Current status of thermal barrier coatings — An overview
TL;DR: The state-of-the-art thermal barrier coatings for gas turbine applications are currently a plasma-sprayed ZrO 2 -(6%8%) Y 2 O 3 ceramic layer over an MCrAlY (M ≡ Ni, Co or NiCo) bond coat layer plasma sprayed at low pressure.
Abstract: The science and technology of thermal barrier coatings has advanced considerably since reports of the first test on turbine blades in a research engine in 1976. Today thermal barrier coatings are flying in revenue service in a low risk location within the turbine section of certain gas turbine engines. The state-of-the-art coating system for gas turbine applications is currently a plasma-sprayed ZrO 2 -(6%–8%) Y 2 O 3 ceramic layer over an MCrAlY (M ≡ Ni, Co or NiCo) bond coat layer plasma sprayed at low pressure. Although the potential for meeting current and short-term goals is high, longer-range goals may not be attainable with current coating concepts. These longer-range goals will involve high risk designs where coating loss could lead directly to component loss. Several steps must be taken to help meet these goals. Improved understanding of coating failure mechanisms is required. Models are needed to predict lifetimes. Process automation and quality control procedures must be instituted. Finally, new concepts in plasma-sprayed coatings must be developed and alternatives to the plasma- spraying process may be required. The current status of thermal barrier coatings and prospects for future progress in the above areas are summarized.
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TL;DR: In this article, the structure, properties, and failure mechanisms of thermal barrier coatings (TBCs) are reviewed, together with a discussion of current limitations and future opportunities.
Abstract: Hundreds of different types of coatings are used to protect a variety of structural engineering materials from corrosion, wear, and erosion, and to provide lubrication and thermal insulation. Of all these, thermal barrier coatings (TBCs) have the most complex structure and must operate in the most demanding high-temperature environment of aircraft and industrial gas-turbine engines. TBCs, which comprise metal and ceramic multilayers, insulate turbine and combustor engine components from the hot gas stream, and improve the durability and energy efficiency of these engines. Improvements in TBCs will require a better understanding of the complex changes in their structure and properties that occur under operating conditions that lead to their failure. The structure, properties, and failure mechanisms of TBCs are herein reviewed, together with a discussion of current limitations and future opportunities.
3,548 citations
TL;DR: In this paper, BaZrO3 and La2Zr2O7 powders were optimized for application as powders for plasma spraying and thermal properties of these materials were determined.
Abstract: Zirconates with high melting points were investigated for
application as materials for thermal barrier coatings at operating temperatures >1300°C. SrZrO3, BaZrO3, and La2Zr2O7
powders were synthesized and sintered to compacts with
various levels of porosity. The sintering results indicated a promising low-sintering activity of the investigated materials. Thermal properties of these dense materials were determined. Thermal expansion coefficients were slightly lower than those of Y2O3-stabilized ZrO2 (YSZ); thermal conductivities of SrZrO3 and BaZrO3 were comparable or slightly higher than those of YSZ. La2Zr2O7 had a lower thermal conductivity. SrZrO3 was not suitable for application as a thermal barrier coating because of a phase transition at temperatures between 700° and 800°C. Mechanical properties (hardness, fracture toughness, and Young’s modulus) of dense BaZrO3 and La2Zr2O7 samples were determined by indentation techniques and showed lower hardness and Young’s modulus compared to YSZ. BaZrO3 and La2Zr2O7 powders were optimized for application as powders for plasma spraying. Plasma-sprayed coatings were produced and characterized. Thermal cycling with a gas burner at 1200°C showed a massive attack of the BaZrO3 coating, with loss of BaO. On the other hand, the La2Zr2O7 coating showed excellent thermal stability and thermalshock behavior.
1,074 citations
TL;DR: In this paper, the thermal conductivities of hot-pressed rare-earth zirconates have been investigated for thermal barrier coatings (TBCs) for gas-turbine engine applications.
Abstract: Rare-earth zirconates have been identified as a class of low-thermal-conductivity ceramics for possible use in thermal barrier coatings (TBCs) for gas-turbine engine applications. To document and compare the thermal conductivities of important rare-earth zirconates, we have measured the thermal conductivities of the following hot-pressed ceramics: (i) Gd 2 Zr 2 O 7 (pyrochlore phase), (ii) Gd 2 Zr 2 O 7 (fluorite phase), (iii) Gd 2.58 Zr 1.57 O 7 (fluorite phase), (iv) Nd 2 Zr 2 O 7 (pyrochlore phase), and (v) Sm 2 Zr 2 O 7 (pyrochlore phase). We have also measured the thermal conductivity of pressureless-sintered 7 wt% yttria-stabilized zirconia (7YSZ)--the commonly used composition in current TBCs. All rare-earth zirconates investigated here showed nearly identical thermal conductivities, all of which were ∼30% lower than the thermal conductivity of 7YSZ in the temperature range 25°-700°C. This finding is discussed qualitatively with reference to thermal-conductivity theory.
596 citations
TL;DR: In this paper, the main experimental techniques for measurement of residual stresse are briefly described, with particular attention given to the method of continuous curvature monitoring, and relationships are presented between residual stresses and corresponding strain energy release rates during interfacial debonding.
Abstract: An overview is presented of the development of residual stresses in thermal spray coatings and their ef-fects on interfacial debonding. The main experimental techniques for measurement of residual stresse are briefly described, with particular attention given to the method of continuous curvature monitoring. Boundary conditions satisfied by all residual stress distributions are identified and expressions derived for the curvatures and stress distributions arising from a uniform misfit strain between coating and sub-strate.It is noted that stress distributions in thick coatings rarely correspond to the imposition of such a uniform misfit strain, so that recourse to numerical methods becomes essential for quantitative predic-tion of stress distributions. Relationships are presented between residual stresses and corresponding strain energy release rates during interfacial debonding. The effect on this of superimposing stresses from an externally applied load is outlined. The initiation of debonding is then considered, covering edge effects and other geometrical considerations. Finally, some specific case histories are briefly outlined to illustrate how the various theoretical concepts involved relate to industrial practice.
445 citations
TL;DR: In this article, substitutions of the pure lanthanum zirconate by other trivalent rare earth elements were made, and the thermal conductivity and thermal expansion coefficient of the manufactured materials were measured.
Abstract: To enhance the insulating properties of a thermal barrier coating, one has to focus on new materials with lower intrinsic thermal conductivity than established yttria-stabilized zirconia. Substances with pyrochlore structure were investigated. Starting from lanthanum zirconate, substitutions of the lanthanum by other trivalent rare-earth elements were made, and the thermal conductivity and the thermal expansion coefficient of the manufactured materials were measured. A complete substitution of the lanthanum led to increased thermal expansion coefficients, whereas the partial substitution did not show an appreciable effect. The thermal conductivities of the modified materials were lower than that of the pure lanthanum zirconate for temperatures <1000°C for all amounts and elements of substitution. A comparison of the observed values with calculated values of the thermal conductivities showed a relatively good agreement.
403 citations
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TL;DR: In this paper, the mechanism of formation of plasma-sprayed coatings was examined and related to the microstructure produced, and it was shown that the real area of contact between individual lamellae within the coating and between lamella and substrate is much less than the apparent area because of adsorbed and entrapped gas, oxide films or other contamination.
367 citations
TL;DR: In this paper, the failure of a ZrO2-8%Y2O3/Ni-14% Al-0.1% Zr coating system on Rene 41 in Mach 0.3 burner rig tests was characterized.
335 citations
TL;DR: In this paper, a procedure for modeling the lives of thermal barrier coatings subjected to high-temperatrue environments is described, based on the assumption that oxidation is the single important time-dependent factor which limits the life of these coatings, and that oxidation-induced strains combine with cyclic strains to promote slow crack growth in the ceramic layer.
Abstract: A procedure is described for modeling the lives of thermal barrier coatings subjected to high-temperatrue environments. The models is used to calculate cycles-to-failure as a function of heating cycle duration. It is based on the presumption that oxidation is the single important time-dependent factor which limits the life of these coatings, and that oxidation-induced strains combine with cyclic strains to promote slow crack growth in the ceramic layer. Good agreement is obtained between calculated and experimental lives for specimens tested in a furnace. This shows that an oxidation-based approach is promising. The importance of reproducible specimen preparation is also discussed.
306 citations
TL;DR: In this paper, the effect of processing on bond coating oxidation and durability is also reviewed, as well as the relationship between process-microstructure relationships and the ability to achieve TBC durability.
252 citations
TL;DR: In this article, a methodology is established to predict thermal barrier coating life in an environment similar to that experienced by gas turbine airfoils, and a preliminary life prediction model developed focuses on the two major damage modes identified in the critical experiments tasks.
Abstract: A methodology is established to predict thermal barrier coating life in a environment similar to that experienced by gas turbine airfoils. Experiments were conducted to determine failure modes of the thermal barrier coating. Analytical studies were employed to derive a life prediction model. A review of experimental and flight service components as well as laboratory post evaluations indicates that the predominant mode of TBC failure involves thermomechanical spallation of the ceramic coating layer. This ceramic spallation involves the formation of a dominant crack in the ceramic coating parallel to and closely adjacent to the topologically complex metal ceramic interface. This mechanical failure mode clearly is influenced by thermal exposure effects as shown in experiments conducted to study thermal pre-exposure and thermal cycle-rate effects. The preliminary life prediction model developed focuses on the two major damage modes identified in the critical experiments tasks. The first of these involves a mechanical driving force, resulting from cyclic strains and stresses caused by thermally induced and externally imposed mechanical loads. The second is an environmental driving force based on experimental results, and is believed to be related to bond coat oxidation. It is also believed that the growth of this oxide scale influences the intensity of the mechanical driving force.
227 citations