Technical and Economical Aspects of Current Thermal Barrier Coating Systems for Gas Turbine Engines by Thermal Spray and EBPVD: A Review |
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Authors: | Albert Feuerstein James Knapp Thomas Taylor Adil Ashary Ann Bolcavage Neil Hitchman |
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Affiliation: | (1) Praxair Surface Technologies, Inc., Indianapolis, IN, USA;(2) Rolls Royce Corporation, Indianapolis, IN, USA |
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Abstract: | The most advanced thermal barrier coating (TBC) systems for aircraft engine and power generation hot section components consist
of electron beam physical vapor deposition (EBPVD) applied yttria-stabilized zirconia and platinum modified diffusion aluminide
bond coating. Thermally sprayed ceramic and MCrAlY bond coatings, however, are still used extensively for combustors and power
generation blades and vanes. This article highlights the key features of plasma spray and HVOF, diffusion aluminizing, and
EBPVD coating processes. The coating characteristics of thermally sprayed MCrAlY bond coat as well as low density and dense
vertically cracked (DVC) Zircoat TBC are described. Essential features of a typical EBPVD TBC coating system, consisting of
a diffusion aluminide and a columnar TBC, are also presented. The major coating cost elements such as material, equipment
and processing are explained for the different technologies, with a performance and cost comparison given for selected examples. |
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Keywords: | advantages of TS APS coatings coatings for gas turbine components TBC topcoats thermal properties review |
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