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Title: IMPERMEABLE THIN Al2O3 OVERLAY FOR TBC PROTECTION FROM SULFATE AND VANADATE ATTACK IN GAS TURBINES

Abstract

In order to improve the hot corrosion resistance of yttria-stabilized zirconia (YSZ), an Al{sub 2}O{sub 3} overlay has been deposited on the surface of YSZ by electron-beam physical vapor deposition. Currently, hot corrosion tests were performed on the YSZ coatings with and without Al{sub 2}O{sub 3} overlay in molten salt mixture (Na{sub 2}SO{sub 4} + 0 {approx} 15wt%V{sub 2}O{sub 5}) at 950 C in order to investigate the effect of amount of vanadate on the hot corrosion behaviors. The results showed that the presence of in V{sub 2}O{sub 5} the molten salt exacerbates the degradation of both the monolithic YSZ coating and the composite YSZ/Al{sub 2}O{sub 3} system. The formation of low-melting Na{sub 2}O-V{sub 2}O{sub 5}-Al{sub 2}O{sub 3} liquid phase is responsible for degradation of the Al{sub 2}O{sub 3} overlay. The Al{sub 2}O{sub 3} overlay acts as a barrier against the infiltration of the molten salt into the YSZ coating during exposure to the molten salt mixture with <5wt% vanadate. In the next reporting period, we will use XPS and SIMS to study the interactions between alumina overlay and molten salt containing vanadate.

Authors:
Publication Date:
Research Org.:
University of Pittsburgh (US)
Sponsoring Org.:
(US)
OSTI Identifier:
821290
DOE Contract Number:
FC26-01NT41189
Resource Type:
Technical Report
Resource Relation:
Other Information: PBD: 10 Jun 2003
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; PROTECTIVE COATINGS; CORROSION RESISTANCE; GAS TURBINES; MOLTEN SALTS; PHYSICAL VAPOR DEPOSITION; SULFATES; VANADATES; ALUMINIUM OXIDES; YTTRIUM OXIDES; ZIRCONIUM OXIDES

Citation Formats

Scott X. Mao. IMPERMEABLE THIN Al2O3 OVERLAY FOR TBC PROTECTION FROM SULFATE AND VANADATE ATTACK IN GAS TURBINES. United States: N. p., 2003. Web. doi:10.2172/821290.
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Scott X. Mao. IMPERMEABLE THIN Al2O3 OVERLAY FOR TBC PROTECTION FROM SULFATE AND VANADATE ATTACK IN GAS TURBINES. United States. doi:10.2172/821290.
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Scott X. Mao. Tue . "IMPERMEABLE THIN Al2O3 OVERLAY FOR TBC PROTECTION FROM SULFATE AND VANADATE ATTACK IN GAS TURBINES". United States. doi:10.2172/821290. https://www.osti.gov/servlets/purl/821290.
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@article{osti_821290,
title = {IMPERMEABLE THIN Al2O3 OVERLAY FOR TBC PROTECTION FROM SULFATE AND VANADATE ATTACK IN GAS TURBINES},
author = {Scott X. Mao},
abstractNote = {In order to improve the hot corrosion resistance of yttria-stabilized zirconia (YSZ), an Al{sub 2}O{sub 3} overlay has been deposited on the surface of YSZ by electron-beam physical vapor deposition. Currently, hot corrosion tests were performed on the YSZ coatings with and without Al{sub 2}O{sub 3} overlay in molten salt mixture (Na{sub 2}SO{sub 4} + 0 {approx} 15wt%V{sub 2}O{sub 5}) at 950 C in order to investigate the effect of amount of vanadate on the hot corrosion behaviors. The results showed that the presence of in V{sub 2}O{sub 5} the molten salt exacerbates the degradation of both the monolithic YSZ coating and the composite YSZ/Al{sub 2}O{sub 3} system. The formation of low-melting Na{sub 2}O-V{sub 2}O{sub 5}-Al{sub 2}O{sub 3} liquid phase is responsible for degradation of the Al{sub 2}O{sub 3} overlay. The Al{sub 2}O{sub 3} overlay acts as a barrier against the infiltration of the molten salt into the YSZ coating during exposure to the molten salt mixture with <5wt% vanadate. In the next reporting period, we will use XPS and SIMS to study the interactions between alumina overlay and molten salt containing vanadate.},
doi = {10.2172/821290},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Tue Jun 10 00:00:00 EDT 2003},
month = {Tue Jun 10 00:00:00 EDT 2003}
}
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Technical Report:
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DOI:  10.2172/821290
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  • The project started on September 1, 2001. During last 4 months, one post-doctor has been hired for this project. We have received TBC samples (YSZ/CoNiCrAlY/ Inconel 601) from Tohoku University, Japan, while processing of the TBC samples was delayed in GE Corp. Research and Development. The TBC preparation in Japan was based on our technical requirement by plasma spray. Bond coat CoNiCrAlY and the YSZ was produced by low-pressure plasma spray and air plasma spray respectively. The morphology of the surface and the microstructure of cross-section of the sample was observed and analyzed by SEM and EDX. XRD was alsomore » used to detect the phases in the YSZ. Currently we are processing the overlay Al{sub 2}O{sub 3} on the TBC samples by EB-PVD and high velocity oxy-fuel (HVOF) spray techniques in collaboration with Penn State University and State University of New York at Stony Brook. We will finish comparing the hot corrosion behavior of the Al{sub 2}O{sub 3}/YSZ/CoNiCrAlY/superalloy system with the YSZ/CoNiCrAlY/superalloy system. The mechanism of hot corrosion will be investigated. The processing-structure-properties relationship of the overlays will be determined.« less

  • In order to improve the hot corrosion resistance of conventional YSZ TBC system (YSZ/CoNiCrAlY/Inconel 601), an overlay Al{sub 2}O{sub 3} was sprayed on the surface of TBC samples by high velocity oxy-fuel (HVOF) spray techniques. The TBC preparation in Japan was based on our technical requirement by plasma spray. Bond coat CoNiCrAlY and the YSZ was produced by low-pressure plasma spray and air plasma spray respectively. Hot corrosion tests were carried out on the TBC with and without Al{sub 2}O{sub 3} coating in molten salts mixtures (Na{sub 2}SO{sub 4} + 5%V{sub 2}O{sub 5}) at 950 C for 10h. The microstructuresmore » of TBC and overlay before and after exposure were examined by means of scanning electron microscopy (SEM), energy-dispersive X-ray spectrometer (EDX) and X-ray diffraction (XRD). It has been found that TBC reacted with V{sub 2}O{sub 5} to form YVO{sub 4}. A substantial amount of M-phase was formed due to the leaching of Y{sub 2}O{sub 3} from YSZ. Al{sub 2}O{sub 3} overlay coating sprayed by HVOF was dense, continues and adherent to the TBC even after exposure to the molten salts. As a result, overlay Al{sub 2}O{sub 3} coating can prevent the YSZ from the attack by molten salts containing vanadium and arrest the penetration of salts into the YSZ along porous and cracks in the YSZ TBC. Accordingly, the amount of M-phase formed in TBC with Al{sub 2}O{sub 3} overlay was significantly lower than that in conventional YSZ TBC system. In the next period, the hot corrosion tests of TBC with EB-PVD Al{sub 2}O{sub 3} coating under Na{sub 2}SO{sub 4} + 5%V{sub 2}O{sub 5} will be again performed at 950 C. However before hot corrosion tests, the post-annealing will be carried at 1273K for 1h in order to transform the as-sputtered {gamma}-Al{sub 2}O{sub 3} overlay to crystalline {alpha}-Al{sub 2}O{sub 3} overlay. In addition, the effect of coating thickness on corrosion resistance and the mechanisms of cracking of EB-PVD alumina layer during hot corrosion will be also investigated.« less

  • In order to improve the hot corrosion resistance of conventional YSZ TBC system, a dense and continues overlay of Al{sub 2}O{sub 3} coating of about 25 {micro}m thick was deposited on the surface of TBC by EB-PVD and high velocity oxy-fuel (HVOF) spray techniques. Hot corrosion tests were carried out on the TBC with and without Al{sub 2}O{sub 3} coating in molten salts mixtures (Na{sub 2}SO{sub 4} + 5% V{sub 2}O5) at 950 C for 10h. The microstructures of TBC and overlay before and after exposure were examined by means of scanning electron microscopy (SEM), energy-dispersive X-ray spectrometer (EDX), X-raymore » diffraction (XRD) and secondary ion mass spectrometry (SIMS). It has been found that TBC will react with V{sub 2}O{sub 5} to form YVO{sub 4}. A substantial amount of M-phase of ZrO{sub 2} was formed due to the leaching of Y{sub 2}O{sub 3} from YSZ. During hot corrosion test, there were no significant interactions between overlay Al{sub 2}O{sub 3} coating and molten salts. After exposure, the alumina coating, especially produced by HVOF, was still very dense and cover the surface of YSZ, although they had been translated to {alpha}-Al{sub 2}O{sub 3} from original {gamma}-Al{sub 2}O{sub 3}. As a result, Al{sub 2}O{sub 3} overlay coating decreased the penetration of salts into the YSZ and prevented the YSZ from the attack by molten salts containing vanadium. Accordingly, only a few M-phase was formed in YSZ TBC, compared with TBC without overlay coating. The penetration of salts into alumina coating was thought to be through microcracks formed in overlay Al{sub 2}O{sub 3} coating and at the interface between alumina and zirconia due to the presence of tensile stress in the alumina coating. In the next year, we will study the mechanisms of cracking of the overlay Al{sub 2}O{sub 3} layer. The hot corrosion test of TBC with EB-PVD deposited Al{sub 2}O{sub 3} coating will be again performed. However before hot corrosion tests, the post-annealing will be carried out in vacuum (residual pressure 10{sup -3} Pa) at 1273K for 1h in order to transform the as-sputtered Al{sub 2}O{sub 3} overlay to crystalline {alpha}-Al{sub 2}O{sub 3} overlay. The effect of thickness of Al{sub 2}O{sub 3} coating on hot corrosion resistance will also be investigated. We will prepare Al{sub 2}O{sub 3} coating by sol-gel method. The corrosion resistance of TBC with sol-gel Al{sub 2}O{sub 3} coating will be determined and discussed with the results of TBC with EB-PVD and HVOF Al{sub 2}O{sub 3} coating.« less

  • In order to improve the hot corrosion resistance of conventional YSZ TBC system, the overlay of Al{sub 2}O{sub 3} coating was deposited on the TBC by EB-PVD techniques. Hot corrosion tests were carried out on the TBC with and without Al{sub 2}O{sub 3} coating in molten salts mixtures (Na{sub 2}SO{sub 4} + 5%V{sub 2}O{sub 5}) at 950 C for different time up to 100h. The microstructures of TBC and overlay before and after exposure were examined by means of scanning electron microscopy (SEM), energy-dispersive X-ray spectrometer (EDX) and X-ray diffraction (XRD). It has been found that TBC will react withmore » V{sub 2}O{sub 5} to form YVO{sub 4}. The amount of M-phase, which was formed due to the leaching of Y{sub 2}O{sub 3} from YSZ, was increased with corrosion time. Al{sub 2}O{sub 3} overlay coating deposited by EB-PVD was dense, continues and adherent to the TBC. As a result, overlay Al{sub 2}O{sub 3} coating can prevent the YSZ from the attack by molten salts containing vanadium and decrease the penetration of salts into the YSZ along porous and cracks in the YSZ TBC. The amount of M-phase formed in YSZ covered with an overlay Al{sub 2}O{sub 3} is substantially lower than that formed in conventional YSZ TBC, even after 100h exposure to the molten salts. In the next reporting period, the hot corrosion test of TBC with EB-PVD deposited Al{sub 2}O{sub 3} coating will be again performed. However before hot corrosion tests, the post-annealing will be carried out in vacuum (residual pressure 10 -3 Pa) at 1273K for 1h in order to transform the as-sputtered Al{sub 2}O{sub 3} overlay to crystalline {alpha}-Al{sub 2}O{sub 3} overlay. In addition, the effect of the thickness of overlay Al{sub 2}O{sub 3} on corrosion resistance will also be investigated.« less

  • In order to improve the hot corrosion resistance of conventional YSZ TBC system, the Al{sub 2}O{sub 3} overlay coating has been successfully produced on the surface of YSZ by the Sol-gel route. The YSZ substrates were coated with boehmite sol by dip coating process, dried to form a gel film and calcined at 1200 C to form {alpha}-Al{sub 2}O{sub 3} overlay. The microstructures of TBC and Al{sub 2}O{sub 3} overlay were examined by scanning electron microscopy (SEM). The results showed that micro-pores ranged from 3 {micro}m to 20 {micro}m and micro-cracks could be clearly seen on the surface of APSmore » YSZ coating. The thickness of alumina overlay increased with increasing the number of dip coating circles. The small microcracks (0.5-1.0 {micro}m width) on the YSZ surface could be filled and blocked by calcined alumina particles, whereas large pores remained empty and the alumina overlay was un-continuous after one time dip coating circle. Alumina overlay thicker than 5 m m obtained by five times dip coating circles largely cracked after calcinations. As a result, multiple dip coatings up to three times were ideal for getting high quality, crack- free and continuous overlay. The optimal thickness of alumina overlay was in the range of 2.5-3.5 {micro}m. In the next reporting period, we will study the hot corrosion behaviors of YSZ TBC with Al{sub 2}O{sub 3} overlay coating produced by sol gel route by exposure the samples to molten salts mixtures (Na{sub 2}SO{sub 4} + 5%V{sub 2}O{sub 5}) at 950 C.« less