Characterization of the Benefit of APS Flash Coatings in Improving TBC Lifetime

Pint, Bruce; Lance, Michael J.; Cakmak, Ercan; Kane, Kenneth; Haynes, James A.; Gildersleeve, Ed; Sampath, S

doi:10.1007/978-3-030-51834-9_71

Characterization of the Benefit of APS Flash Coatings in Improving TBC Lifetime

Conference · Tue Sep 01 04:00:00 EDT 2020 · The Minerals, Metals & Materials Series

DOI:https://doi.org/10.1007/978-3-030-51834-9_71· OSTI ID:1657978

^[1]; ^[1]; ^[1]; Kane, Kenneth ^[1]; ^[1]; Gildersleeve, Ed ^[2]; Sampath, S ^[2]

ORNL
Stony Brook University (SUNY)

The addition of an air plasma sprayed (APS) “flash” layer on top of a high velocity oxygen fuel (HVOF) bond coating has been shown to extend the lifetime of thermal barrier coatings. A series of furnace cycle tests (FCTs) has been conducted at 1100 °C in air + 10% H₂O to study the benefit of flash coatings on rod and disk alloy 247 specimens and provide a better mechanistic understanding of their benefit. Flash coatings of NiCoCrAlY and NiCoCrAlYHfSi both improved the FCT lifetime of rod specimens tested in 100-h cycles and disk specimens tested in 1-h cycles. In 1-h cycles, the NiCoCrAlY flash coating significantly outperformed an HVOF-only NiCoCrAlYHfSi bond coating and a NiCoCrAlYHfSi flash coating. Both flash coatings increased the bond coating roughness compared to HVOF. During exposure, the flash layer formed an intermixed alumina-metal layer that appeared to inhibit crack formation. Using a time series of observations, the lower Y + Hf content in the Y-only flash coating appeared to reduce Al consumption. The HVOF layer acted as a source of Al for the adjacent mixed zone. A second series of specimens included a fully APS bond coating where oxide had penetrated through the entire coating to the substrate after only 100, 1-h cycles and lifetime was similar to an HVOF-only bond coating. The inner HVOF layer with the outer APS flash coating prevented this complete penetration from occurring.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE; USDOE Office of Fossil Energy (FE)

DOE Contract Number:: AC05-00OR22725

OSTI ID:: 1657978

Conference Information:: Journal Name: The Minerals, Metals & Materials Series

Country of Publication:: United States

Language:: English

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