Thermal response of various thermal barrier coatings in a high heat flux rocket engine
Traditional APS ZrO2-Y2O3 thermal barrier coatings (TBCs) formed by air plasma spraying and low pressure and air plasma sprayed ZrO2-Y2O3/NiCrAlY cermet coatings were tested in an H2-O2 rocket engine. The test cycle was approximately 1.2 s at 1400 C in a hydrogen-rich environment. During testing, the maximum metal temperature without a coating was 1310 C. The traditional ZrO2-Y2O3 TBCs with a 100-125 micron thick ceramic layer reduced the maximum metal temperature by approximately 350 C. Increasing the ceramic layer thickness to 200-225 microns resulted in an additional metal temperature reduction of 100 C. However, the cermet coatings, consisting of a ceramic and metal mixture, exhibited a much lower thermal protection capability by reducing the maximum metal temperature by approximately 100 C. It was also found that the surface roughness of the traditional TBCs had little effect on the thermal response.