The Role Of Thermally Grown Oxide In The Failure Thermal Barrier Coatings For Gas Turbine Engine Applications

• Main Authors: Pankov, Vladimir, Patnaik, Prakash C., Chen, Kuiying
• Format: Conference Object
• Language: English
• Published: Zenodo 2018
• Subjects: Laser Powder Bed; Fusion Process; Surface Roughness Quality; Hastelloy X Components; Beck; DuBois; Fuller; Indian; Meier; Spitsberg
• Online Access: https://dx.doi.org/10.5281/zenodo.1345000; https://zenodo.org/record/1345000

Thermal barrier coatings (TBCs) are widely used in gas turbine engines for propulsion and power generation to maximize engine operating temperature and fuel efficiency. TBCs comprise primarily three major components: the ceramic top coat, the intermetallic bond coat and a thin layer of a thermally grown oxide (TGO) formed at the bond coat/top coat interface. It was demonstrated that the TGO layer plays a critical role in determining the TBC life time with many TBC failure events occurring with its direct involvement. However, the actual mechanisms that govern TBC degradation and failure are still not fully understood in terms of the TGO role and the effects of its properties on the failure process. Stress analysis and TBC life time modelling were used in this study to demonstrate that the TGO morphology, its specific mechanical and thermal properties significantly affect the degradation modes and failure behaviour of the entire TBC system while the particular failure mechanisms differ depending on the ceramic top coat fabrication process. In this paper, the effect of changes in the TGO layer during thermal cycling has been theoretically investigated for TBC with top coats fabricated by atmospheric plasma spray and electron be am physical vapour deposition and the differences in their degradation and failure have been discussed. : {"references": ["Ahrens M., Va\u03b2en R., and St\u00f6ver D. (2002). Stress distributions in plasma - sprayed thermal barrier coatings as a function of interface roughness and oxide scale thickness. Surface and Coatings Technology 161 (1), 26 - 35.", "Beele W., Marijnissen G., and van Lieshout A. (1999). The evolution of thermal barrier coatings - status and upcoming solutions for today's key issues. Surface & Coatings Technology 120, 61 - 67.", "Chang - Jiu Li, Yong Li, Guan - Jun Yang, and Cheng - Xin Li (2012). A novel plasma - s prayed durable thermal barrier coating with a well - bonded YSZ interlayer between porous YSZ and bond c oat. Journal of Thermal Spray Technology 21 (3), 383 - 390.", "Echsler H, Shemet V., Schutze M, Singheiser L., and Quadakkers W.J. ( 2006). Cracking in and around the thermally grown oxide in thermal barrier coatings: A comparison of isothermal and cyclic oxidation. J. Mater. Sci. 41 (4), 1047 - 1058.", "Evans A. G, Mumm D. R. Hutchinson J. W, Meier G. H, and Pettit F. S. (2001). Mechanisms controlling the durability of thermal barrier coatings. Progress in Materials Science 46 (5), 505 - 553.", "Hsueg C. H. and Fuller E. R. (2000). Analytical Modeling of Oxide Thickness Efforts on Residual Stresses in Thermal Barrier Coatings. Scripta mater. 42 (8), 781 - 787.", "Liu D., Seraffon M., Flewitt P. E. J., Simms N. J., Nicholls J. R., Rickerby D. S. (2013). Effect of substrate curvature on residual stresses and failure modes of an air plasma sprayed thermal barrier coating system. Journal of the European Ceramic Society 33 (15 - 16), 3345 - 3357.", "Magnus J. and Brodin H. (2004). Crack initiation and propagation in air plasma sprayed thermal barrier coatings, testing and mathematical modelling of low cycle fatigue behaviour. Materials Science & Engineering A 379 (1 - 2), 45 - 57.", "Mumm D. R., Evans A. G. and Spitsberg I. T. (2001), Characterization of a cyclic displacement instability for a thermally grown oxide in a thermal barrier system. Acta Mater. 49 (12), 2329 - 2340.", "Padure N. P., Gell M., and Jordan Eric E. H. (2002). Thermal barrier coatings for gas - turbine engine applications. Science 296 (5566), 280 - 283.", "Rabiei A. and Evans A. G. ( 2000 ). Failure mechanisms associated with the thermally grown oxide in plasma - sprayed thermal barrier coatings. Acta Mater. 48 (15), 3963 - 3976.", "Ranjbar - Far M., Absi J., Mariaux G., and Dubois F. (2010). Simulation of the effect of material properties and interface roughness on the stress distribution in thermal barrier coatings using finite element method. Materials and Design 31 (2),.772 \u2013 781.", "Renusch D., Schorr M., and Sch\u00fctze M. (2008). The role that bond coat depletion of aluminum has on the lifetime of APS - TBC under oxidizing conditions. Materials and Corrosion 59 (7), 7 - 15.", "Schlichting K. W., Padture N. P., Jordan N. P., and Gell M. ( 2003 ). Failure modes in plasma - sprayed thermal barrier coatings. Materials Science and Engineering A 342 (1 - 2) 120 - 130.", "Steinbrech R. W. and Basu D. (2003). Ceramic based thermal barrier coating (TBC) for gas turbine application : Elastic behaviour of plasma s prayed TBC. Transactions of the Indian Ceramic Society 62 (4), 192 - 199.", "Tanaka M., Hasegawa M., and Kagawa Y. (2006). Detection of micro - damage evolution of air plasma - sprayed Y2 O3 - ZrO2 thermal barrier coating through TGO stress measurement. Materials Transactions 47 (10), 2512 - 2517.", "Tolpygo V. K., Clarke D. R., and Murphy K. S. (2004). Evaluation of interface degradation during cyclic oxidation of EB - PVD thermal barrier coatings and correlation with TGO luminescence. Surface & Coatings Technology 188 - 189, 62 \u2013 70.", "Traeger F., Ahrens M., Va\u00dfen R., and St\u00f6ver D. (2003). A life time model for ceramic thermal barrier coatings. Materials Science and Engineering A358 (1 - 2), 255 - 265.", "Trunova O., Beck T., Herzog R., Steinbrech R. W., Singheise r L. ( 2008 ). Damage mechanisms and lifetime behaviour of plasma sprayed thermal barrier coating systems for gas turbines \u2014 Part I: Experiments. Surface and Coatings Technology 202 (20) 5027 - 5032.", "Va\u00dfen R., Kerkhoff G., and St\u00f6ver D. (2001). Development of a micromechanical life prediction model for plasma sprayed thermal barrier coatings. Materials Science and Engineering A303 (1-2), 100\u2013109.", "Va\u00dfen R., Giesen S., and St\u00f6ver D. (2009). Lifetime of plasma - sprayed thermal barrier coatings : Comparison of numerical and experimental results. Journal of Thermal Spray Technology 18 (5 - 6), 835 \u2013 845.", "Wen M., Jordan E. H., and Gell M. (2006). Effect of temperature on rumpling and thermally grown oxide stress in an EB - PVD thermal barrier coating. Surface & Coatings Technology 201 (6), 3289 - 3298.", "Zhao X., Wang X., and Xiao P. (2006). Sintering and failure behaviour of EB - PVD thermal barrier coating after isothermal treatment. Surface & Coatings Technology 200 (20-21), 5946 - 5955."]}