Improvement of sputtered oxide coating adherence and integrity for turbine airfoil applications. Combustion zone durability program. Task III: dense surface sputtered ceramic coatings. Annual technical progress report, October 1, 1978-September 30, 1979

Technical Report · Tue Jan 01 04:00:00 EST 1980

DOI:https://doi.org/10.2172/5477078· OSTI ID:5477078

Patten, J W; Busch, R; Moss, R W; Bayne, M A; Fairbanks, J W

Two aspects of the durability of modified ZrO/sub 2/ ceramic thermal barrier coatings for gas turbine airfoils are being investigated in this program. First, adherence of coatings of these materials has historically been difficult to achieve due to mismatch in thermal expansion coefficients and other properties between ceramic coatings and metallic substrates. Second, if the ceramic coatings are discontinuous, as for many plasma sprayed coatings, then condensate from the combustion environment may permeate the coating and volume changes in this condensate during subsequent service cycles may produce coating spallation. The adherence problem was approached by seeking to sputter deposit ceramic coatings over either sputter-etched, closely spaced, high aspect ratio substrate surface cones or by sputter depositing ceramic coatings over sputtered CoCrAlY coatings containing a very high density of columnar voids (leaders). The objective in both instances was to provide a compliant fibrous metal attachment between metal substrate and ceramic coating to absorb property mismatches. The permeability problem was approached both by coating a segmented (fibrous columnar) ceramic layer with a continuous and impervious metal sealing layer that is not required to provide structural strength or insulation, and by coating the segmented ceramic layer with a continuous layer of the same ceramic material.

• Research Organization: Battelle Pacific Northwest Labs., Richland, WA (USA)
• DOE Contract Number: EY-76-C-06-1830
• OSTI ID: 5477078
• Report Number(s): PNL-3289
• Country of Publication: United States
• Language: English

Related Subjects

20 FOSSIL-FUELED POWER PLANTS
200104* -- Fossil-Fueled Power Plants-- Components
36 MATERIALS SCIENCE
360200 -- Ceramics
Cermets
& Refractories
CERAMICS
CHALCOGENIDES
COATINGS
DEPOSITION
EROSION
GAS TURBINES
MACHINERY
OXIDES
OXYGEN COMPOUNDS
POWER PLANTS
RESEARCH PROGRAMS
SPUTTERING
THERMAL CYCLING
THERMAL INSULATION
TRANSITION ELEMENT COMPOUNDS
TURBINE BLADES
TURBINES
TURBOMACHINERY
ZIRCONIUM COMPOUNDS
ZIRCONIUM OXIDES