Thermal barrier coating life prediction model development, phase 2. Final report
The objective of this program was to generate a life prediction model for electron-beam-physical vapor deposited (EB-PVD) zirconia thermal barrier coating (TBC) on gas turbine engine components. Specific activities involved in development of the EB-PVD life prediction model included measurement of EB-PVD ceramic physical and mechanical properties and adherence strength, measurement of the thermally grown oxide (TGO) growth kinetics, generation of quantitative cyclic thermal spallation life data, and development of a spallation life prediction model. Life data useful for model development was obtained by exposing instrumented, EB-PVD ceramic coated cylindrical specimens in a jet fueled burner rig. Monotonic compression and tensile mechanical tests and physical property tests were conducted to obtain the EB-PVD ceramic behavior required for burner rig specimen analysis. As part of that effort, a nonlinear constitutive model was developed for the EB-PVD ceramic. Spallation failure of the EB-PVD TBC system consistently occurred at the TGO-metal interface. Calculated out-of-plane stresses were a small fraction of that required to statically fail the TGO. Thus, EB-PVD spallation was attributed to the interfacial cracking caused by in-plane TGO strains. Since TGO mechanical properties were not measured in this program, calculation of the burner rig specimen TGO in-plane strains was performed by using alumina properties. A life model based on maximum in-plane TGO tensile mechanical strain and TGO thickness correlated the burner rig specimen EB-PVD ceramic spallation lives within a factor of about plus or minus 2X.
- Research Organization:
- Pratt and Whitney Aircraft, East Hartford, CT (United States)
- OSTI ID:
- 6775916
- Report Number(s):
- N-93-12589; NASA-CR-189111; NAS-1.26:189111; CNN: NAS3-23944
- Country of Publication:
- United States
- Language:
- English
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Related Subjects
GAS TURBINE ENGINES
PROTECTIVE COATINGS
MECHANICAL PROPERTIES
PHYSICAL PROPERTIES
SERVICE LIFE
ADHESION
AGING
CERAMICS
CRACK PROPAGATION
ELECTRON BEAMS
FORECASTING
INTERFACES
MATHEMATICAL MODELS
PHYSICAL VAPOR DEPOSITION
SPALLATION
THERMAL CYCLING
THERMAL INSULATION
ZIRCONIUM OXIDES
BEAMS
CHALCOGENIDES
COATINGS
DEPOSITION
ENGINES
HEAT ENGINES
INTERNAL COMBUSTION ENGINES
LEPTON BEAMS
LIFETIME
NUCLEAR REACTIONS
OXIDES
OXYGEN COMPOUNDS
PARTICLE BEAMS
SURFACE COATING
TRANSITION ELEMENT COMPOUNDS
ZIRCONIUM COMPOUNDS
330103* - Internal Combustion Engines- Turbine