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Failure analysis of thermally cycled columnar thermal barrier coatings produced by high-velocity-air fuel and axial-suspension-plasma spraying: A design perspective
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.ORCID iD: 0000-0003-1897-0171
University West, Department of Engineering Science.
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0002-9578-4076
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0002-2857-0975
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2018 (English)In: Ceramics International, ISSN 0272-8842, E-ISSN 1873-3956, Vol. 44, no 3, 3161-3172 p.Article in journal (Refereed) Published
Abstract [en]

Axial-suspension-plasma spraying (ASPS) is a fairly recent thermal spray technology which enables production of ceramic top coats in TBCs, incorporating simultaneously the properties of both the conventional-plasma sprayed (highly insulating porous structures) and electron-beam-physical-vapor-deposited (strain-tolerant columnar structures) top coats. TBCs are required to insulate the hot components in a gas turbine engine against high temperature and harsh operating conditions. Periodic heating and cooling of turbine engines during operation can create severe thermal cyclic fatigue conditions which can degrade the performance of these coatings eventually leading to the failure. An in-depth experimental investigation was performed to understand the failure behavior of columnar TBCs subjected to thermal cyclic fatigue (TCF) test at 1100 C. The study revealed that the TCF performance was influenced to an extent, by the top coat microstructure, but was primarily affected by the severity of thermally grown oxide (TGO) growth at the bond coat-top coat interface. Mixed failure modes comprising crack propagation through the bond coat-TGO interface, through TGO and within the top coat were identified. Based on the analysis of the experimental results and thorough discussion a novel design of microstructure for the high TCF performance columnar TBC is proposed. © 2017 Elsevier Ltd and Techna Group S.r.l.

Place, publisher, year, edition, pages
Elsevier Ltd , 2018. Vol. 44, no 3, 3161-3172 p.
Keyword [en]
Air; Coatings; Engines; Gas turbines; Microstructure; Plasma jets; Plasma spraying; Sprayed coatings; Structural design; Suspensions (components); Thermal spraying, Columnar structures; Experimental investigations; High velocity air fuels; Physical vapor deposited; Suspension plasma spraying; Thermal cyclic fatigue; Thermal spray technology; Thermally grown oxide, Thermal barrier coatings
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-11920DOI: 10.1016/j.ceramint.2017.11.084Scopus ID: 2-s2.0-85034822127OAI: oai:DiVA.org:hv-11920DiVA: diva2:1165680
Available from: 2017-12-13 Created: 2017-12-13 Last updated: 2017-12-18Bibliographically approved

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Ganvir, AshishMarkocsan, NicolaieGupta, Mohit Kumar

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Ganvir, AshishVaidhyanathan, VenkateswaranMarkocsan, NicolaieGupta, Mohit Kumar
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Division of Subtractive and Additive ManufacturingDepartment of Engineering Science
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Manufacturing, Surface and Joining Technology

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