barrier Coatings Based on Pyrochlore/YSZ Double-Layer Systems

Pyrochlore materials La₂Zr₂O₇ and Gd₂Zr₂O₇ have been used to produce thermal barrier coating systems by atmospheric plasma spraying. The materials have been applied as single-layer coatings with only a topcoat made of pyrochlore material. In addition, double-layer systems with a first layer of yttria-stabilized zirconia (YSZ) and a top layer made of pyrochlore material were produced. These systems have been tested in thermal cycling test rigs at surface temperatures between 1200-1450°C and the results were compared to the behavior of YSZ coatings. Single-layer coatings had a rather poor thermal cycling performance. On the other hand, double-layer systems showed similar results to YSZ coatings at temperatures below about 1300°C. At higher temperatures the double-layer coatings produced from our own powders revealed excellent thermal cycling behavior. At the highest test conditions, lifetime was thereby orders of magnitude better than that of YSZ coatings. Results indicate that an increase of the maximum surface temperature in gas turbines by at least 100 K becomes possible with the new coatings. Coatings produced from commercial powders showed a somewhat reduced performance.     

Microstructures and Properties of Plasma-Sprayed Segmented Thermal Barrier Coatings

Thermal barrier coatings (TBCs) with different levels of segmentation crack density were produced by spraying two types of ZrO₂–8Y₂O₃ powders. The fused and crushed powder has a greater capability of forming segmented coatings than the hollow sphere (HOSP) one. The highly segmented coatings reveal much lower porosity compared with traditionally sprayed coatings, thereby compromising the property of thermal insulation of TBCs. Microstructure and thermal conductivity of the HOSP coatings are more sensitive to the changes in spray conditions. Segmentation cracks had a strong influence in decreasing Young's modulus of coatings. Fifty hours heat treatment at 1250°C had little effect on the mechanical property of the highly segmented coatings.     

Creep Behavior of Plasma-Sprayed Zirconia Thermal Barrier Coatings

Thermally sprayed ceramic coatings deposited from nanostructured feedstock powder have often demonstrated improved properties relative to coatings produced from conventional powders. This type of coating has been reported to exhibit better wear resistance and higher adhesion strength compared with conventional deposits. Powder consisting of hollow spherical particles has been reported to produce coating with lower unmelted particles and lower thermal conductivity. In this study, the thermo-mechanical properties of plasma-sprayed yttria-stabilized zirconia coatings deposited using each of these types of powder were investigated. Creep strain and creep rate were measured using free-standing thick coatings loaded in a four-point bend configuration at temperatures ranging from 800° to 1200°C in air under a range of loads. The creep exponent and activation energy were determined.     

等离子喷涂热障涂层的质量检验

对等离子喷涂制备的某高温部件的热障涂层进行检测和评定,提供了关于涂层厚度、微观结构、成分组成、结合强度、抗热冲击性能等性能的检测分析方法和分析结果。所采取的分析方法具有工程可行性和实用性,有助于了解、比较和控制高温部件热障涂层的内在质量状况及可能存在的缺陷,有助于对喷涂工艺的评价和优化。同时,亦可作为喷涂质量管理的一个有效途径。     

基于不同基体条件的Sm2Zr2O7/YSZ双层热障涂层界面残余热应力的数值仿真

采用有限元分析软件ANSYS对2Cr13基体等离子喷涂Sm2Zr2O7/YSZ双层热障涂层界面残余热应力分布进行了仿真。结果表明:在涂层Sm2Zr2O7/YSZ及YSZ/NiCoCrAlY界面存在较大的残余热应力,且应力梯度基本不变,表明应力梯度与基体厚度、半径无关。