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Improving the lifetime of suspension plasma sprayed thermal barrier coatings
University of West, Sweden.
University of West, Sweden.
Siemens Ind Turbomachinery AB, Sweden.
Linköping University, Department of Management and Engineering, Engineering Materials. Linköping University, Faculty of Science & Engineering.
2017 (English)In: Surface & Coatings Technology, ISSN 0257-8972, E-ISSN 1879-3347, Vol. 332, p. 550-559Article in journal (Refereed) Published
Abstract [en]

Development of thermal barrier coating systems (TBCs) for gas turbine applications allowing higher combustion temperatures is of high interest since it results in higher fuel efficiency and lower emissions. TBCs produced by suspension plasma spraying (SPS) have been shown to exhibit significantly lower thermal conductivity as compared to conventional systems due to their very fine porosity microstructure. However they have not been commercialised yet due to low reliability and life expectancy of the coatings. In addition to the initial topcoat microstructure and its sintering resistance, lifetime of a TBC system is highly dependent on bondcoat chemistry as it influences the growth rate of thermally grown oxide (TGO) layer. To enhance the lifetime of SPS TBCs, fundamental understanding of relationships between topcoat microstructure and its evolution with time, bondcoat chemistry, TGO growth rate, and lifetime is essential. The objective of this work was to study the effect of topcoat microstructure evolution and TGO growth rate on lifetime in SPS TBC systems. Experimental MCrAIY bondcoat powders with different aluminium activities were investigated and compared to a commercial bondcoat powder. High velocity air fuel spraying was used for bondcoat deposition while axial-SPS was used for yttria stabilized zirconia topcoat deposition. Lifetime was examined by thermal cyclic fatigue testing. Isothermal heat treatment was performed to study TGO evolution with time. The changes in microstructure of SPS coatings due to sintering under long term exposure at high temperatures were investigated. Different failure modes in SPS TBCs were also examined. The bondcoat with higher aluminium activity resulted in a significantly higher thermal cyclic lifetime of the corresponding TBC as it could have promoted protective alumina layer growth for a longer period of time. The results indicate that the significant changes in topcoat microstructure due to sintering as observed in this work could have a detrimental effect on TBC lifetime.

Place, publisher, year, edition, pages
ELSEVIER SCIENCE SA , 2017. Vol. 332, p. 550-559
Keyword [en]
Thermal barrier coatings (TBCs); Suspension plasma spraying (SPS); Lifetime; Sintering; Bondcoat chemistry; Thermally grown oxide (TGO)
National Category
Manufacturing, Surface and Joining Technology
Identifiers
URN: urn:nbn:se:liu:diva-144269DOI: 10.1016/j.surfcoat.2017.07.078ISI: 000418968100064OAI: oai:DiVA.org:liu-144269DiVA: diva2:1173621
Conference
44th International Conference on Metallurgical Coatings and Thin Films (ICMCTF)
Note

Funding Agencies|Knowledge Foundation [20160022]; GKN Aerospace, Sweden

Available from: 2018-01-12 Created: 2018-01-12 Last updated: 2018-01-12

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