skip to main content
OSTI.GOV title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: Stresses within rare-earth doped yttria-stabilized zirconia thermal barrier coatings from in-situ synchrotron X-ray diffraction at high temperatures

Journal Article · · Surface and Coatings Technology

There is a growing interest for smart coatings that can be integrated into turbine engines for in-situ temperature measurements or health monitoring. The addition of rare-earth dopants into standard thermal barrier ceramic top coat materials is used to obtain luminescent coatings that enable spectral measurements, for real-time temperature or health monitoring. The thermomechanical performance and durability of such novel coating compositions in extreme environments still remains to be evaluated. Consequently, the ability to manufacture sensor coatings which present suitable thermal properties needs to be demonstrated. For this study, highly luminescent erbium and europium doped yttria-stabilized zirconia and state-of-the-art yttria-stabilized zirconia coatings manufactured by air plasma spray were characterized to determine the effects of the embedded rareearth dopants on coating internal strain and stress and to quantify and compare their high temperature response using synchrotron X-ray diffraction. In-situ depth-resolved strain measurements were performed at 15 μm intervals along the depth of the coatings to evaluate materials response at key locations, specifically at layer interfaces. In-plane stress was calculated for the coatings and a finite element model was implemented to supplement the results and enable further predictions. The results show that the sensor coatings that were manufactured in this work revealed only minor variations in the strain response of sensor coatings under a typical thermal cycle and especially at temperatures closer to that of gas turbine operating conditions, compared to state-of-the-art coatings. This work demonstrates the viability of manufacturing rare-earth doped yttria-stabilized zirconia coatings that provide beneficial spectroscopic monitoring capabilities while having minimal impact on the thermomechanical response of the thermal barrier coatings.

Research Organization:
Argonne National Lab. (ANL), Argonne, IL (United States)
Sponsoring Organization:
National Energy Technology Laboratory (NETL); USDOE Office of Fossil Energy - University Turbine Systems Research; USDOE Office of Science - Office of Basic Energy Sciences - Scientific User Facilities Division
DOE Contract Number:
Journal Information:
Surface and Coatings Technology, Vol. 444
Country of Publication:
United States

References (44)

Thermal-barrier coatings for more efficient gas-turbine engines journal October 2012
Thermal Cycling Behavior of Plasma-Sprayed Thermal Barrier Coatings with Various MCrAIX Bond Coats journal March 2000
Comparison of the Failures during Cyclic Oxidation of Yttria-Stabilized (7 to 8 Weight Percent) Zirconia Thermal Barrier Coatings Fabricated via Electron Beam Physical Vapor Deposition and Air Plasma Spray journal November 2010
Concept of Functionally Graded Materials for Advanced Thermal Barrier Coating Applications journal December 1996
The Tetragonal-Monoclinic Transformation in Zirconia: Lessons Learned and Future Trends journal September 2009
Thermal Barrier Coatings for Gas-Turbine Engine Applications journal April 2002
Thermal barrier coatings technology: critical review, progress update, remaining challenges and prospects journal August 2013
Thermal barrier coating materials journal June 2005
Phosphor thermometry instrumentation for synchronized acquisition of luminescence lifetime decay and intensity on thermal barrier coatings journal February 2020
Remote thermometry with thermographic phosphors: Instrumentation and applications journal July 1997
Optical Nondestructive Condition Monitoring of Thermal Barrier Coatings journal August 2008
Temperature Sensing inside Thermal Barrier Coatings using Phosphor Thermometry conference January 2014
Industrial Sensor TBCs: Studies on Temperature Detection and Durability journal September 2005
Modeling luminescence behavior for phosphor thermometry applied to doped thermal barrier coating configurations journal January 2019
Comparison of IR Thermography and Reflectance-Enhanced Photoluminescence for early Quantitative Diagnostic of Thermal Barrier Coatings Spallation
  • Copin, E. B.; Le Maoult, Y.; Sentenac, T.
  • 2014 Quantitative InfraRed Thermography, Proceedings of the 2014 International Conference on Quantitative InfraRed Thermography
conference January 2014
Delamination-Indicating Thermal Barrier Coatings Using YSZ:Eu Sublayers journal October 2006
Monitoring delamination of plasma-sprayed thermal barrier coatings by reflectance-enhanced luminescence journal December 2006
Delamination-indicating of atmosphere-plasma-sprayed thermal barrier coating system using Eu 3+ luminescence mapping journal July 2018
Feasibility of luminescent multilayer sol-gel thermal barrier coating manufacturing for future applications in through-thickness temperature gradient sensing journal December 2014
On the thermal sensitivity and resolution of a YSZ:Er3+/YSZ:Eu3+ fluorescent thermal history sensor journal April 2018
Sensor Thermal Barrier Coatings: Remote In Situ Condition Monitoring of EB-PVD Coatings at Elevated Temperatures
  • Steenbakker, Rémy J. L.; Feist, Jörg P.; Wellman, Richard G.
  • Journal of Engineering for Gas Turbines and Power, Vol. 131, Issue 4
journal April 2009
Thermal Barrier Coatings Design with Increased Reflectivity and Lower Thermal Conductivity for High-Temperature Turbine Applications journal March 2006
Modeling of residual stresses in a plasma-sprayed zirconia/alumina functionally graded-thermal barrier coating journal June 2003
An analytical model for predicting thermal residual stresses in multilayer coating systems journal September 2005
Mechanics-based scaling laws for the durability of thermal barrier coatings journal January 2001
An analytical model of rumpling in thermal barrier coatings journal April 2005
The displacement of the thermally grown oxide in thermal barrier systems upon temperature cycling journal June 2003
The mechanics of coating delamination in thermal gradients journal June 2007
NIH Image to ImageJ: 25 years of image analysis journal June 2012
Processing effects on porosity-property correlations in plasma sprayed yttria-stabilized zirconia coatings journal October 2003
Synchrotron X-ray measurement techniques for thermal barrier coated cylindrical samples under thermal gradients journal August 2013
Monitoring Local Strain in a Thermal Barrier Coating System Under Thermal Mechanical Gas Turbine Operating Conditions journal April 2015
Strain response of thermal barrier coatings captured under extreme engine environments through synchrotron X-ray diffraction journal July 2014
Synchrotron X-Ray Diffraction Measurements Mapping Internal Strains of Thermal Barrier Coatings During Thermal Gradient Mechanical Fatigue Loading journal August 2015
Capturing the Competing Influence of Thermal and Mechanical Loads on the Strain of Turbine Blade Coatings via High Energy X-rays journal September 2018
Internal strains and stresses measured in cortical bone via high-energy X-ray diffraction journal October 2005
DECcalc - A Program for the Calculation of Diffraction Elastic Constants from Single Crystal Coefficients journal March 2011
Single-Crystal Elastic Constants of Yttria-Stabilized Zirconia in the Range 20° to 700°C journal May 1984
Calculations of single crystal elastic constants for yttria partially stabilised zirconia from powder diffraction data journal August 2014
Introduction to two-dimensional X-ray diffraction journal June 2003
Phase equilibria in the refractory oxide systems of zirconia, hafnia and yttria with rare-earth oxides journal August 2008
Understanding the residual stress distribution through the thickness of atmosphere plasma sprayed (APS) thermal barrier coatings (TBCs) by high energy synchrotron XRD; digital image correlation (DIC) and image based modelling journal June 2017
Stress analysis of polycrystalline thin films and surface regions by X-ray diffraction journal January 2005
Quenching, thermal and residual stress in plasma sprayed deposits: NiCrAlY and YSZ coatings journal January 1999