Papers by Keyword: Bond Coat

Abstract: Bond coats play a vital role in multi-layered thermal barrier coatings (TBCs), commonly made of B2 (Ni, Pt)Al. However, the presence of platinum (Pt) makes the bond coats costly. To reduce the overall cost and enhance the working temperature of TBCs, Pt can be partially or completely replaced by ruthenium (Ru). For the development of Ru-based bond coats, understanding the interdiffusion behavior of (Ni, Ru)Al is essential. In the present work, the interdiffusion behavior in the single B2 phase of the ternary (Ni, Ru)Al system was studied at 1100 °C using the diffusion couple technique. Experimental concentration profiles were obtained using an Electron Probe Micro-Analyzer, which was further fitted and analyzed for interdiffusion fluxes by utilizing the MultiDiflux software. Kirkaldy's approach was employed to determine the interdiffusion coefficients in the ternary B2 (Ni, Ru)Al system.

Abstract: Thermal barrier coatings are widely used for protection of gas turbine parts against high temperature oxidation and hot corrosion. In present work the microstructural assessment of TBCs produced by atmospheric plasma spray (APS) method was conducted. Three types of ceramic powders were used: magnesia- stabilized zirconia oxide (Metco 210), yttria stabilized zirconia oxide (YSZ -Metco 204) and fine-grained YSZ – Metco 6700. As a base material the Inconel 713 was used as well and CoNiCrAlY was plasma sprayed (APS) as a bond coat. The thickness of all ceramic layers was in range 80 – 110 μm. The elemental mapping of cross-section of magnesia-stabilized zirconia showed the presence of Mg, Zr and O in outer layer. In the YSZ ceramic layer the Y, Zr and O were observed during elemental mapping. The isothermal oxidation test was conducted at 1100 °C for 500 h in static laboratory air. On all samples the delamination and spallation of ceramic layers was observed. Chemical composition analysis of coatings showed the presence of two areas: the first one contained elements from bond coats: Ni, Cr, Al, Co and second area contained O, Cr Co and O that suggest the scale formation. The obtained results showed the total degradation of all ceramic layers as a result of internal stresses in bond-coat. Microscopic analysis showed the areas with complete degradation of bond coats and formation of thick oxides layer.

Abstract: The thermal barrier coatings (TBC) are commonly used for protection of jet engine parts. In presented article the influence of chemical composition of TBCs bond coats on isothermal oxidation resistance was analysed. The bond coat was plasma sprayed (APS) using different MCrAlY alloys produced by Oerlikon-Metco: Metco 4451, AMDRY 997, AMDRY 962, AMDRY 365-1, AMDRY 995C. The conducted research showed big difference in coating thickness despite the same spraying parameters. The difference in porosity was not observed. The isothermal oxidation test was conducted during 500h at 1100°C in static laboratory air. The obtained results showed, that degradation mechanism of MCrAlY bond coats regardless of chemical composition is similar. The formation of scale contained aluminium and chromium oxides was observed. The internal oxidation effect was also observed in produced coatings.

Abstract: The use of NiCrAlY is a great alternative as Bond Coat - BC (bonding layer) in coatings for turbine vane, and it is possible to increase its life. This work aims to study the BC layer of NiCrAlY on the substrate of 316 steel which was deposited by the High Velocity Oxygen Fuel method (HVOF) and after laser remelting irradiated_. selective laser melting which is an innovative process. The laser treatment induced changes in porosity, microhardness and wear resistance. After spraying, the samples were irradiated with a CO₂ laser beam by varying the scan speed in 50, 100 e 200 mm/s. The speed at which the metallurgical bond between the coating and the substrate occurred was of 50 mm/s. A wear test was performed to analyze the thickness of the coating, which was 60 μm, and the hardness profile and hardness profile where it presented a higher hardness in the coating after the laser treatment. The investigations range included analysis of top surface of coatings by XRD characterization oxides formed types and microscopic investigations of coatings morphology.

Abstract: In the present paper, an attempt has been made to discuss the degradation mechanism of bond coat and bond coat/top coat interface in thermal barrier coating system in the presence of corrosive salts such Na2SO4 and V2O5.These salts come from impurities in low grade fuel used in gas turbine industry. Salt mixture of Na2SO4 + V2O5 was prepared and applied on surface of thermal barrier coating (TBC) specimens. The specimens were exposed isothermally to 900oC for 200, 400 and 700 hours. SEM analysis revealed the formation of thermally grown oxide (TGO) in specimens sprayed with corrosive salts. Results revealed that there was no degradation of either bond coat or bond coat/top coat interface up to 200 hours of isothermal exposure .Interface cracking and spallation was observed after 400 hours of isothermal exposure owing to depletion of zirconia stabilizer i.e yttria and phase transformation of tetragonal zirconia to monoclinic zirconia.

Abstract: Thermal fatigue damage evolution behavior in thermal barrier coatings (TBCs) was studied, by employing the originally designed two dimensional ring-shape TBC specimen. The TBC specimen consisted of Ni-based superalloy IN738LC substrate, bond coat, and 8 wt.% Y2O3-stabilized ZrO2 (YSZ) top coat. The top coat was fabricated by electron-beam physical vapor deposition (EB-PVD) method with 250 micron-meters in thickness. Three kinds of MCrAlY bond coat alloys were specified as an experimental variable. Through the work, special attention was paid not only to the failure life of TBC specimen, but also to the underlying failure mechanisms. Some problems have been also pointed out, on feeding back these experimental findings to engineering applications.

Abstract: The effects of bond coat nature in thermal barrier coating (TBC) systems on the delamination or fracture behavior of the TBCs with different bond coats prepared using two different processes—air plasma spray (APS) and high velocity oxyfuel (HVOF)—were investigated by cyclic thermal fatigue tests. The TBCs with the HVOF bond coat were delaminated or fractured after 3–6 cycles, whereas those with the APS bond coat were delaminated after 10 cycles or show a sound condition. These results indicate that the TBC system with the APS bond coat has better thermal durability than the system with the HVOF bond coat under long-term cyclic thermal exposure. The hardness values of the TBCs (top coats) in both systems are dependent on applied loads, irrespective of the hardness of the bond coats and the substrate. The values are not responded to the bond coat nature or the exposure time. Thermally grown oxide (TGO) layers in both cases consist of two regions with the inner TGO layer containing only Al2O3 and the outer TGO layer of mixed-oxide zone containing Ni, Co, Cr, Al in Al2O3 matrix. The outer TGO layer has a more irregular shape than the inner TGO layer, and there are many pores within the outer layer. At failure, the TGO thickness of the TBC system with the HVOF bond coat is 9–13 m, depending on the total exposed time, and that of the TBC system with the APS bond coat is about 20 m. The both TBC systems show the diffusion layer on the side of substrate in the interface between the bond coat and the substrate. The relationship between the delamination or fracture behavior and the bond coat nature has been discussed, based on the elemental analysis and microstructural evaluation.

Abstract: Thermal barrier systems, used for turbine blades, are made of a nickel-based superalloy, a nickel aluminide bond coat layer and a ceramic thermal barrier. The aim of the present work is to study the initial stages of oxidation of the AM1/NiAl(Zr) system. It is currently of prime importance to characterize the initial thin oxide layer that covers the bond coat prior to the topcoat deposition. Indeed, the adhesion of the thermal barrier layer and the lifetime of the system are partly influenced by the substrate pre-heating oxidizing treatment. In order to determine the contribution of zirconium during this intermediate temperature range oxidation, the AM1/NiAl(Zr) system was heat treated at 950°C, in two vacuum conditions, that were close to the industrial ones. The compositions of the extreme surface of the nickel aluminide and of the thermally grown oxide were investigated by Xray photoelectron spectroscopy. In particular, these experiments allowed us to detect zirconium at the surface of the system and to determine its oxidation state.

Abstract: Conventional two-layered structure thermal barrier coatings (TBCs) with different pre-oxide layer thicknesses were produced by EB-PVD onto Ni-based superalloy. The pre-oxide layer with different thicknesses was formed after vacuum heat treatment for 2 hours and before ceramic deposition by heating the bond coat to 1323K in air for different times. It has been found that with pre-oxide layer thickness increasing from 1μm to 3.1μm, the growth rate of thermally grown oxide (TGO) increased during thermal cycling test and the thermal cyclic lifetime of TBCs decreased from 730hs to 400hs Two failure modes were observed for TBCs with different pre-oxide layer thicknesses and different TGO layer growth rates.

Abstract: Ni-base single crystal (SC) superalloys containing high concentrations of refractory elements are prone to generate a diffusion layer called Secondary Reaction Zone (SRZ) beneath their bond coating during exposure at high temperatures. SRZ causes a reduction of the load bearing cross section and is detrimental to the creep properties of thin-wall turbine airfoils. In this study, a new coating system – “EQ coating”, which is in thermodynamic equilibrium with the substrate, has been proposed and the formation behavior of SRZ beneath bond coat materials was investigated on the 5th generation Ni-base SC superalloy developed by NIMS. Diffusion couples of several alloys were made and were heat treated at 1100°C for 300 h, 1000 h. The concentration profiles were analyzed by EPMA. Also, cyclic oxidation tests were carried out at 1100°C in air.