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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

The Development of Erosion and Impact Resistant Turbine Airfoil Thermal Barrier Coatings

Thermal barrier coatings are used in gas turbine engines to protect engine hot-section components in the harsh combustion environments and extend component lifetimes. For thermal barrier coatings designed for turbine airfoil applications, further improved erosion and impact resistance are crucial for engine performance and durability. Advanced erosion resistant thermal barrier coatings are being developed, with a current emphasis on the toughness improvements using a combined rare earth- and transition metal-oxide doping approach. The performance of the doped thermal barrier coatings has been evaluated in burner rig and laser heat-flux rig simulated engine erosion and thermal gradient environments. The results have shown that the coating composition optimizations can effectively improve the erosion and impact resistance of the coating systems, while maintaining low thermal conductivity and cyclic durability. The erosion and impact damage mechanisms of the thermal barrier coatings will also be discussed.

Zhu, Dongming↗
NASA NTRS2005

Low Conductivity Thermal Barrier Coatings

Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. In this presentation, thermal barrier coating development considerations and requirements will be discussed. An experimental approach is established to monitor in real time the thermal conductivity of the coating systems subjected to high-heat-flux, steady-state and cyclic temperature gradients. Advanced low conductivity thermal barrier coatings have also been developed using a multi-component defect clustering approach, and shown to have improved thermal stability. The durability and erosion resistance of low conductivity thermal barrier coatings have been improved utilizing advanced coating architecture design, composition optimization, in conjunction with more sophisticated modeling and design tools.

Zhu, Dong-Ming↗
NASA NTRS1983

Improved performance thermal barrier coatings

Thermal barrier coatings offer an attractive approach to improving the durability and efficiency of the hot section of heat engines. The coatings typically consist of an inner alloy bond coating about 0.01 cm thick resistant to oxidation and hot corrosion and an outer ceramic layer, usually a stabilized zirconia, 0.01-0.05 cm thick. Here, the materials, thermomechanical stress, and hot corrosion problems associated with thermal barrier coatings are reviewed along with the capabilities and limitations of current technology. The coatings discussed include ZrO2-Y2O3/NiCrAlY, ZrO2-Y2O3/NiCoCrAlY, ZrO2-MgO/NiCoCrAlY, CaO-SiO2/Co-Cr-Al-Y, and CaO-SiO2/NiCrAlY systems. It is emphasized that the performance of thermal barrier coatings is governed by many complex and interrelated factors, so that optimization of these coatings always involves certain tradeoffs.

Levine, S. R.↗
NASA NTRS2003

Therma1 Conductivity and Durability of Advanced Thermal Barrier Coatings

Thermal barrier coatings (TBCs) will play a crucial role in advanced gas turbine engines because of their ability to further increase engine operating temperature and reduce cooling, thus helping to achieve engine emission and efficiency goals. Future TBCs must be designed with increased phase stability, lower thermal conductivity, and improved sintering and thermal stress resistance in order to effectively protect engine hot-section components. Advanced low conductivity TBCs are being developed at NASA by incorporating multi-component oxide dopants into zirconia-yttria or hafnia-yttria to promote the formation of thermodynamically stable defect clusters within the coating structures. This presentation will primarily focus on thermal conductivity and durability of the novel defect cluster thermal barrier coatings for turbine airfoil and combustor applications, determined by a unique CO2 laser heat-flux approach. The laser heat-flux testing approach emphasizes the real-time monitoring and assessment of the coating thermal conductivity under simulated engine temperature and thermal gradient conditions. The conductivity increase due to coating sintering (and/or phase change) and the conductivity decrease due to coating delamination have been determined under steady-state, cyclic, uniform or non-uniform heat-flux conditions. The coating radiation flux resistance has been evaluated by varying coating thermal gradients, and also by using a laser-heated radiative-flux source. Advanced multi-component TBC systems have been shown to have significantly reduced thermal conductivity and improved high temperature stability due to the nano-sized, low mobility defect clusters associated with the paired rare earth dopant additions. The effect of oxide defect cluster dopants on coating thermal conductivity, thermal stability and furnace cyclic durability will also be discussed. The current low conductivity TBC systems have demonstrated long-term cyclic durability at very high temperatures which is far beyond the baseline ZrO2-Y2O3 capabilities.

Zhu, Dong-Ming↗
NASA NTRS1998

Residual Stresses Modeled in Thermal Barrier Coatings

Thermal barrier coating (TBC) applications continue to increase as the need for greater engine efficiency in aircraft and land-based gas turbines increases. However, durability and reliability issues limit the benefits that can be derived from TBC's. A thorough understanding of the mechanisms that cause TBC failure is a key to increasing, as well as predicting, TBC durability. Oxidation of the bond coat has been repeatedly identified as one of the major factors affecting the durability of the ceramic top coat during service. However, the mechanisms by which oxidation facilitates TBC failure are poorly understood and require further characterization. In addition, researchers have suspected that other bond coat and top coat factors might influence TBC thermal fatigue life, both separately and through interactions with the mechanism of oxidation. These other factors include the bond coat coefficient of thermal expansion, the bond coat roughness, and the creep behavior of both the ceramic and bond coat layers. Although it is difficult to design an experiment to examine these factors unambiguously, it is possible to design a computer modeling "experiment" to examine the action and interaction of these factors, as well as to determine failure drivers for TBC's. Previous computer models have examined some of these factors separately to determine their effect on coating residual stresses, but none have examined all the factors concurrently. The purpose of this research, which was performed at DCT, Inc., in contract with the NASA Lewis Research Center, was to develop an inclusive finite element model to characterize the effects of oxidation on the residual stresses within the TBC system during thermal cycling as well as to examine the interaction of oxidation with the other factors affecting TBC life. The plasma sprayed, two-layer thermal barrier coating that was modeled incorporated a superalloy substrate, a NiCrAlY bond coat, and a ZrO2-8 wt % Y2O3 ceramic top coat. We examined the effect on stress during burner rig thermal cycling of the following independent variables: creep in the bond coat and top coat, oxidation, bond coat coefficient of thermal expansion, number of thermal cycles, and interfacial roughness. All these factors were suspected of influencing TBC failure. The model showed that all the material properties studied had a significant effect on the coating's residual stresses if the interface of the bond coat was rough. Bond coat expansion, bond coat oxidation, and bond coat creep had the highest effect on coating stresses, and these were highly interactive. The model also showed that the mechanism of stress generation during thermal cycling changed with the number of thermal cycles. Bond coat and top coat creep dominated stress generation during early thermal cycles, greatly increasing delamination stresses at the peaks of the bond coat. Therefore, creep is the prime driver for delamination cracking early in life, but cracking is limited to the bond coat peak region. Oxidation of the bond coat, on the other hand, tended to dominate stress generation during later cycles by greatly increasing delamination stresses over bond coat valleys. These results indicate that oxidation is the driver for the continued cracking necessary to cause ceramic layer spallation.

Freborg, A. M.↗
NASA NTRS1983

Covering solid, film cooled surfaces with a duplex thermal barrier coating

Thermal barrier coating systems were applied to hardware having passageways in the walls connecting apertures in the surface to a gas supply for film cooling. An inert gas, such as argon, is discharged through the apertures during the application of the thermal barrier coating system by plasma spraying. This flow of inert gas reduces both blocking of the holes and base metal oxidation during the coating operation.

Liebert, C. H.↗
NASA NTRS2009

Optical Diagnostics for High-Temperature Thermal Barrier Coatings

Thermal barrier coatings (TBCs) are typically composed of translucent ceramic oxides that provide thermal protection for metallic components exposed to high-temperature environments, such as in jet turbine engines. Taking advantage of the translucent nature of TBCs, optical diagnostics have been developed that can provide an informed assessment of TBC health that will allow mitigating action to be taken before TBC degradation threatens performance or safety. In particular, rare-earth-doped luminescent sublayers have been integrated into the TBC structure to produce luminescence that monitors TBC erosion, delamination, and temperature gradients. Erosion monitoring of TBC-coated specimens is demonstrated by utilizing visible luminescence that is excited from a sublayer that is exposed by erosion. TBC delamination monitoring is achieved in TBCs with a base rare-earth-doped luminescent sublayer by the reflectance-enhanced increase in luminescence produced in regions containing buried delamination cracks. TBC temperature monitoring is demonstrated using the temperature-dependent decay time for luminescence originating from the specific coating depth associated with a rare-earth-doped luminescent sublayer. The design and implementation of these TBCs with integrated luminescent sublayers is discussed, including co-doping strategies to produce more penetrating near-infrared luminescence. It is demonstrated that integration of the rare-earth-doped sublayers is achieved with no reduction in TBC life. In addition, results for multilayer TBCs designed to also perform as radiation barriers are also presented.

Eldridge, Jeffrey I.↗
NASA NTRS1995

Thermal conductivity of zirconia thermal barrier coatings

Thermal barrier coatings (TBC's) applied to the hot gas components of turbine engines lead to enhanced fuel efficiency and component reliability. Understanding the mechanisms which control the thermal transport behavior of the TBC's is of primary importance. Physical vapor description (PVD) and plasma spraying (PS) are the two most commonly used coating techniques. These techniques produce coatings with unique microstructures which control their performance and stability. The PS coatings were applied with either standard power or hollow sphere particles. The hollow sphere particles yielded a lower density and lower thermal conductivity coating. The thermal conductivity of both fully and partially stabilized zirconia, before and after thermal aging, will be compared. The thermal conductivity of the coatings permanently increase upon being exposed to high temperatures. These increases are attributed to microstructural changes within the coatings. Sintering of the as fabricated plasma sprayed lamellar structure is observed by scanning electron microscopy of coatings isothermally heat treated at temperatures greater than 1100 C. During this sintering process the planar porosity between lamella is converted to a series of small spherical pores. The change in pore morphology is the primary reason for the observed increase in thermal conductivity. This increase in thermal conductivity can be modeled using a relationship which depends on both the temperature and time of exposure. Although the PVD coatings are less susceptible to thermal aging effects, preliminary results suggest that they have a higher thermal conductivity than PS coatings, both before and after thermal aging. The increases in thermal conductivity due to thermal aging for partially stabilized plasma sprayed zirconia have been found to be less than for fully stabilized plasma sprayed zirconia coatings. The high temperature thermal diffusivity data indicates that if these coatings reach a temperature above 1100 C during operation, they will begin to lose their effectiveness as a thermal barrier.

Dinwiddie, R. B.↗
NASA NTRS1995

Thermal conductivity of zirconia thermal barrier coatings

Thermal barrier coatings (TBC's) applied to the hot gas components of turbine engines lead to enhanced fuel efficiency and component reliability. Understanding the mechanisms which control the thermal transport behavior of the TBC's is of primary importance. Physical vapor deposition (PVD) and plasma spraying (PS) are the two most commonly used coating techniques. These techniques produce coatings with unique microstructures which control their performance and stability. The PS coatings were applied with either standard powder or hollow sphere particles. The hollow sphere particles yielded a lower density and lower thermal conductivity coating. The thermal conductivity of both fully and partially stabilized zirconia, before and after thermal aging, will be compared. The thermal conductivity of the coatings permanently increases upon exposed to high temperatures. These increases are attributed to microstructural changes within the coatings. Sintering of the as-fabricated plasma sprayed lamellar structure is observed by scanning electron microscopy of coatings isothermally heat treated at temperatures greater than 1100 C. During this sintering process the planar porosity between lamella is converted to a series of small spherical pores. The change in pore morphology is the primary reason for the observed increase in thermal conductivity. This increase in thermal conductivity can be modeled using a relationship which depends on both the temperature and time of exposure. Although the PVD coatings are less susceptible to thermal aging effects, preliminary results suggest that they have a higher thermal conductivity than PS coatings, both before and after thermal aging. The increases in thermal conductivity due to thermal aging for partially stabilized plasma sprayed zirconia have been found to be less than for fully stabilized plasma sprayed zirconia coatings. The high temperature thermal diffusivity data indicate that if these coatings reach a temperature above 1100 C during operation, they will begin to lose their effectiveness as a thermal barrier.

Dinwiddie, R. B.↗
NASA NTRS1998

Analysis of Thermal Radiation Effects on Temperatures in Turbine Engine Thermal Barrier Coatings

Thermal barrier coatings are important, and in some instances a necessity, for high temperature applications such as combustor liners, and turbine vanes and rotating blades for current and advanced turbine engines. Some of the insulating materials used for coatings, such as zirconia that currently has widespread use, are partially transparent to thermal radiation. A translucent coating permits energy to be transported internally by radiation, thereby increasing the total energy transfer and acting like an increase in thermal conductivity. This degrades the insulating ability of the coating. Because of the strong dependence of radiant emission on temperature, internal radiative transfer effects are increased as temperatures are raised. Hence evaluating the significance of internal radiation is of importance as temperatures are increased to obtain higher efficiencies in advanced engines.

Siegel, Robert↗
NASA NTRS1985

Thermal expansion mismatch and oxidation in thermal barrier coatings

Thermal barrier coatings (TBC) for advanced gas turbine blades have been under intensive development during the last several years. This investigation is intended to achieve a clearer understanding of the mechanical behavior of plasma sprayed zirconia-yttria TBCs, involving a nickle-chromium-aluminum bond coat. The near term objectives are to study the stress states in a relatively simple model TBC subjected to steady state thermal loading. The resulting thermal expansion mismatch and oxidation have been primary targets for the study. The finite element approach and the effects of thermal mismatch and oxidation are described. A proposed mechanism for oxidation induced coating failure is also presented.

Chang, G. C.↗
NASA NTRS2004

Sintering and Fracture Behavior of Plasma-sprayed Thermal Barrier Coatings

Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. There is a need to characterize the fundamental sintering and fracture behavior of the current ZrO2-(7 to 8)wt%Y2O3 coating, in order to fully take advantage of the coating capability. In addition, a thorough evaluation of the coating behavior and temperature limits will be useful for more accurately assessing the benefit gained from future advanced coating systems. In this study, the sintering behavior of plasma-sprayed ZrO2-8wt%Y2O3 coatings was systematically investigated as a function of temperature and time using a dilatometer in the temperature range of 1200-1500 C. The coating sintering kinetics obtained by dilatometry were compared with the coating thermal conductivity increase kinetics, determined by a steady-state laser heat-flux testing approach, under high temperature and thermal gradient sintering conditions. The mode I, mode II, and mixed mode I-mode II fracture behavior of as-processed and sintering-annealed coatings was determined in asymmetric flexure loading at ambient and elevated temperatures in order to evaluate the coating sintering effects on the fracture envelope of K(sub I) versus K(sub II). The coating thermal conductivity cyclic response associated with the interface delamination of the coating systems under simulated engine heat-flux conditions will be discussed in conjunction with the sintering and fracture testing results.

Zhu, Dongming↗
NASA NTRS1978

Thermal Barrier Coatings

Thermal barrier coatings offer gas turbines one way to reach fuel flexibility and improved efficiency. Test/analytical results are encouraging for this young technology.

Grisaffe, S. J.↗
NASA NTRS1984

Oxidation behavior of a thermal barrier coating

Thermal barrier coatings, consisting of a plasma sprayed calcium silicate ceramic layer and a CoCrAlY or NiCrAlY bond coat, were applied on B-1900 coupons and cycled hourly in air in a rapid-response furnace to maximum temperatures of 1030, 1100, or 1160 C. Eight specimens were tested for each of the six conditions of bond-coat composition and temperature. Specimens were removed from test at the onset of failure, which was taken to be the formation of a fine surface crack visible at 10X magnification. Specimens were weighed periodically, and plots of weight gain vs time indicate that weight is gained at a parabolic rate after an initial period where weight was gained at a much greater rate. The high initial oxidation rate is thought to arise from the initially high surface area in the porous bond coat. Specimen life (time to first crack) was found to be a strong function of temperature. However, while test lives varied greatly with time, the weight gain at the time of specimen failure was quite insensitive to temperature. This indicates that there is a critical weight gain at which the coating fails when subjected to this test.

Miller, R. A.↗
NASA NTRS1984

Introduction to life modeling of thermal barrier coatings

Thermal barrier coatings may be applied to air-cooled turbine section airfoils to insulate such components from hot gases in the engine. The coatings, which typically consist of about 0.01 to 0.04 cm of zirconia-yttria ceramic over about 0.01 cm of NiCrAlY or NiCrAlZr alloy bond coat, allow increased gas temperatures or reduced cooling air flows. This, in turn, leads to marked improvements in engine efficiency and performance. However, certain risks are associated with designing for maximum benefits, and eventually a point is reached where coating loss would immediately jeopardize the underlying component. Therefore, designers must be able to accurately predict the life of a given bill-of-material coating in any particular design. The results of an in-house aeronautics, base research and technology program which is designed to provide the first steps towards developing mission-capable life-prediction models are outlined.

Miller, R. A.↗
NASA NTRS1985

Development of thermomechanical life prediction models for thermal barrier coatings

Thermal barrier coatings (TBCs) for turbine airfoils in high-performance engines represent an advanced materials technology with both performance and durability benefits. The foremost TBC benefit is the reduction of heat transferred into air-cooled components. To achieve these benefits, however, the TBC system must be reliable. Mechanistic thermomechanical and thermochemical life models and statistically significant design data are therefore required for the reliable exploitation of TBC benefits on gas turbine airfoils. Garrett's NASA-HOST Program (NAS3-23945) is designed to fulfill these requirements. This program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant TBC systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma-spray (LPPS) applied oxidation resistant NiCrAlY bond coating, and an air-plasma-sprayed yttria partially stabilized zirconia insulated layer is applied by both Chromalloy and Klock. The second type of TBC is applied by the electron beam-physical vapor deposition process by Temescal. Thermomechanical life models are being tailored to predict TBC strain tolerance in terms of materials, engine, and mission parameters. Continuum and fracture mechanics approaches and statistical methods are being evaluated to develop tensile and compressive strain functions required to drive a mission analysis capable thermomechanical life model for TBCs. Results of initial testing to calibrate these life models will be presented.

Strangman, T. E.↗
NASA NTRS1995

Mechanical properties testing and results for thermal barrier coatings

Thermal Barrier Coatings (TBC's) provide a significant challenge in the evaluation of their mechanical properties in ways that provide data that is not specimen dependent. The paper reviews various developments of the principal author over the past several years for both plasma sprayed and physical vapor deposited (PVD) materials, as well as new data on the fatigue behavior of one material system. The test methods that have been employed address tensile and compressive modulus and ultimate strength, tensile and compressive fatigue strength, and interfacial strength. This testing is now underway. Property testing is especially difficult for TBC's owing to the limitation on fabrication thickness of the coating. Bending tests are not used as these tests do not provide sufficiently uniform states of strain for property evaluations. Test specimens with uniform states of axial stress have been devised for each material system. The results show that the material property results between various experimenters and experimental methods are not yet consistent. However, the results provide critical design data at a suitable level of accuracy for life prediction. The paper will review both tensile and compressive mechanical testing of uniaxial specimens showing property dependencies on material density and temperatures for both material systems. Successful test results for both tensile and compressive fatigue loadings will be given. The test data shows that the fatigue strength of the TBC's is highly stress dependent in both loading conditions and is likely to depend on stress range and not mean stress. The fatigue strength of the plasma sprayed TBC's appears to increase with elevated temperatures in a range of temperatures below the creep activation temperature for the materials. The plasma sprayed TBC materials have been confirmed to have cyclic hysteresis at all temperature levels down to room temperature. Limited failure analysis data for various specimens suggest that the failure modes are driven by normal geometric discontinuities in the TBC's.

Cruse, T. A.↗
NASA NTRS1998

Effect of Layer-Graded Bond Coats on Edge Stress Concentration and Oxidation Behavior of Thermal Barrier Coatings

Thermal barrier coating (TBC) durability is closely related to design, processing and microstructure of the coating Z, tn systems. Two important issues that must be considered during the design of a thermal barrier coating are thermal expansion and modulus mismatch between the substrate and the ceramic layer, and substrate oxidation. In many cases, both of these issues may be best addressed through the selection of an appropriate bond coat system. In this study, a low thermal expansion and layer-graded bond coat system, that consists of plasma-sprayed FeCoNiCrAl and FeCrAlY coatings, and a high velocity oxyfuel (HVOF) sprayed FeCrAlY coating, is developed to minimize the thermal stresses and provide oxidation resistance. The thermal expansion and oxidation behavior of the coating system are also characterized, and the strain isolation effect of the bond coat system is analyzed using the finite element method (FEM). Experiments and finite element results show that the layer-graded bond coat system possesses lower interfacial stresses. better strain isolation and excellent oxidation resistance. thus significantly improving the coating performance and durability.

Zhu, Dongming↗