Advanced ceramic coating development for industrial/utility gas turbines. Final report, 11 Mar 1979-1 Sep 1981

Technical Report · Fri Jan 01 04:00:00 EST 1982

OSTI ID:6237686

Vogan, J W; Stetson, A R

A program was conducted with the objective of developing advanced thermal barrier coating (TBC) systems. Coating application was by plasma spray. Duplex, triplex and graded coatings were tested. Coating systems incorporated both NiCrAly and CoCrAly bond coats. Four ceramic overlays were tested: ZrO/sub 2/.82O/sub 3/, CaO.TiO/sub 2/, 2CaO.SiO/sub 2/, and MgO.Al/sub 2/O/sub 3/. The best overall results were obtained with a CaO.TiO/sub 2/ coating applied to a NiCrAly bond coat. This coating was less sensitive than the ZrO/sub 2/.8Y/sub 2/O/sub 3/ coating to process variables and part geometry. Testing with fuels contaminated with compounds containing sulfur, phosphorus and alkali metals showed the zirconia coatings were destabilized. The calcium titanate coatings were not affected by these contaminants. However, when fuels were used containing 50 ppm of vanadium and 150 ppm of magnesium, heavy deposits were formed on the test specimens and combustor components that required frequent cleaning of the test rig. During the program Mars engine first-stage turbine blades were coated and installed for an engine cyclic endurance run with the zirconia, calcium titanate, and calcium silicate coatings. Heavy spalling developed with the calcium silicate system. The zirconia and calcium titanate systems survived the full test duration. It was concluded that these two TBC's showed potential for application in gas turbines.

• Research Organization: Solar Turbines International, San Diego, CA (USA)
• OSTI ID: 6237686
• Report Number(s): N-8233494; NASA-CR-169852; DOE/NASA-0109-1
• Country of Publication: United States
• Language: English

Related Subjects

33 ADVANCED PROPULSION SYSTEMS
330103 -- Internal Combustion Engines-- Turbine
36 MATERIALS SCIENCE
360205* -- Ceramics
Cermets
& Refractories-- Corrosion & Erosion
ALKALINE EARTH METAL COMPOUNDS
ALUMINIUM COMPOUNDS
ALUMINIUM OXIDES
CALCIUM COMPOUNDS
CALCIUM OXIDES
CALCIUM SILICATES
CERAMICS
CHALCOGENIDES
COATINGS
COMBUSTION CHAMBERS
CORROSION RESISTANCE
DEPOSITION
ELEMENTS
ENERGY CONSUMPTION
FUEL CONSUMPTION
GAS TURBINES
MACHINERY
MAGNESIUM COMPOUNDS
MAGNESIUM OXIDES
METALS
OXIDES
OXYGEN COMPOUNDS
PHYSICAL PROPERTIES
PLASMA ARC SPRAYING
PROTECTIVE COATINGS
SILICATES
SILICON COMPOUNDS
SPRAY COATING
SPRAYED COATINGS
SUBSTRATES
SURFACE COATING
THERMODYNAMIC PROPERTIES
TITANATES
TITANIUM COMPOUNDS
TRANSITION ELEMENT COMPOUNDS
TRANSITION ELEMENTS
TURBINE BLADES
TURBINES
TURBOMACHINERY
VANADIUM
ZIRCONIUM COMPOUNDS
ZIRCONIUM OXIDES