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The effects of inelastic behavior of yttria-stabilized zirconia (YSZ) materials were analyzed. The results show these materials to be sensitive to small changes in temperature and are supported by measurements of inelastic behavior in disc and bar specimens at temperatures as low as 1010 C (1850 F). At higher thermomechanical loadings, the test specimens can deform to strains above 1 percent.
The reactions between partially stabilized zirconia, containing 8 weight-percent yttria, and oxides and sulfates of various elements were studied at 1200, 1300, and 1400 C for times to 800, 400, and 200 hours, respectively. These oxides and sulfates represent impurities and additives potentially present in gas turbine fuels or impurities in the turbine combustion air as well as the elements of the substrate alloys in contact with zirconia. Based on the results, these compounds can be classified in four groups: (1) compounds which did not react with zirconia (Na2SO4, K2SO4, Cr2O3, Al2O3 and NiO); (2) compounds that reached completely with both zirconia phases (CaO, BaO, and BaSO4); (3) compounds that reacted preferentially with monoclinic zirconia (Na2O, K2O, CoO, Fe2O3, MgO, SiO2, and ZnO); and (4) compounds that reacted preferentially with cubic zirconia (V2O5, P2O5).
The Ames pilot heater is a ceramic regenerative heater that provides high temperature air for aerodynamic and combustion experiments. The development of this heater to provide a heat storage bed with temperature capability of about 4600 R is described. A bed was designed and installed having cored brick elements of yttria-stabilized zirconia. The bed dimensions were 14 inches in diameter by 10 feet high. The thermal stress limitations of the bed were studied and maximum air flow rates based upon these limits were established. A combustion reheat system was designed and installed to provide the necessary control over the bed temperature distribution. The revised heater system was successfully operated at a maximum bed temperature of 4600 R. The successful operation demonstrated that yttria-stabilized zirconia cored brick can satisfy the high temperature-long duration requirement for storage heater applications.
The spectral emittance of a NASA developed zirconia ceramic thermal barrier coating system, consisting of a metal substrate, a layer of Ni-Cr-Al-Y bond material and a layer of yttria-stabilized zirconia ceramic material, is analyzed. The emittance, needed for evaluation of radiant heat loads on cooled coated gas turbine components, was measured over a range of temperatures that would be typical of its use on such components. Emittance data were obtained with a spectrometer, a reflectometer and a radiation pyrometer at a single bond coating thickness of 0.010 cm and at a ceramic coating thickness of 0-0.076 cm. The data were transformed into the hemispherical total emittance and were correlated to the ceramic coating thickness and temperature using multiple-regression curve-fitting techniques. The system was found to be highly reflective, and, consequently, capable of significantly reducing radiation heat loads on cooled gas turbine engine components.
Ceramic thermal-barrier coatings on hot engine parts have the potential to reduce metal temperatures, coolant requirements, cost, and complexity of the cooling configuration, and to increase life, turbine efficiency and gas temperature. Coating systems consisting of a plasma-sprayed layer of zirconia stabilized with either yttria, magnesia or calcia over a thin alloy bond coat have been developed, their potential analyzed and their durability and benefits evaluated in a turbojet engine. The coatings on air-cooled rotating blades were in good condition after completing as many as 500 two-minute cycles of engine operation between full power at a gas temperature of 1644 K and flameout, or as much as 150 hours of steady-state operation on cooled vanes and blades at gas temperatures as high as 1644 K witn 35 start and stop cycles. On the basis of durability and processing cost, the yttria-stabilized zirconia was considered the best of the three coatings investigated.
Spectral emittance measurements were made on a two-layer ceramic thermal barrier coating system consisting of a metal substrate, a NiCrAly bond coating and a yttria-stabilized zirconia ceramic coating. Spectral emittance data were obtained for the coating system at temperatures of 300 to 1590 K, ceramic thickness of zero to 0.076 centimeter, and wavelengths of 0.4 to 14.6 micrometers. The data were transformed into total hemispherical emittance values and correlated with respect to ceramic coating thickness and temperature using multiple regression curve fitting techniques. The results show that the ceramic thermal barrier coating system is highly reflective and significantly reduces radiation heat loads on cooled gas turbine engine components. Calculation of the radiant heat transfer within the nonisothermal, translucent ceramic coating material shows that the gas-side ceramic coating surface temperature can be used in heat transfer analysis of radiation heat loads on the coating system.
Currently proposed thermal barrier systems for aircraft gas turbine engines consist of NiCrAlY bond coating covered with an insulating oxide layer of yttria-stabilized zirconia. The effect of yttrium concentration (from 0.15 to 1.08 w/o) in the bond coating and the yttria concentration (4 to 24.4 w/o) in the oxide layer were evaluated. Furnace, natural gas-oxygen torch, and Mach 1.0 burner rig cyclic tests on solid specimens and air-cooled blades were used to identify trends in coating behavior. Results indicate that the combinations of yttrium levels between 0.15 - 0.35 w/o in the bond coating and the yttria concentration between 6 - 8 w/o in the zirconium oxide layer were the most adherent and resistant to high temperature cyclic exposure.
A two-layer thermal barrier coating system with a bond coating of nickel-chromium-aluminum-yttrium and a ceramic coating of yttria-stabilized zirconia was tested for corrosion protection, thermal protection and durability. Full-scale gas-turbine engine tests demonstrated that this coating eliminated burning, melting, and warping of uncoated parts. During cyclic corrosion resistance tests made in marine diesel fuel products of combustion in a burner rig, the ceramic cracked on some specimens. Metallographic examination showed no base metal deterioration.
Ceramic thermal barrier coating (TBC) system was tested by industrial and governmental organizations for a variety of aeronautical, marine, and ground-based gas turbine engine applications. This TBC is a two-layer system with a bond coating of nickel-chromium-aluminum-yttrium (Ni-16Cr-6Al-0.6Y, in wt. percent) and a ceramic coating of yttria-stabilized zirconia (ZrO2-12Y2O3, in wt. percent). Seven tests evaluated the system's thermal protection and durability. Five other tests determined thermal conductivity, vibratory fatigue characteristics, and corrosion resistance of the system. The information presented includes test results and photographs of the coated parts. Recommendations are made for improving the coating procedures.
A cyclic furnace study was conducted between 990 - 280 C and 1095 - 280 C to evaluate the effects of yttrium, chromium, and aluminum concentrations in nickel base alloy bond coatings and also the effect of the bond coating thickness on the performance of yttria-stabilized zirconia thermal barrier coatings. The presence and the concentration of yttrium is very critical. Without yttrium, rapid oxidation of Ni-Al, Ni-Cr, and Ni-Cr-Al bond coatings causes zirconia thermal barrier coatings to fail very rapidly. Concentrations of chrominum and aluminum in Ni-Cr-Al-Y bond coating have a very significant effect on the thermal barrier coating life. This effect, however, is not as great as that due to yttrium. Furthermore, the thickness and the thickness uniformity also have a very significant effect on the life of the thermal barrier system.
A cyclic furnace study was conducted on thermal barrier systems to evaluate the effects of yttrium, chromium, and aluminum in nickel-base alloy bond coatings and the effect of bond coating thickness on yttria-stabilized zirconia thermal barrier coating life. Without yttrium in the bond coatings, the zirconia coatings failed very rapidly. Increasing chromium and aluminum in the Ni-Cr-Al-Y bond coatings increased total coating life. This effect was not as great as that due to yttrium. Increased bond coat thickness was also found to increase life.
A cyclic furnace study was conducted on thermal barrier systems to evaluate the effects of yttrium, chromium and aluminum in nickel-base alloy bond coatings and the effect of bond coating thickness on yttria-stabilized zirconia thermal barrier coating life. Without yttrium in the bond coatings, the zirconia coatings failed very rapidly. Increasing chromium and aluminum in the Ni-Cr-Al-Y bond coatings increased total coating life. This effect was not as great as that due to yttrium. Increased bond coat thickness was also found to increase life.
The paper studies calculated and measured metal wall temperatures of uncoated vanes and the same vanes coated with a thermal barrier coating system of NiCrAlY bond and yttria-stabilized zirconia ceramic. It is shown that thermal contact between layers is negligible. The significance of data scatter and of published ceramic thermal conductivity values is discussed.
The variables affecting the design of a composite turbine shroud, consisting of a metal base, an interlayer of porous metal, and an outer layer of yttria-stabilized zirconia, are analyzed. Results show that significant reductions in the cooling-air to gas-flow ratio are indicated for the composite shrouds compared to an all-metal shroud that was only impingement air cooled. The good insulating properties of the ceramic reduced the temperatures of the porous metal and support wall significantly. For a given porous metal density and coolant- to gas-flow ratio, decreasing the thickness of the porous metal and increasing ceramic thickness resulted in lower support wall temperatures. To maintain given allowable inter-layer temperatures and coolantto gas-flow ratios, porous-metal density or thermal conductivity must increase as the ratio of the thickness of the ceramic-to-porous metal decreases. It is concluded that a 1.78 mm thickness of porous material with a density of 0.2 and a 1.78 mm thickness of ceramic appears to be a good composite wall configuration for the assumed conditions
A cyclic furnace study was conducted on thermal barrier systems to evaluate the effects of yttrium, chromium and aluminum in nickel-base alloy bond coatings and the influence of the bond coating thickness on yttria-stabilized zirconia thermal barrier coating lifetimes. Without yttrium in the bond coatings, the zirconia coatings failed very rapidly. Increasing concentrations of chromium and aluminum in the Ni-Cr-Al-Y bond coatings increased the total coating lifetimes. This effect was not as great as that due to yttrium. Increased bond coating thickness was also found to increase the lifetimes.
The way in which a chemical processor that uses the Martian atmosphere as its only feedstock, thereby reducing the mass that must be launched from earth, can help to return a surface sample from Mars from a single Space Shuttle launch is described. Richter's (1981) study on both the theoretical and experimental aspects of oxygen separation using yttria-stabilized zirconia membranes is cited. Here, separation is accomplished by applying a voltage across the membrane which results in the selective conduction of oxygen ions from one side to the other. It is noted that by using thermal dissociation of the carbon dioxide in the Martian atmosphere to produce oxygen (and carbon monoxide), these zirconia electrolytic cells can be employed to separate oxygen from the atmospheric stream. Descriptions are also given of atmospheric filtration, atmospheric compression, and waste heat recovery, and of the oxygen precooler and oxygen compressor.
Thermally induced failure processes of plasma-sprayed thermal barrier coatings are examined. Cracking processes give rise to noise which was monitored by acoustic emission (AE) techniques. The sequential failure of coatings was examined from samples which were thermally cycled. Coatings of yttria-stabilized zirconia with and without a NiCrAlZr bond coat were plasma-sprayed onto U700 alloy rod. In some cases the substrate was intentionally overheated during deposition of the thermal protection system to check how this process variable influenced the AE response of the specimen. In this way a qualitative appraisal of how process variables affect coating integrity could be discerned in terms of cracking behavior. Results from up to seven consecutive thermal cycles are reported here. Coating failure was observed in all cases. Failure of the thermal protection system is progressive, since cracking and crack growth were observed prior to ultimate failure. Thus castastrophic failure occurs at some stage when there is a transformation from the microcrack to a macrocrack network.
The application of ceramics to gas turbine combustor liners to reduce liner metal temperature was studied in an experiment in which yttria-stabilized zirconia plasma was sprayed on compliant metal substrates exposed to near stoichiometric combustion. The strain isolation pad materials chosen were Hoskins Alloy 875 and BRUNSLLOY 534 Fiber Metal of 0.25 and 0.38 cm thicknesses and 35 and 45 percent density levels. Combustor screening tests of all specimens showed no evidence of deterioration or failure. Specimens exposed to flame temperatures in excess of 2100 K were convectively or convective-transpiration cooled and were evaluated in a 10 cm sq flame tube at inlet air temperature of 533 K and pressure of 0.5 MPa. The results suggest the superiority of a system composed of the Hoskins Alloy 875 compliant pad with 0.25 cm thickness and 35 percent density coupled with a NiCrAlY bond coat and a 8 percent Y2O3-ZrO2 ceramic top coat of 0.19 cm thickness.