Development of advanced plasma sprayed ceramic coatings for industrial gas turbine engine. Final report

Technical Report · Thu Jan 01 00:00:00 EST 1981

OSTI ID:5401277

Bevan, C E

Twenty-eight candidate coating systems were selected from prior experience for their potential erosion/corrosion resistance, and were screened to determine clean fuel cyclic spall resistance. Results of these tests were used to select four coating systems with a high level of spall and/or anticipated corrosion resistance for subsequent 1300/sup 0/F and 1600/sup 0/F hot corrosion and erosion-corrosion testing. The four systems selected were: 8 to 10 mil thick 20% Y/sub 2/O/sub 3/-80% ZrO/sub 2/ applied over high Cr (35%) NiCoCrAlY, 1 to 3 mil thick 20% Y/sub 2/O/sub 3/-80% ZrO/sub 2/ applied over high Cr (35%) NiCoCrAlY, 8 to 10 mil thick 6% Y/sub 2/O/sub 3/-94% ZrO/sub 2/ applied over nominal Cr (18%) NiCoCrAlY, and 1 to 3 mil thick ZrSiO/sub 4/ applied over nominal Cr (18%) NiCoCrAlY. Except for the ZrSiO/sub 4/ (zirconium silicate) system, results of 1300/sup 0/F hot corrosion tests indicated exceptionally good ceramic durability with at least a 13X improvement of hot corrosion life as compared to concurrently tested conventional metallic MCrAlY coatings. At 1600/sup 0/F the 8 to 10 mil thick ceramics spalled at about one half the corrosion life of conventional metallic coatings. However, even after spalling a thin ceramic layer remained which continued to provide a high level of corrosion protection to 1.5X the corrosion life of concurrently tested metallic coatings, at which point testing was terminated with no evidence of corrosion damage on the ceramic coated specimens.

• Research Organization: Pratt and Whitney Aircraft, East Hartford, CT (USA). Commercial Products Div.
• DOE Contract Number: AC06-76RL01830
• OSTI ID: 5401277
• Report Number(s): DOE/RL/01830-T13; ON: DE84002185
• Country of Publication: United States
• Language: English

Related Subjects

33 ADVANCED PROPULSION SYSTEMS
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION
GAS TURBINE ENGINES
CORROSION RESISTANCE
SPRAYED COATINGS
AIRFOILS
CERAMICS
EROSION
SERVICE LIFE
SPRAY COATING
TESTING
YTTRIUM OXIDES
ZIRCONIUM OXIDES
CHALCOGENIDES
COATINGS
DEPOSITION
ENGINES
HEAT ENGINES
INTERNAL COMBUSTION ENGINES
OXIDES
OXYGEN COMPOUNDS
SURFACE COATING
TRANSITION ELEMENT COMPOUNDS
YTTRIUM COMPOUNDS
ZIRCONIUM COMPOUNDS
330103* - Internal Combustion Engines- Turbine
320303 - Energy Conservation
Consumption
& Utilization- Industrial & Agricultural Processes- Equipment & Processes