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Failure mechanisms in APS and SPS thermal barrier coatings during cyclic oxidation and hot corrosion

機譯：循環(huán)氧化和熱腐蝕過程中APS和SPS熱障涂層的失效機理

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Thermal Barrier Coatings (TBCs) are advanced material systems that are being used in the hot sections of gas turbines such as combustor, turbine blades, and vanes. The top ceramic coating in TBCs provides insulation against the hot gases and the intermediate metallic bond coat provides oxidation and corrosion resistance to the underlying turbine components. Durability of thermal barrier coatings is very important for the overall performance of the gas turbine. TBCs can fail in several different ways and there is a combination of more than one failure mechanism in most situations. One of the most widely used TBC is atmospheric plasma sprayed (APS) yttria stabilized zirconia (YSZ). Both the deposition technique and the TBC material have certain limitations. The main aim of this research is to study new TBC materials and/or new deposition techniques and compare with the conventional YSZ and understand their failure mechanisms during cyclic oxidation and hot corrosion. Thermal cyclic oxidation of a newly developed high purity nano YSZ thermal barrier coating has been studied. Cross sectional analysis of exposed as well as completely failed samples showed a mixed-type failure caused by crack propagation parallel to the bond coat/top coat interface. The majority of the damage occurred towards the end of the coating life. A finite element model has been developed to study the probability of crack growth along different paths that leads to the final failure. Hot corrosion mechanism in suspension plasma sprayed two-layer gadolinium zirconate/YSZ, three-layer dense gadolinium zirconate/gadolinium zirconate/YSZ, and a single-layer YSZ has been studied in the presence of sodium sulfate and vanadium pentoxide. The test results showed that gadolinium zirconate coatings were more susceptible to corrosion compared to YSZ coatings despite gadolinium zirconate coatings having lower reactivity with the corrosive salts. Thermal cycling behavior of a high chromium bond coat has been studied. Cross-sectional analysis showed formation of sandwich type microstructure with chromium rich oxide and alumina as the top and the bottom layers. Inter-diffusion of minor elements between different MCrAlY coatings – substrate systems has been studied using, diffusion simulation software, DICTRA. The simulation results showed that the diffusion of minor elements in the coatings is dependent on the rate of β phase depletion in the beginning. After the depletion of β phase there was no clear dependence of the coating composition on the diffusion of minor elements.
機譯：熱障涂層（TBC）是先進的材料系統(tǒng)，正在燃氣輪機的熱區(qū)使用，例如燃燒室，渦輪葉片和葉片。 TBC中的頂部陶瓷涂層可提供對熱氣體的絕緣，中間的金屬粘結(jié)層可為下方的渦輪機組件提供抗氧化和抗腐蝕性能。隔熱涂層的耐久性對于燃氣輪機的整體性能非常重要。 TBC可能以幾種不同的方式發(fā)生故障，并且在大多數(shù)情況下，存在不止一種故障機制的組合。最廣泛使用的TBC之一是大氣等離子噴涂（APS）氧化釔穩(wěn)定的氧化鋯（YSZ）。沉積技術(shù)和TBC材料都具有一定的局限性。這項研究的主要目的是研究新的TBC材料和/或新的沉積技術(shù)，并與常規(guī)YSZ進行比較，并了解它們在循環(huán)氧化和熱腐蝕過程中的破壞機理。研究了一種新開發(fā)的高純度納米YSZ熱障涂層的熱循環(huán)氧化。暴露的以及完全失效的樣品的橫截面分析表明，混合裂紋由平行于粘結(jié)層/面涂層界面的裂紋擴展引起。大部分損壞發(fā)生在涂層壽命即將結(jié)束時。已經(jīng)開發(fā)了一個有限元模型來研究沿著不同路徑導致最終破壞的裂紋擴展的可能性。在硫酸鈉和五氧化二釩存在下，對懸浮液等離子噴涂兩層鋯ir / YSZ，三層致密鋯z /鋯z / YSZ和單層YSZ的熱腐蝕機理進行了研究。測試結(jié)果表明，與鋯石相比，鋯酸g涂層對腐蝕更敏感，盡管鋯酸ado涂層與腐蝕性鹽的反應(yīng)性較低。已經(jīng)研究了高鉻粘結(jié)層的熱循環(huán)行為。橫截面分析顯示以富鉻氧化物和氧化鋁為頂層和底層的夾心型微結(jié)構(gòu)的形成。微量元素在不同MCrAlY涂層之間的擴散-使用擴散模擬軟件DICTRA研究了基材系統(tǒng)。模擬結(jié)果表明，涂??層中次要元素的擴散首先取決于β相的耗竭率。 β相耗盡后，涂料組合物對次要元素的擴散沒有明顯的依賴性。

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