Thermal Shock and Oxidation Stability Tests to Grade Plasma Sprayed Functionally Gradient Thermal Barrier Coatings

Pasupuleti Kirti Teja; Parvati Ramaswamy; Narayana Murthy S.V.S.

doi:10.34256/famr1911

Pasupuleti Kirti Teja Department of Mechanical & Automobile Engineering, Faculty of Engineering, CHRIST (Deemed to be University) Bangalore, India.
Parvati Ramaswamy Department of Mechanical & Automobile Engineering, Faculty of Engineering, CHRIST (Deemed to be University) Bangalore, India.
Narayana Murthy S.V.S. Materials Characterization Division, Vikram Sarabhai Space Center, Trivandrum, India

DOI: https://doi.org/10.34256/famr1911

Keywords: Thermal Barrier Coatings, Functionally Gradient Materials, Plasma Spray

Abstract

Functionally graded layers in thermal barrier coatings reduce the stress gradient between the overlaid ceramic coatings and the underlying metallic component. Introduced to alleviate early onset of spallation of the coating due to thermal expansion mismatch, this facilitates improvement in the life of the component. Conventional thermal barrier coatings typically comprise of duplex layers of plasma sprayed 8% yttria stabilized zirconia (ceramic) coatings on bond coated (NiCrAlY) components/substrates (Inconel 718 for example). This work highlights the superiority of plasma sprayed coatings synthesized from blends of the intermetallic bond coat and ceramic plasma spray powders on Inconel 718 substrates in three-layer configuration over the duplex layered configuration. Assessed through (a) thermal shock cyclic tests (at 1200^oC and 1400^oC) in laboratory scale basic burner rig test facility and (b) oxidation stability test in high temperature furnace (at 800^oC and 1000^oC) the functionally graded coatings of certain configurations exhibited more than double the life of the conventional 8% yttria stabilized zirconia duplex (double layer) coatings. Micro- and crystal structure analysis support the findings and results are detailed and discussed.

Downloads

Download data is not yet available.

Metrics

Metrics Loading ...

References

N.P. Padture, M. Gell, and E.H. Jordan, Thermal barrier coatings for gas-turbine engine applications, Science, 296(2002) 280–284

David R. Clarke, Matthias Oechsner, and Nitin P. Padture, Thermal-barrier coatings for more efficient gas-turbine engines, MRS Bulletin, 37 (2012) 891- 898

X.Q. Cao, R. Vaßen and D. Stöver, Ceramic materials for thermal barrier coatings, J. Eur. Ceram. Soc., 24 (2004) 1-10

Robert Vassen, Alexandra Stuke, and Detlev Stover, Recent Developments in the Field of Thermal Barrier Coatings, Therm. Spray Technology, 18 (2009) 181

G.A. Kawasaki and R. Watanable, Cyclic Thermal Fracture Behavior and Spallation life of PSZ/NiCrAlY functional graded TBC, Mater. Science Forum, 308 (1999) 402-409

Dongming Zhu, Advanced Oxide Material Systems for 1650 °C Thermal/Environmental Barrier Coating Applications, NASA/TM—2004-213219, ARL–TR–3298.2004

G. Johner and K.K. Schweitzer., Thermal Barrier Coatings for Jet Engine Improvement, Metallurgical And Protective Coatings, Thin Solid Films, 119 (1984) 301-315.

M. Ali, X. Chen and G. Newaz, Oxide layer development under thermal cycling and its role on damage evolution and spallation in TBC system, J Mater Sci, 36 (2001) 4535-4542.

Robert Vassen, Alexandra Stuke and Detlev Stover, Recent Developments in the Field of Thermal Barrier Coatings, Thermal Spray Technology, 18 (2009) 181.

C.U. Hardwicke Lau, Advances in Thermal Spray Coatings for Gas Turbines and Energy Generation: A Review, J. Therm. Spray Technol. 22(5) (2013) 564-576.

W.Y. Lee, D.P. Stinton, C.C. Berndt, F. Erdogan, Y.-D. Lee & Z. Mutasim, Concept of Functionally Graded Materials for Advanced Thermal Barrier Coating Applications, Metallurgical and Protective Coatings, J Am Ceram Soc, 79 (1996) 3003-3012.

Y.W. Gu, K.A. Khor, Y.Q. Fu and Y. Wang, Functionally graded ZrO2-NiCrA1Y coatings prepared by plasma spraying using pre-mixed, spheroidized powders, Surf Coat Technol. 96 (1997) 305-312.

Valmik Bhavar, Prakash Kattire, Sandeep Thakare, Sachin Patil and R.K.P. Singh, A Review on Functionally Gradient Materials (FGMs) and Their Applications, IOP Conf. Series: Mater. Sci. Eng. 229 (2017).

A. Ashofteha, M. Mosavi Mashhadi and A. Amadeh, Thermal shock behavior of multilayer and functionally graded micro- and nano-structured topcoat APS TBCs, Ceram. Int. 44 (2018) 1951-1963

Klod Kokini, Jeffery DeJonge, Sudarshan Rangaraj and Brad Beardsley, Thermal shock of functionally graded thermal barrier coatings with similar thermal resistance, Surf Coat Technol. 154 (2002) 223–231.

K.A. Khor and Y.W. Gu, Thermal properties of plasma-sprayed functionally graded thermal barrier coatings, Thin Solid Films, 372 (2000) 104-113.

B. Kieback, A. Neubrand and H. Riedel, Processing techniques for functionally graded materials, Mater Sci Forum, 362 (2003) 81-106.

M.N. Baig and F.A. Khalid, Deposition and characterization of plasma sprayed Ni-5Al/ magnesia stabilized zirconia based functionally graded thermal barrier coating, IOP Conf. Ser.: Mater. Sci. Eng. 60 (2014) 12053.

K.A. Khor, Z.L. Dong and Y.W. Gu, Plasma sprayed functionally graded thermal barrier coatings, Mater. Lett. 38 (1999) 437– 444.

Pierre Fauchais, Ghislain Montavon and Ghislaine Bertrand, From Powders to Thermally Sprayed Coatings, J. Therm. Spray. Techn. 19 (2010) 56–80.

Zhe Lu, Sang-Won Myoung, Yeon-Gil Jung, Govindasamy Balakrishnan, Jeongseung Lee and Ungyu Paik, Thermal Fatigue Behavior of Air-Plasma Sprayed Thermal Barrier Coating with Bond Coat Species in Cyclic Thermal Exposure, Materials, 6 (2013) 3387-3403.

ASTM D 6944 – 15, Standard Practice for Determining the Resistance of Cured Coatings to Thermal Cycling

W. Brand, H.J. Grabke, D. Tom and J. Kruger, The oxidation behaviour of sprayed MCrAIY coatings, Surf. Coat. Technol., 87 (1996) 41-47.

G. Moskal, L. Swadźba, B. Mendala, M. Góral and M. Hetmańczyk, Degradation of the TBC system during the static oxidation test, J. Microsc. 237 (2009) 450-455.

Kadir Mert Doleker, Yasin Ozgurluk, Abdullah Selim Parlakyigit, Dervis Ozkan, Turgut Gulmez, Abdullah and Cahit Karaoglanli, Oxidation Behaviours of NiCr/YSZ Thermal Barrier Coatings (TBCs), Open Chem. 16 (2018) 876–881.

Hui Dong, Guan‐Jun Yang, Cheng‐Xin Li, Xiao‐Tao Luo and L. Chang‐Jiu, Effect of TGO Thickness on Thermal Cyclic Lifetime and Failure Mode of Plasma-Sprayed TBCs. J. Am. Ceram. Soc. 97(2014) 1226-1232.

C. Giolli, A. Scrivani, G. Rizzi, F. Borgioli, G. Bolelli and L. Lusvarghi, Failure Mechanism for Thermal Fatigue of Thermal Barrier Coating Systems, J. Therm. Spray. Techn. 18(2009) 223-230.

Kirti Teja Pasupuleti, Shawn Dsouza, Thejaraju R, Shankar Venkataraman, Parvati Ramaswamy, S.V.S. Narayana Murty, Performance and Steady State Heat Transfer Analysis of Functionally Graded Thermal Barrier Coatings Systems, Materials Today : Proceedings (Elsevier), 5(2018) 27936-27945.