Role of bond coat processing methods on the durability of plasma sprayed thermal barrier systems
Abstract
Metallic alloy bond coats are used as an interlayer to promote adhesion of ceramic Thermal Barrier Coatings (TBCs) to the superalloy substrates. These bond coats can be applied through a variety of processing means such as Air Plasma Spray (APS), High-Velocity Oxy Fuel spray (HVOF), and Vacuum Plasma Spray (VPS). While widely adopted in the industry, some uncertainties remain as to the specific microstructural attributes which are influenced by the processing routes and their implications on durability. This paper seeks to elucidate these subtleties between bond coat deposition processing routes through an integrated study of processing to connect to furnace cycle durability on a single bond coat chemistry of NiCoCrAlYHfSi. A standard porous APS TBC top coating based on yttria stabilized zirconia (7YSZ) was consistently applied on these distinct bond coats and tested for durability in cyclic furnace testing at 1100 °C. The results point to substantial differences in durability which are not readily explained only by the variances in coating roughness. Detailed assessment of deposited bond coat properties (modulus, thermal expansion, chemistry) provided some explanation relative to durability. Here, the results suggest a complex interplay among roughness, compliance, aluminum diffusion pathway, and thermal expansion mismatch. Photo-stimulated luminescence piezospectroscopy (PLPS)more »
- Authors:
-
[2];
[2];
[2];
- Stony Brook Univ., Stony Brook, NY (United States)
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Publication Date:
- Research Org.:
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Sponsoring Org.:
- USDOE Office of Fossil Energy (FE)
- OSTI Identifier:
- 1570908
- Alternate Identifier(s):
- OSTI ID: 1556848
- Grant/Contract Number:
- AC05-00OR22725
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Surface and Coatings Technology
- Additional Journal Information:
- Journal Volume: 375; Journal Issue: C; Journal ID: ISSN 0257-8972
- Publisher:
- Elsevier
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE; Bond coat; APS; HVOF; VPS; YSZ TBC; PLPS
Citation Formats
Gildersleeve V V, Edward J., Viswanathan, Vaishak, Lance, Michael J., Haynes, J. Allen, Pint, Bruce A., and Sampath, Sanjay. Role of bond coat processing methods on the durability of plasma sprayed thermal barrier systems. United States: N. p., 2019.
Web. doi:10.1016/j.surfcoat.2019.07.065.
Gildersleeve V V, Edward J., Viswanathan, Vaishak, Lance, Michael J., Haynes, J. Allen, Pint, Bruce A., & Sampath, Sanjay. Role of bond coat processing methods on the durability of plasma sprayed thermal barrier systems. United States. https://doi.org/10.1016/j.surfcoat.2019.07.065
Gildersleeve V V, Edward J., Viswanathan, Vaishak, Lance, Michael J., Haynes, J. Allen, Pint, Bruce A., and Sampath, Sanjay. Thu .
"Role of bond coat processing methods on the durability of plasma sprayed thermal barrier systems". United States. https://doi.org/10.1016/j.surfcoat.2019.07.065. https://www.osti.gov/servlets/purl/1570908.
@article{osti_1570908,
title = {Role of bond coat processing methods on the durability of plasma sprayed thermal barrier systems},
author = {Gildersleeve V V, Edward J. and Viswanathan, Vaishak and Lance, Michael J. and Haynes, J. Allen and Pint, Bruce A. and Sampath, Sanjay},
abstractNote = {Metallic alloy bond coats are used as an interlayer to promote adhesion of ceramic Thermal Barrier Coatings (TBCs) to the superalloy substrates. These bond coats can be applied through a variety of processing means such as Air Plasma Spray (APS), High-Velocity Oxy Fuel spray (HVOF), and Vacuum Plasma Spray (VPS). While widely adopted in the industry, some uncertainties remain as to the specific microstructural attributes which are influenced by the processing routes and their implications on durability. This paper seeks to elucidate these subtleties between bond coat deposition processing routes through an integrated study of processing to connect to furnace cycle durability on a single bond coat chemistry of NiCoCrAlYHfSi. A standard porous APS TBC top coating based on yttria stabilized zirconia (7YSZ) was consistently applied on these distinct bond coats and tested for durability in cyclic furnace testing at 1100 °C. The results point to substantial differences in durability which are not readily explained only by the variances in coating roughness. Detailed assessment of deposited bond coat properties (modulus, thermal expansion, chemistry) provided some explanation relative to durability. Here, the results suggest a complex interplay among roughness, compliance, aluminum diffusion pathway, and thermal expansion mismatch. Photo-stimulated luminescence piezospectroscopy (PLPS) provided additional insights enabling a comprehensive assessment of processing-performance linkages.},
doi = {10.1016/j.surfcoat.2019.07.065},
journal = {Surface and Coatings Technology},
number = C,
volume = 375,
place = {United States},
year = {Thu Aug 01 00:00:00 EDT 2019},
month = {Thu Aug 01 00:00:00 EDT 2019}
}
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Cited by: 22 works
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Figures / Tables:
Table I: Particle size distribution of the Amdry 386-2 (Fine) and 386-4 (Coarse) bond coat feedstock used in this study.
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Works referencing / citing this record:
Influence of Substrate Shape and Roughness on Coating Microstructure in Suspension Plasma Spray
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