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Title: Effect of Air Plasma Sprayed Flash Bond Coatings on Furnace Cycle Lifetime of Disks and Rods

Abstract

Air plasma sprayed (APS) flash coatings on high velocity oxygen fuel (HVOF) bond coatings are well known to extend the lifetime of thermal barrier coatings (TBCs). Recent work compared flash coatings of NiCoCrAlY and NiCoCrAlYHfSi applied to both rods and disk substrates of alloy 247. For rod specimens, 100 h cycles were used at 1100 °C in wet air. Both flash coatings significantly improved the lifetime compared to HVOF-only and vacuum plasma spray (VPS)-only MCrAlY bond coatings with no statistical difference between the two flash coatings. For disk specimens tested in 1 h cycles at 1100 °C in wet air, the NiCoCrAlY flash coating significantly outperformed an HVOF-only NiCoCrAlYHfSi bond coating and a NiCoCrAlYHfSi flash coating. The flash coatings formed a mixed oxide-metal zone that appeared to inhibit crack formation and therefore extend lifetime. In addition to the flash coating increasing the bond coating roughness, the underlying HVOF layer acted as a source of Al for this intermixed zone and prevented the oxide from penetrating deeper into the bond coating. Here, the lower Y+Hf content in the Y-only flash coating appeared to minimize oxidation in the flash layer, thereby increasing the benefit compared to a NiCoCrAlYHfSi flash coating.

Authors:
ORCiD logo [1]; ORCiD logo [1]; ORCiD logo [1];  [2];  [2]
  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  2. Stony Brook Univ., NY (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:
1731076
Grant/Contract Number:  
AC05-00OR22725; FEAA122
Resource Type:
Accepted Manuscript
Journal Name:
Journal of Engineering for Gas Turbines and Power
Additional Journal Information:
Journal Volume: 142; Journal Issue: 12; Journal ID: ISSN 0742-4795
Publisher:
ASME
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING; Coatings; Cycles; Disks; Rods; Plasmas (Ionized gases)

Citation Formats

Pint, Bruce, Lance, Michael J., Haynes, James A., Gildersleeve, Edward J., and Sampath, Sanjay. Effect of Air Plasma Sprayed Flash Bond Coatings on Furnace Cycle Lifetime of Disks and Rods. United States: N. p., 2020. Web. https://doi.org/10.1115/1.4046694.
Pint, Bruce, Lance, Michael J., Haynes, James A., Gildersleeve, Edward J., & Sampath, Sanjay. Effect of Air Plasma Sprayed Flash Bond Coatings on Furnace Cycle Lifetime of Disks and Rods. United States. https://doi.org/10.1115/1.4046694
Pint, Bruce, Lance, Michael J., Haynes, James A., Gildersleeve, Edward J., and Sampath, Sanjay. Mon . "Effect of Air Plasma Sprayed Flash Bond Coatings on Furnace Cycle Lifetime of Disks and Rods". United States. https://doi.org/10.1115/1.4046694.
@article{osti_1731076,
title = {Effect of Air Plasma Sprayed Flash Bond Coatings on Furnace Cycle Lifetime of Disks and Rods},
author = {Pint, Bruce and Lance, Michael J. and Haynes, James A. and Gildersleeve, Edward J. and Sampath, Sanjay},
abstractNote = {Air plasma sprayed (APS) flash coatings on high velocity oxygen fuel (HVOF) bond coatings are well known to extend the lifetime of thermal barrier coatings (TBCs). Recent work compared flash coatings of NiCoCrAlY and NiCoCrAlYHfSi applied to both rods and disk substrates of alloy 247. For rod specimens, 100 h cycles were used at 1100 °C in wet air. Both flash coatings significantly improved the lifetime compared to HVOF-only and vacuum plasma spray (VPS)-only MCrAlY bond coatings with no statistical difference between the two flash coatings. For disk specimens tested in 1 h cycles at 1100 °C in wet air, the NiCoCrAlY flash coating significantly outperformed an HVOF-only NiCoCrAlYHfSi bond coating and a NiCoCrAlYHfSi flash coating. The flash coatings formed a mixed oxide-metal zone that appeared to inhibit crack formation and therefore extend lifetime. In addition to the flash coating increasing the bond coating roughness, the underlying HVOF layer acted as a source of Al for this intermixed zone and prevented the oxide from penetrating deeper into the bond coating. Here, the lower Y+Hf content in the Y-only flash coating appeared to minimize oxidation in the flash layer, thereby increasing the benefit compared to a NiCoCrAlYHfSi flash coating.},
doi = {10.1115/1.4046694},
journal = {Journal of Engineering for Gas Turbines and Power},
number = 12,
volume = 142,
place = {United States},
year = {2020},
month = {11}
}

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