Influence of Water Vapor on the Isothermal Oxidation Behavior of Thermal Barrier Coatings

The oxidation of specimens with thermal barrier coating (TBC) consisted of nickel-base superalloy, low-pressure plasma sprayed Ni-28Cr-6AI-0.4Y (wt pct) bond coating and electron beam physical vapor deposited 7.5 wt pct yttria stabilized zirconia (YSZ) top coating was studied at 1050℃ respectively in flows of 02, and mixture of O2 and 5%H2O under atmospheric pressure. The thermal barrier coating has relatively low oxidation rate at 1050℃ in pure O2. Oxidation rate of thermal barrier coating in the atmosphere of O% and 5%H2O is increased The oxidation kinetics obeys almost linear law after long exposure time in the presence of 5% water vapor. Oxide formed along the interface between bond coat and top coat after oxidation at 1050℃ in pure O2 consisted of Al2O3, whereas interfacial scales formed after oxidation at 1050℃ in a mixture of O2 and 5%H2O were mainly composed of Ni(AI,Cr)2O4,NiO and AI2O3. It is suggested that the effect of water vapor on the oxidation of the NiCrAlY coating may be attributed to the increase in Ni and Cr ions transport in the oxides.

Impedance spectroscopy study of high-temperature oxidation of Gd_2O_3-Yb_2O_3 codoped zirconia thermal barrier coatings

3Gd2O3-3Yb2O3-4Y2O3 （mole fraction, %） co-doped ZrO2 （GY-YSZ） thermal barrier coatings （TBCs） were produced by electron beam physical vapor deposition （EB-PVD）. The oxidation behavior of GY-YSZ at 1 050 ℃ was investigated using impedance spectroscopy （IS） combined with scanning electron microscopy （SEM）, Raman spectroscopy and X-ray diffractometry （XRD）. Various electrical responses observed in the impedance spectra corresponding to GY-YSZ grains and grain boundaries were explained using circuit modeling. The change in the conduction mechanism of GY-YSZ was found to be related to the O^2- vacancy and lattice distortion due to the stabilizer diffusion during the oxidation. The results also suggested that the specific oxidation information about the GY-YSZ grains and grain boundaries should be acquired at a moderate measurement temperature, which was related to the resistance value in the impedance spectra. The resistance values of the GY-YSZ grains and grain boundaries should be measured at 200 ℃ and 300 ℃, respectively.

Effects of supersonic fine particles bombarding on thermal barrier coatings after isothermal oxidation

This work was attempted to modify the current technology for thermal barrier coatings（TBCs） by adding an additional step of surface modification,namely,supersonic fine particles bombarding（SFPB） process,on bond coat before applying the topcoat.After isothermal oxidation at 1000 °C for different time,the surface state of the bond coat and its phase transformation were investigated using X-ray diffraction（XRD）,scanning electron microscopy（SEM） equipped with energy-dispersive X-ray spectrometry（EDS）,transmission electron microscopy（TEM） and Cr3＋ luminescence spectroscopy.The dislocation density significantly increases after SFPB process,which can generate a large number of diffusion channels in the area of the surface of the bond coat.At the initial stage of isothermal oxidation,the diffusion velocity of Al in the bond coat significantly increases,leading to the formation of a layer of stable α-Al2O3 phase.A great number of Cr3＋ positive ions can diffuse via diffusion channels during the transient state of isothermal oxidation,which can lead to the presence of（Al0.9Cr0.1）2O3 phase and accelerate the γ→θ→α phase transformation.Cr3＋ luminescence spectroscopy measurement shows that the residual stress increases at the initial stage of isothermal oxidation and then decreases.The residual stress after isothermal oxidation for 310 h reduces to 0.63 GPa compared with 0.93 GPa after isothermal oxidation for 26 h.In order to prolong the lifespan of TBCs,a layer of continuous,dense and pure α-Al2O3 with high oxidation resistance at the interface between topcoat and bond coat can be obtained due to additional SFPB process.

High temperature cyclic oxidation behavior of Y_2O_3-ZrO_2 thermal barrier coatings irradiated by high-intensity pulsed ion beam

The high-temperature oxidation resistance behavior of 7% （mass fraction） Y203-ZrO2 thermal barrier coatings （TBCs） irradiated by high-intensity pulsed ion beam （HIPIB） was investigated under the cyclic oxidation condition of 1 050 ℃ and 1 h. The columnar grains in the TBCs disappear after the HIPIB irradiation at ion current densities of 100-200 A/cm^2 and the irradiated surface becomes smooth and densified after remelting and ablation due to the HIPIB irradiation. The thermally grown oxide （TGO） layer thickness of the irradiated TBCs is smaller than that of the original TBCs. After 15 cycles, the mass gains of the original TBCs and those irradiated by ion current densities of 100 and 200 A/cm^2 due to the oxidation are found to be 0.8-0.9, 0.6-0.7, and 0.3-0.4 mg/cm^2, respectively. The inward diffusion of oxygen through the irradiated TBCs is significantly impeded by the densified top layer formed due to irradiation, which is the main reason for the improved overall oxidation resistance of the irradiated TBCs.

Oxidation and Hot Corrosion of Gradient Thermal Barrier Coatings Prepared by EB-PVD

The performances of gradient thermal barrier coatings (GTBCs) produced by EB-PVD were evaluated by isothermal oxidation and cyclic hot corrosion (HTHC) tests. Compared with conventional two-layered TBCs, the GTBCs exhibite better resistance to not only oxidation but also hot-corrosion. A dense Al2O3 layer in the GTBCs effectively prohibites inward diffusion of O and S and outward diffusion of Al and Cr during the tests. On the other hand, an "inlaid" interface, resulting from oxidation of the Al along the columnar grains of the bond coat, enhances the adherence of AI2O3 layer. Failure of the GTBC finally occurred by cracking at the interface between the bond coat and AI2O3 layer, due to the combined effect of sulfidation of the bond coat and thermal cvcling.

Influence of the Thermal Barrier Coatings Design on the Oxidation Behavior

The properties of two different types of thermal barrier coatings （TBCs） were compared to improve the surface characteristics on high temperature components. These TBCs consisted of a duplex TBC and a five-layered functionally graded TBC. NiCrAIY bond coats were deposited on a number of Inconel-738LC specimens using high velocity oxy-fuel spraying （HVOF） technique. For duplex coating, a group of these specimens were coated with yttria stabilized zirconia （YSZ） using plasma spray technique. Functionally graded NiCrAIY/YSZ coatings were fabricated by plasma spray using co-injection of the two different powders in a single plasma torch. The amount of zirconia in functionally graded coatings were gradually increased from 30 to 100 vol. pct. Microstructural changes, thermally grown oxide （TGO） layer growth and damage initiation of the coatings were investigated as a function of isothermal oxidation test at 970℃. As a complementary test, the performance of the fabricated coatings by the optimum processing conditions was evaluated as a function of intense thermal cycling test at 1100℃. Also the strength of the adhesive coatings of the substrate was also measured. Microstructural characterization was analyzed by scanning electron microscopy （SEM） and optical microscopy whereas phase analysis and chemical composition changes of the coatings and oxides formed during the tests were studied by XRD （X-ray diffraction） and EDS （energy dispersive spectrometer）. The results showed that microstructure and compositions gradually varied in the functionally graded coatings. By comparison of duplex and functionally graded TBCs oxidation behavior （duplex failure after 1700 h and funcitionally graded TECs failure after 2000 h）, thermal shock test and adhesion strength of the coatings, the functionally graded TBC had better performance and more durability.

Effect of enamel top coating on oxidation behavior of multi-arc ion plating NiCrAlY coating in oxygen containing water vapor

The oxidation behavior of Ni-Cr-Al-Y coating produced by multi-arc ion plating with and without an enamel coating was investigated in flow oxygen and oxygen containing water vapor at 900 ℃. The results show that Ni-Cr-Al-Y coating exhibits low oxidation rate at 900 ℃ in pure oxygen and the oxidation kinetics follow the parabolic rate law. The presence of water vapor accelerates the oxidation rate of Ni-Cr-Al-Y coating and K38G alloy.The enamel top coating is very effective in protecting the Ni-Cr-Al-Y coating from water vapor corrosion attack, but the corrosion attack beneath the enamel coating is not observed.

Thermal oxidation description methodology of thermal barrier coatings on gas turbine blades considering service characteristics

Predicting the thickness of Thermally Grown Oxide(TGO)and the residual stresses induced by TGO growth in the Thermal Barrier Coatings(TBCs)is significant work in analyzing the failure of TBCs.In practical applications,the operating temperature,oxygen partial pressure,aluminium content in TBCs,and porosity of the topcoat affect the oxidation rate.Therefore,a novel oxidation rate model is proposed to describe the effect of such factors.The parameters in the proposed model were fitted with isothermal degradation test data from prior literature.Then,a method for calculating the residual stress in a disk-shaped specimen was developed based on the oxidized growth strain model and the oxidized model.Finally,a variable-temperature oxidation experiment was performed to validate the new oxidation model.The average error between the predicted and experimental thicknesses is approximately 10%,and the average error between the residual stresses is 30%.Under the variable-temperature condition,the error between the predicted thickness and the average experimental thickness is 3.9%.

Improvement of thermally grown oxide layer in thermal barrier coating systems with nano alumina as third layer

A thermally grown oxide （TGO） layer is formed at the interface of bond coat/top coat. The TGO growth during thermal exposure in air plays an important role in the spallation of the ceramic layer from the bond coat. High temperature oxidation resistance of four types of atmospheric plasma sprayed TBCs was investigated. These coatings were oxidized at 1000 °C for 24, 48 and 120 h in a normal electric furnace under air atmosphere. Microstructural characterization showed that the growth of the TGO layer in nano NiCrAlY/YSZ/nano Al2O3 coating is much lower than in other coatings. Moreover, EDS and XRD analyses revealed the formation of Ni（Cr,Al）2O4 mixed oxides （as spinel） and NiO onto the Al2O3 （TGO） layer. The formation of detrimental mixed oxides （spinels） on the Al2O3 （TGO） layer of nano NiCrAlY/YSZ/nano Al2O3 coating is much lower compared to that of other coatings after 120 h of high temperature oxidation at 1000 °C.

Porous a-Al_2O_3 thermal barrier coatings with dispersed Pt particles prepared by cathode plasma electrolytic deposition

Porous α-Al2O3 thermal barrier coatings （TBCs） containing dispersed Pt particles were prepared by cathode plasma electrolytic deposition （CPED）. The influence of the Pt particles on the microstructure of the coatings and the CPED process were studied. The prepared coatings were mainly composed of α-Al2O3. The average thickness of the coatings was approximately 100 μm. Such single-layer TBCs ex- hibited not only excellent high-temperature cyclic oxidation and spallation resistance, but also good thermal insulation properties. Porous α-Al2O3 TBCs inhibit further oxidation of alloy substrates because of their extremely low oxygen diffusion rate, provide good thermal insu- lation because of their porous structure, and exhibit excellent mechanical properties because of the toughening effect of the Pt particles and because of stress relaxation induced by deformation of the porous structure.

Rheological Behaviour, Synthesis and Performance of Smart Thermal Barrier Coating Systems Based on Hollow Alumina

The stability of three water-based slurries containing different loads of Al microparticles was measured by laser scattering. The slurries displayed a Newtonian behaviour and the evolution of viscosity over nine days was found to be constant. Ground surfaces of nickel were also wetted similarly irrespective of the Al content in the slurries (30, 40 or 50 wt%) thereby demonstrating that the 1/10 PVA/H2O water based slurries are adequate for spraying. After deposition and annealing of the as-sprayed coatings, a thermal barrier coating system was formed with a top coat of hollow alumina spheres, an intermediate thermally grown oxide and a bottom aluminized bond coat. The coating system is shown to display very low thermal conductivity and remarkable oxidation resistance at high temperatures.

THE CHARACTERISTICS OF OXIDE SCALE FORMED ON LOW PRESSURE PLASMA SPRAYED NiCrAlY COATING IN THE PRESENCE OF 5% WATER VAPOR

The oxidations of low pressure plasma sprayed (LPPS) NiCrAlY coating on nickel base superalloy were studied at 1050℃ in flows of O2, and mixture of O2 and 5%H2O under atmospheric pressure. Oxide formed on the surface of LPPS NiCrAlY coating after oxidation at 1050℃ in pure O2 consisted of NiCr2O4, whereas oxide formed on the surface of LPPS NiCrAlY coating after oxidation at 1050℃ in a mixture of O2 and 5%H2O is mainly composed of NiO. The effect of water vapor on the characteristics of the oxide scale is attributed to the increase in Ni cation transport.

Microstructure and properties of sputtered thermal barrier coatings

A 3 kW radio frequency (RF) magnetron-sputtering unit was used to producezirconia ceramic coatings on hollow turbine blades and vanes, which had been deposited a NiCrAlYbond coat layer by cathodic arc deposition. The NiCrAlY coating surface was shot-peened, and theresidual stress in the bond coat layer and the effects of heat treatment on the residual stress arepresented. After shot peening porosities and microgaps disappear in the NiCrAlY bond coat, the wholedepth profile is residual compressive stress. Coarseness tests show that the roughness value (Rz)decreases from 16.4 to 3.3 mu m. The microstructure and phase composition of the coatings wereinvestigated using electron probe microanalysis (EPMA) and X-ray diffraction (XRD). The results showthat the/ NiCrAlY bond coat is composed of gamma and Cr phases, and the A1_2O_3 scales are formednear the interface between the ZrO_2 ceramic layer and the NiCrAlY bond coat. No degradationoccurred to RF sputtered ceramic coatings after oxidating at 1150 deg C for 100 h, heating at 1150deg C for 5 min and then air-cooling for 500 thermal cycles.

Thermal conductivity of (Sm_(1-x)La_x)_2Zr_2O_7 (x=0,0.25,0.5,0.75 and 1) oxides for advanced thermal barrier coatings

Pyrochlore oxides of general compositions, A2Zr2O7, where A is a 3＋ cation （La to Lu）, are promising candidate materials for applications as high temperature thermal barrier coatings because of their high melting points, high thermal expansion coefficients, and low thermal conductivities. In this study, oxides of Sm2Zr2O7, （Smo.75La0.25）2Zr2O7, （Sm0.5 La0.5）2 ZreO7, （Sm0.25La0.75）eZr2O7 and La2Zr2O7 were prepared by solid reactions at 1600℃ for 10 h using Sm2O3, La2O3 and ZrO2 as the reactants. The phase compositions of these ceramic materials were analyzed by X-ray diffractometer （XRD） and fourier transform infrared spectroscopy （FT-IR） methods, respectively. The microstructure was observed by scanning electron microscope （SEM）. The thermal conductivities of these ceramic materials were measured using laser-flash method. XRD and FT-IR results showed that pure ceramic materials with pyrochlore structure were prepared successfully. SEM results indicated that microstructures of these ceramic materials were dense and grain boundaries were very clean. The La2O3 doped Sm2Zr2O7 pyrochlores （Sm0.75 La0.25）2Zr2O7 and （Sm0.5 La0.5）2 Zr2O7 had lower thermal conductivity than the undoped Sm2Zr2O7. The thermal conductivity of （Sm0.25La0.75）2Zr2O7 was found to be lower than that of La2Zr2O7. The results showed that these ceramic materials had the potential to be used as candidate materials for TBCs.

Effect of rare earth doping on thermo-physical properties of lanthanum zirconate ceramic for thermal barrier coatings

The effect of rare earth doping on thermo-physical properties of lanthanum zirconate was investigated. Oxide powders of various compositions La2Zr2O7 were synthesized by coprecipitation-calcination method. High-temperature dilatometer, DSC, and laser thermal diffusivity methods were used to analyze thermal expansion coefficient （TEC）, specific heat, and thermal diffusivity. The results showed that CeO2 doped pyrochlores La2（Zr1.8Ce0.2）2O7 and La1.7（DyNd）0.15（Zr0.8Ce0.2）2O7 had higher TEC than La2Zr2O7 and La1.7Dy0.3Zr2O7. La2（Zr1.8Ce0.2）2O7, La1.7Dy0.3Zr2O7, and La1.7（DyNd）0.15（Zr0.8Ce0.2）2O7 had lower thermal conductivity than undoped La2Zr2O7. The Dy2O3, Nd2O3, and CeO2 codoped composition showed the lowest thermal conductivity and the highest TEC. Thermo-physical results also indicated that TEC of rare earth oxide doped La2Zr2O7 ceramic was slightly higher than that of conventional ZrO2-8Wt.% Y2O3 （8YSZ）, and its thermal conductivity was lower than that of 8YSZ.

Effect of Supersonic Fine Particles Bombarding on the Service Life of Thermal Barrier Coating

Thermally Grown Oxide（TGO） is a dominating component in controlling the effectiveness of thermal barrier coating.During the growth of TGO,whether we could homogeneously distribute Al atom on the TGO and the intermediate metal layer will be the key factor in forming TGO with continuous,uniform and single-ingredient（Al2O3）.In this experiment,we bombarded particles on to the metallic bound layer.We studied the influence of supersonic particle bombardment on the diffusion of Al.We hope to control the growth of TGO by monitoring the diffusion of Al.Thermal barrier coating（TBC）,which consists of a NiCoCrAlY bond coat and a ZrO2-8Y2O3（wt.%） topcoat（TC）,is fabricated on the nickel-base superalloy by air plasma spray（APS）.NiCoCrAlY bond coat is treated by supersonic fine particles bombarding（SFPB）.The morphology,oxidation behavior of TBC and phase are characterized by scanning electron microscope（SEM） equipped with an energy dispersive spectromrter（EDS） and X-ray diffractometer（XRD）.The influence of supersonic fine particles bombarding technique on the service life of thermal barrier coating is studied.The results show that SFPB technique improves the flaw of excessive surface undulation in the as-sprayed bond coat.A continuous,uniform and single-ingredient（Al2O3） TGO can quickly form in the SFPB TBC during high temperature oxidation process.The thickening of TGO is relatively slow.These will effectively suppress the formation of other non-protective oxides.Therefore,SFPB technique reduces the growth stress level generated by the continuous growth of TGO,and also avoids the stress concentration induced by formation of the large particle spinal oxide.Thermal barrier coating still remains well after 350 thermal cycles.The service life of TBC is improved.The proposed research provides theoretical basis and technical references to further improve and enhance the SFPB technique.

Failure of EB-PVD Thermal Barrier Coatings Subjected to Thermo-Mechanical Loading

Thermal barrier coatings （TBCs） were developed to protect metallic blades and vanes working in turbo-engines. The two-layered structure TBCs, consisting of NiCoCrAlY bond coat and yttria stabilized zirconia （YSZ）, were deposited on a cylinder of superalloy substrate by the electron beam-physical vapor deposition （EB-PVD）. The failure mechanism of the TBCs was investigated with a thermo-mechanical fatigue testing system under the service condition similar to that for turbine blades. Non-destructive evaluation of the coated specimens was conducted through the impedance spectroscopy. It is found that the crack initiation mainly takes place on the top coat at the edge of the heated zones.

Review of Numerical Simulation of TGO Growth in Thermal Barrier Coatings

Thermally grown oxide(TGO)is a critical factor for the service life of thermal barrier coatings(TBC).Numerical simulations of the growth process of TGO have become an effective means of comprehensively understanding the progressive damage of the TBC system.At present,technologies of numerical simulation to TGO growth include two categories:coupled chemical-mechanical methods and mechanical equivalent methods.The former is based on the diffusion analysis of oxidizing elements,which can describe the influence of bond coat(BC)consumption and phase transformation in the growth process of TGO on the mechanical behavior of each layer of TBC,and has high accuracy for the thickness evolution of TGO,but they cannot describe the lateral growth of TGO and the rumpling phenomenon induced.The latter focuses on describing the final stress and strain state after the growth of a specific TGO rather than the complete growth processes of TGO.Based on the measured TGO thickness growth curve,simulations of thickening and lateral growth can be achieved by directly applying anisotropic volumetric strain to oxidized elements and switching elements properties from the BC to the TGO.