TOPPCOAT wards design and rocessing of advanced, com etitive - - PowerPoint PPT Presentation

• EU joint project

TOPPCOAT

wards design and rocessing of advanced, cometitive thermal barrier ing systems

Aerodays2011 Matthias Karger, Robert Vaßen

IEK(1, Forschungszentrum Jülich GmbH

• Outline
• Short project description
• Main objectives
• Development of new TBC systems
• Testing new TBC systems
• Coating of real components
• Summary, outlook

• Project

Coordinator Forschungszentrum Jülich Budget 4.2 Mio.€, (EC contribution 2.1 Mio. €) Period

• Feb. 2006 – Jan. 2010

Consortium

• Project plan

Basics Management Technical specifications, material procurement Powders and materials

Main objective: Significant improvement of thermal barrier coating systems used for gas turbine applications

Development Interface modification Advanced technology for manufacture of strain tolerant coatings Screening of key properties and full characterisation Evaluation Transfer & application of technology Final evaluation under close(to(service conditions

Increase temperature capability Increase engine efficiency Provide cost effective alternative to EB(PVD

Improve APS coating lifetimes comparable to those of EB(PVD (segmentation, 3D interface) Introduce gas phase processes for industrial application (coating of complex shaped specimen)

• Project approaches for new TBC systems

with conventional feedstock

• Highly segmented coatings
• Feedstock: fused and crushed
• r spray dried YSZ

to induce seg.cracks /stop horizontal cracks !

• Advanced processes using gas

phase deposition

• Processes: LPPS(TF, PE(CVD

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• Advanced APS process with nano

sized feedstock or alternative TBC material

• Feedstock: suspension with

agglomerated nano particles

Transfer of technology coating of real components

• IP / know how situation at project start:

T.A. Taylor, Patent (1991)

• P. Bengtsson, J. Wigren (1999)
• M. Madhwal, E. H. Jordan, M. Gell (2004)
• S. Ahmaniemi (2004)
• H. Guo, R. Vaßen, D. Stöver (2005)

State of the art: 3(5 cracks/mm

• Vertical structured TBCs

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Compressive stress level lower at surface

• Advanced APS coatings

Milestones: Coatings on bond(coated substrates

• Plasma(sprayed coatings with % & - & )
• Gas(phase deposited coatings with '%$* "$* !""). structure
• Process conditions for % ", ' established

500Im

Triplex II technology Feedstock: 8YSZ fused & crushed (TIAG) Porosity: Overall: ~6% (Mercury porosimetry) Crack density: ~9 cracks/mm @500Im thickness F4 technology Feedstock: 8YSZ spray dried (SM) Crack density: ~9 cracks/mm @500Im thickness with conventional feedstock

• Highly segmented coatings

Further development of Taylor (1991), Bengtsson et.al. (1999), state of the art were 3(4 cracks/mm

• Interface modifications

New processes

500Im

Surface modified by application of laser(cladded 3D structures to induce seg.cracks /stop horizontal cracks PVD(LPPS (fka LPPS(TF)

• 2 – 5 mbar
• High power input
• Enables growth of columnar structures

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• New processes

Suspension plasma spraying Triplex II

• Nano suspension, agglomaterated, nano

sized YSZ particles in ethanol

• High segmentation crack density, combined

with high porosity values (~35%)

• Low thermal conductivity

SPS coating SPS plasma jet injecton

• Midterm status

2 21 bondcoat/topcoat systems (~250 specimen) tested "2 Microstructure Furnace cycling 1st Burner rig test

• 2 Systems 3D interface APS top coat
• VPS bondcoat, F4 APS top coat
• VPS bondcoat, Triplex II APS top coat
• PtAl bondcoat, LPPS(TF top coat
• Porous APS reference
• EB(PVD reference

commercial PtAl+EB(PVD reference Bondcoat: Thickness 150–200Im Ra 12(14 Pm

• commercial. APS reference

3"$

• Long term stability
• furnace cycling test
• Thermal shock resistance
• burner rig tests
• Erosion resistance
• Corrosion resistance

Reference systems

• Specimen procurement

Cyclix oxidation Erosion Burner Rig Corrosion Mechanical response Thermography

~250 CMSX4 specimen with different geometries were needed

• Characterisation: Furnace Cycling Test

Test conditions: TBC thickness FT Cycling 150Im 1100 23hFT,1h RT 300Im(400Im 1050 23hFT,1h RT 500Im 1000 23hFT,1h RT Test results 3D APS LPPS(TF F4 APS Triplex II APS APS Ref. EB(PVD Ref.

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• Characterisation: Burner Rig Test

Test conditions: CMSX4 pipes, 150x16mm Surface Temp. 1200°C

• Temp. Gradient

>100°C Cycle 210s hot 75 cooling (<100°C) Test Results 3D APS LPPS(TF F4 APS Triplex II APS APS Ref. EB(PVD Ref.

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• Test conditions:

Test temperature 700°C Impingement angles 30°, 90° Erosive Material Quartz Particle feeding rate 2g/min Impaction speed 25(40m/s Test Results 3D APS LPPS(TF F4 APS Triplex II APS APS Ref. EB(PVD Ref.

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Characterisation: Erosion

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• Characterisation: Corrosion

Test conditions: Test temperature 900°C Test medium 75% NaSo4, 25% NaCl Test specimen massive Pins CMAS(like test Test Results 3D APS LPPS(TF F4 APS Triplex II APS APS Ref. EB(PVD Ref.

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• Characterisation: Cyclic oxidation

Test conditions: Dwell temperature 1050°C/‘ 1100°C(*) Cycle duration 2h Heating/cooling 15min

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Test Results 3D APS LPPS(TF (*) F4 APS Triplex II APS APS Ref. EB(PVD Ref.(*)

83)#/;'<= 0)4'<=

• Characterisation: Summary & Ranking

0,00 0,25 0,50 0,75 1,00 3D new FZJ LPPS(TF SM (~300Im) APS SM204BNS HTU APS f&c FZJ APS ref TUC EB(PVD ref SNS NLR Burner Rig VAC Burner Rig ALSTOM FCT AVIO corrosion Cesi Erosion

3D APS LPPS TF F4 APS TriplexII APS APS ref. EB(PVD ref

Main obejective: Properties of developed system superior to EB(PVD coatings, evaluated performace

• Thermal conductivity

0,5 1 1,5 2 2,5 3 200 400 600 800 1000 1200 $6=7 '5$>6:?7

3D + seg APS 2.5 Porous APS (ref) 0.6 Triplex 2 APS seg. 1.9 EB(PVD (ref) 2.0 F4 APS seg. 2.1 LPPS(TF 1.6 Measured via Laser Flash Technology [ W/mK

• Technology transfer ( Coating of real components

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• Spraying transfer evaluation

TBC thickness

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TBC porosity TBC thickness

TBC thickness and porosity on real components

• YSZ

Eu/Dy doped YSZ layer 3:$.

Laser Luminescence

Sensor Coatings Repair technology

EB(PVD coating LPPS(TF coating Defect

Modelling / FEM analysis of 3D modifications Monitoring the process

Further activities

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linear fit

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YSZ Thickness Intensity Ratio

Mechanical tests

• 4(point bending
• Pulse exccitation

• Summary, Outlook

( Development of innovative coatings succesful

( Highly segmented, columnar LPPS(TF, sensor coatings, HVOF bondcoat, SPS

( Enhancements in understanding processes

( 3D modified surfaces, suspension plasma spraying, repair of TBC

( Testing and evaluation of new TBC systems with promising results

( Highly segmented APS and LPPS show performance at least comparable to EB(PVD coatings

( Transfer of spraying processes and microstructures to real components

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