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Next generation thermal barrier coatings for the gas turbine industry
University West, Department of Engineering Science, Division of Production Engineering. (PTW)ORCID iD: 0000-0003-0209-1332
University West, Department of Engineering Science, Division of Production Engineering. (PTW)ORCID iD: 0000-0002-9578-4076
Siemens Industrial Turbomachinery AB, Finspong, Sweden.
Volvo Aero, Trollhättan.
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2011 (English)In: Journal of Thermal Spray Technology, Vol. 20, no 1-2, 108-115 p.Article in journal (Refereed) Published
Abstract [en]

The aim of this study is to develop the next generation of production ready air plasma sprayed thermal barrier coating with a low conductivity and long lifetime. A number of coating architectures were produced using commercially available plasma spray guns. Modifications were made to powder chemistry, including high purity powders, dysprosia stabilized zirconia powders, and powders containing porosity formers. Agglomerated & sintered and homogenized oven spheroidized powder morphologies were used to attain beneficial microstructures. Dual layer coatings were produced using the two powders. Laser flash technique was used to evaluate the thermal conductivity of the coating systems from room temperature to 1200 °C. Tests were performed on as-sprayed samples and samples were heat treated for 100 h at 1150 °C. Thermal conductivity results were correlated to the coating microstructure using image analysis of porosity and cracks. The results show the influence of beneficial porosity on reducing the thermal conductivity of the produced coatings. © 2010 ASM International.

Place, publisher, year, edition, pages
2011. Vol. 20, no 1-2, 108-115 p.
Keyword [en]
APS coatings, coatings for gas turbine components, porosity of coatings, TBC topcoats
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-2993DOI: 10.1007/s11666-010-9593-xISBN: 10599630 (ISSN) OAI: oai:DiVA.org:hv-2993DiVA: diva2:387104
Available from: 2011-01-13 Created: 2011-01-12 Last updated: 2016-02-11Bibliographically approved
In thesis
1. Design of Thermal Barrier Coating Systems
Open this publication in new window or tab >>Design of Thermal Barrier Coating Systems
2014 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Thermal barrier coatings (TBC’s) are used to provide both thermal insulation and oxidation protection to high temperature components within gas turbines. The development of turbines for power generation and aviation has led to designs where the operation conditions exceed the upper limits of most conventional engineering materials. As a result there has been a drive to improve thermal barrier coatings to allow the turbine to operate at higher temperatures for longer.

The focus of this thesis has been to design thermal barrier coatings with lower conductivity and longer lifetime than those coatings used in industry today. The work has been divided between the development of new generation air plasma spray (APS) TBC coatings for industrial gas turbines and the development of suspension plasma spray (SPS) TBC systems.

The route taken to achieve these goals with APS TBC’s has been twofold. Firstly an alternative stabiliser has been chosen for the zirconium oxide system in the form of dysprosia. Secondly, control of the powder morphology and spray parameters has been used to generate coating microstructures with favourable levels of porosity.

In terms of development of SPS TBC systems, these coatings are relatively new with many of the critical coating parameters not yet known. The focus of the work has therefore been to characterise their lifetime and thermal properties when produced in a complete TBC system.

Results demonstrate that dysprosia as an alternative stabiliser gives a reduction in thermal conductivity. While small at room temperature and in the as produced state; the influence becomes more pronounced at high temperatures and with longer thermal exposure time. The trade-off for this lowered thermal conductivity may be in the loss of high temperature stability. Overall, the greatest sustained influence on thermal conductivity has been from creating coatings with high levelsof porosity.

In relation to lifetime, double the thermo-cyclic fatigue (TCF) life relative to the industrial standard was achieved using a coating with engineered porosity. Introducing a polymer to the spray powder helps to generate large globular pores within the coating together with a large number of delaminations. Such a structure was shown to be highly resistant to TCF testing.

SPS TBC’s were shown to have much greater performance relative to their APS counterparts in thermal shock life, TCF life and thermal conductivity. Columnar SPS coatings are a prospective alternative for strain tolerant coatings in gas turbine engines.

Place, publisher, year, edition, pages
Trollhättan: University West, 2014. 109 p.
Series
PhD Thesis: University West, 3
Keyword
Industrial Gas Turbine; Aero Turbine; Thermal Barrier Coating; Atmospheric Plasma Spraying; Suspension Plasma Spraying; Thermal Conductivity; Thermo-cyclic fatigue; Thermal Shock
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-5931 (URN)978-91-977943-9-8 (ISBN)978-91-977943-8-1 (ISBN)
Public defence
2014-02-28, F127, University West, Gustava Melins Gata 2, Trollhättan, 09:53 (English)
Opponent
Supervisors
Available from: 2014-02-19 Created: 2014-02-19 Last updated: 2015-06-24Bibliographically approved

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