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Influence of substrate material on the life of atmospheric plasmas prayed thermal barrier coatings
Linköping University, Department of Management and Engineering, Engineering Materials. Linköping University, The Institute of Technology.
Linköping University, Department of Management and Engineering, Engineering Materials. Linköping University, The Institute of Technology.
Linköping University, Department of Management and Engineering, Engineering Materials. Linköping University, The Institute of Technology.
Linköping University, Department of Physics, Chemistry and Biology, Thin Film Physics. Linköping University, The Institute of Technology.ORCID iD: 0000-0003-3277-1945
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2013 (English)In: Surface & Coatings Technology, ISSN 0257-8972, E-ISSN 1879-3347, Vol. 232, no 15, 795-803 p.Article in journal (Refereed) Published
Abstract [en]

Thermal barrier coatings (TBCs) are used in gas turbines to prolong the life of the underlying substrates and to increase the efficiency of the turbines by enabling higher combustion temperatures. TBCs may fail during service due to thermal fatigue or through the formation of non-protective thermally grown oxides (TGOs). This study compares two atmospheric plasma sprayed (APS) TBC systems comprising of two identical TBCs deposited on two different substrates (Haynes 230 and Hastelloy X). The thermal fatigue life was found to differ between the two TBC systems. The interdiffusion of substrate elements into the coating was more pronounced in the TBC system with shorter life, however, very few of the substrate elements (only Mn and to some extent Fe) formed oxides in the bond coat/top coat interface. Fractography revealed no differences in the fracture behaviour of the TBCs; the fracture occurred, in both cases, to about 60% in the top coat close to the interface and the remainder in the interface. Nanoindentation revealed only small differences in mechanical properties between the TBC systems and a finite element crack growth analysis showed that such small differences did not cause any significant change in the crack driving force. The oxidation kinetics was found to be similar for both TBC systems for the formation of Al2O3 but differed for the kinetics of non-Al2O3 TGOs where the TBC system with shortest life had a faster formation of non-Al2O3 TGOs caused by a faster Al depletion. The difference in non-Al2O3 TGO growth kinetics was considered to be the main reason for the difference in life.

Place, publisher, year, edition, pages
Elsevier, 2013. Vol. 232, no 15, 795-803 p.
Keyword [en]
Thermal barrier coating; TBC; Substrate influence; Interdiffusion; Fatigue life; Oxidation kinetics
National Category
Engineering and Technology
Identifiers
URN: urn:nbn:se:liu:diva-96810DOI: 10.1016/j.surfcoat.2013.06.101ISI: 000327691300103OAI: oai:DiVA.org:liu-96810DiVA: diva2:643477
Available from: 2013-08-27 Created: 2013-08-27 Last updated: 2017-12-06Bibliographically approved
In thesis
1. Thermal Barrier Coatings: Durability Assessment and Life Prediction
Open this publication in new window or tab >>Thermal Barrier Coatings: Durability Assessment and Life Prediction
2013 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Thermal barrier coating (TBC) systems are coating systems containing a metallic bond coat and a ceramic top coat. TBCs are used in gas turbines for thermal insulation and oxidation resistance. Life prediction of TBCs is important as high-temperature exposure degrades the coatings through mechanisms such as thermal fatigue and the formation and growth of thermally grown oxides (TGOs). This thesis presents research on durability assessment and life prediction of air plasma sprayed TBCs.

The adhesion of thermal barrier coatings subjected to isothermal oxidation, thermal cycling fatigue and thermal shock was studied. The adhesion strength and fracture characteristics were found to vary with heat treatment type.

The influence of interdiffusion between bond coat and substrate was studied on TBCs deposited on two different substrates. The thermal fatigue life was found to differ between the two TBC systems. While fractography and nanoindentation revealed no differences between the TBC systems, the oxidation kinetics was found to differ for non-alumina oxides.

The influence of bond coat/top coat interface roughness on the thermal fatigue life was studied; higher interface roughness promoted longer thermal fatigue life. Different interface geometrieswere tried in finite element crack growth simulations, and procedures for creating accurate interface models were suggested.

The influence of water vapour and salt deposits on the oxidation/corrosion of a NiCoCrAlY coating and a TBC were studied. Salt deposits gave thicker TGOs and promoted an Y-rich phase. The effect of salt deposits was also evident for TBC coated specimens.

A microstructure-based life model was developed using the Thermo-Calc software. The model included coupled oxidation-diffusion, as well as diffusion blocking due to the formation of internal oxides and pores. The model predicted Al-depletion in acceptable agreement with experimental observations.

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2013. 65 p.
Series
Linköping Studies in Science and Technology. Dissertations, ISSN 0345-7524 ; 1527
National Category
Engineering and Technology
Identifiers
urn:nbn:se:liu:diva-96816 (URN)978-91-7519-569-8 (ISBN)
Public defence
2013-10-18, ACAS, Hus A, Campus Valla, Linköpings universitet, Linköping, 10:15 (English)
Opponent
Supervisors
Funder
Swedish Energy Agency
Available from: 2013-08-27 Created: 2013-08-27 Last updated: 2014-01-07Bibliographically approved

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Eriksson, RobertJohansson, StenBrodin, HåkanBroitman, Esteban

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