Effect of Semi-Molten Particulate on Tailored Thermal Barrier Coatings for Gas Turbine Engine

2016 ◽  
Author(s):  
Anindya Ghoshal ◽  
Muthuvel Murugan ◽  
Michael Walock ◽  
Blake Barnett ◽  
Marc Pepi ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Thermal Barrier Coatings ◽  
Gas Turbine Engine ◽  
Thermal Barrier ◽  
Barrier Coatings ◽  
Turbine Engine

Synchrotron X-Ray Diffraction to Quantify In-Situ Strain on Rare-Earth Doped Yttria-Stabilized Zirconia Thermal Barrier Coatings

2021 ◽  
Author(s):  
Quentin Fouliard ◽  
Johnathan Hernandez ◽  
Hossein Ebrahimi ◽  
Khanh Vo ◽  
Ranajay Ghosh ◽  
...  
Keyword(s):  
Rare Earth ◽  
Gas Turbine ◽  
Thermal Barrier Coatings ◽  
Gas Turbine Engine ◽  
Temperature Sensing ◽  
Thermal Barrier ◽  
X Ray Diffraction ◽  
Barrier Coatings ◽  
Turbine Engine ◽  
X Ray

Abstract The recent advancement in multifunctional thermal barrier coatings (TBCs) for temperature sensing or defect monitoring has gained interest over the past decade as they have shown great potential for optimized engine operation with higher efficiency, reduced fuel consumption and maintenance costs. Specifically, sensor coatings containing luminescent ions enable materials monitoring using integrated spectral characteristics. While facilitating sensing capabilities, luminescent rare-earth dopants ideally present minimal intrusiveness for the thermal barrier coating. However, the effects of rare-earth dopant addition on thermomechanical and thermochemical properties remain unclear. Our study intends to fill this knowledge gap by characterizing coatings’ internal thermomechnical properties under realistic gas turbine engine operating temperatures. In this work, TBC configurations including industry standard coatings and sensor coatings were compared to quantify dopant intrusiveness. The TBC configurations have been characterized using high-energy synchrotron X-ray diffraction while being heated up to gas turbine engine temperatures. The TBC samples have been subjected to a single cycle thermal load with multiple ramps and holds during XRD data collection. Depth-resolved XRD was used to obtain the 2D diffraction patterns corresponding to each depth location for the determination of strain distributions along the TBCs. Internal strains and stresses acting through the coatings were quantified mostly highlighting that there is negligible variation between the standard and novel sensor coatings. Thus, the thermal response at high temperature remains unaffected with addition of luminescent dopants. This evaluation of novel coating configurations provides valuable insight for future safe implementation of these temperature sensing coatings without performance reductions.

scholarly journals Microstructure Based Material-Sand Particulate Interactions and Assessment of Coatings for High Temperature Turbine Blades

2017 ◽  
Author(s):  
Muthuvel Murugan ◽  
Anindya Ghoshal ◽  
Michael Walock ◽  
Andy Nieto ◽  
Luis Bravo ◽  
...  
Keyword(s):  
High Temperature ◽  
Gas Turbine ◽  
Turbine Blade ◽  
Thermal Barrier Coatings ◽  
Turbine Blades ◽  
Turbine Engines ◽  
Thermal Barrier ◽  
Gas Turbine Engines ◽  
Barrier Coatings ◽  
Turbine Engine

Gas turbine engines for military/commercial fixed-wing and rotary wing aircraft use thermal barrier coatings in the high-temperature sections of the engine for improved efficiency and power. The desire to further make improvements in gas turbine engine efficiency and high power-density is driving the research and development of thermal barrier coatings with the goal of improving their tolerance to fine foreign particulates that may be contained in the intake air. Both commercial and military aircraft engines often are required to operate over sandy regions such as in the middle-east nations, as well as over volcanic zones. For rotorcraft gas turbine engines, the sand ingestion is adverse during take-off, hovering near ground, and landing conditions. Although most of the rotorcraft gas turbine engines are fitted with inlet particle separators, they are not 100% efficient in filtering fine sand particles of size 75 microns or below. The presence of these fine solid particles in the working fluid medium has an adverse effect on the durability of turbine blade thermal barrier coatings and overall performance of the engine. Typical turbine blade damage includes blade coating wear, sand glazing, Calcia-Magnesia-Alumina-Silicate (CMAS) attack, oxidation, and plugged cooling holes, all of which can cause rapid performance deterioration including loss of aircraft. The objective of this research is to understand the fine particle interactions with typical turbine blade ceramic coatings at the microstructure level. Finite-element based microstructure modeling and analysis has been performed to investigate particle-surface interactions, and restitution characteristics. Experimentally, a set of tailored thermal barrier coatings and surface treatments were down-selected through hot burner rig tests and then applied to first stage nozzle vanes of the gas generator turbine of a typical rotorcraft gas turbine engine. Laser Doppler velocity measurements were performed during hot burner rig testing to determine sand particle incoming velocities and their rebound characteristics upon impact on coated material targets. Further, engine sand ingestion tests were carried out to test the CMAS tolerance of the coated nozzle vanes. The findings from this on-going collaborative research to develop the next-gen sand tolerant coatings for turbine blades are presented in this paper.

scholarly journals Erosion Performance of Atmospheric Plasma Sprayed Thermal Barrier Coatings with Diverse Porosity Levels

Coatings ◽  
2021 ◽  
Vol 11 (1) ◽  
pp. 86
Author(s):  
Satyapal Mahade ◽  
Abhilash Venkat ◽  
Nicholas Curry ◽  
Matthias Leitner ◽  
Shrikant Joshi
Keyword(s):  
Gas Turbine ◽  
Thermal Barrier Coatings ◽  
Sem Analysis ◽  
Atmospheric Plasma ◽  
Thermal Barrier ◽  
Barrier Coatings ◽  
Turbine Engine ◽  
Plasma Sprayed ◽  
Engine Components ◽  
Micro Indentation

Thermal barrier coatings (TBCs) prolong the durability of gas turbine engine components and enable them to operate at high temperature. Several degradation mechanisms limit the durability of TBCs during their service. Since the atmospheric plasma spray (APS) processed 7–8 wt.% yttria stabilized zirconia (YSZ) TBCs widely utilized for gas turbine applications are susceptible to erosion damage, this work aims to evaluate the influence of their porosity levels on erosion behavior. Eight different APS TBCs were produced from 3 different spray powders with porosity ranging from 14% to 24%. The as-deposited TBCs were examined by SEM analysis. A licensed software was used to quantify the different microstructural features. Mechanical properties of the as-deposited TBCs were evaluated using micro-indentation technique. The as-deposited TBCs were subjected to erosion tests at different angles of erodent impact and their erosion performance was evaluated. Based on the results, microstructure-mechanical property-erosion performance was correlated. Findings from this work provide new insights into the microstructural features desired for improved erosion performance of APS deposited YSZ TBCs.

scholarly journals Ceramic Thermal Barrier Coatings for Turbine Engine Components

1982 ◽  
Author(s):  
D. S. Duvall ◽  
D. L. Ruckle
Keyword(s):  
Thermal Barrier Coatings ◽  
Ceramic Coatings ◽  
Thermal Barrier ◽  
Barrier Coatings ◽  
Turbine Engine ◽  
Thermal Environments ◽  
Strain Tolerance ◽  
Endurance Testing ◽  
Plasma Sprayed ◽  
Cooling Air

The durability of plasma sprayed ceramic thermal barrier coatings subjected to cyclic thermal environments has been improved substantially by improving the strain tolerance of the ceramic structure and also by controlling the substrate temperature during the application of the coating. Improved strain tolerance was achieved by using ceramic structures with increased porosity, microcracking or segmentation. Plasma spraying on a controlled-temperature substrate also has been shown to improve durability by reducing harmful residual stresses. The most promising of the strain tolerant ceramic coatings have survived up to 6000 cycles of engine endurance testing with no coating or vane platform damage. In side-by-side engine tests, thermal barrier coatings have shown that they greatly reduce platform distress compared to conventionally coated vanes in addition to permitting reductions in cooling air and attendant increases in engine efficiency.

scholarly journals Analysis of the energetic/environmental performances of gas turbine plant: Effect of thermal barrier coatings and mass of cooling air

2009 ◽  
Vol 13 (1) ◽  
pp. 147-164 ◽  
Author(s):  
Ion Ion ◽  
Anibal Portinha ◽  
Jorge Martins ◽  
Vasco Teixeira ◽  
Joaquim Carneiro
Keyword(s):  
Thermal Conductivity ◽  
Gas Turbine ◽  
Thermal Barrier Coatings ◽  
Turbine Blades ◽  
Heat Transfer Analysis ◽  
Thermal Barrier ◽  
Inlet Temperature ◽  
Barrier Coatings ◽  
Cooling Air Flow ◽  
Cooling Air

Zirconia stabilized with 8 wt.% Y2O3 is the most common material to be applied in thermal barrier coatings owing to its excellent properties: low thermal conductivity, high toughness and thermal expansion coefficient as ceramic material. Calculation has been made to evaluate the gains of thermal barrier coatings applied on gas turbine blades. The study considers a top ceramic coating Zirconia stabilized with 8 wt.% Y2O3 on a NiCoCrAlY bond coat and Inconel 738LC as substrate. For different thickness and different cooling air flow rates, a thermodynamic analysis has been performed and pollutants emissions (CO, NOx) have been estimated to analyze the effect of rising the gas inlet temperature. The effect of thickness and thermal conductivity of top coating and the mass flow rate of cooling air have been analyzed. The model for heat transfer analysis gives the temperature reduction through the wall blade for the considered conditions and the results presented in this contribution are restricted to a two considered limits: (1) maximum allowable temperature for top layer (1200?C) and (2) for blade material (1000?C). The model can be used to analyze other materials that support higher temperatures helping in the development of new materials for thermal barrier coatings.

Field Evaluation of 2CaO-SiO2-CaO-ZrO2 Thermal Barrier Coating on Gas Turbine Vanes

1997 ◽  
Author(s):  
N. Mifune ◽  
Y. Harada ◽  
H. Taira ◽  
S. Mishima
Keyword(s):  
Gas Turbine ◽  
Thermal Barrier Coating ◽  
Thermal Barrier Coatings ◽  
Field Evaluation ◽  
Thermal Barrier ◽  
Barrier Coatings ◽  
Thermal Change ◽  
Barrier Coating ◽  
Turbine Vanes ◽  
Higher Temperature

Abstract Higher-temperature operation in a gas turbine has urged development of heat-resistant coatings and thermal barrier coatings. We have developed a 2CaO-SiO2-CaO-ZrO2 based thermal barrier coating. This coating should effectively prevent separation of the coating by relieving the shear stress generated due to thermal change of environment between layers with dissimilar properties. The coating was applied to stationary vanes of an actual gas turbine in a 25,000-hour test. This paper describes the results of the field test.

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