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Variation of Thermal Barrier Coating Lifetime Characteristics with Thermal Durability Evaluation Methods

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Abstract

The thermal durability of thermal barrier coating systems (TBCs) obtained using feedstock powders with different purity and phase content was investigated by thermal shock testing with different cycle times, including the effects on the sintering and phase transformation behaviors. Four 8 wt.% yttria-stabilized zirconia powders, with regular purity (TC1), high purity (TC2 and TC3), and without monoclinic phase (TC4), were employed to prepare the topcoat of TBC by atmospheric plasma spray on a NiCoCrAlY bondcoat deposited by high velocity oxy-fuel. The microstructure and phase stability of the topcoats affected the TBCs’ lifetime in the short-term (1 h) and long-term (24 h) furnace cyclic test (FCT) at 1100 °C and jet engine thermal shock (JETS) test. In the short-term FCT and JETS tests, in which coatings are severely subjected to thermal stress, the TBCs’ lifetime is most affected by the microstructure of the topcoat. The coating layer with the lowest monoclinic phase in the as-sprayed state showed the lowest phase-transformation characteristics in the isothermal oxidation test (1400 °C). These properties resulted in the best lifetime in the long-term FCT. Therefore, the coating material and evaluating methods of TBCs’ life should be selected depending on the usage environment.

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Acknowledgments

This work was supported by a Korea Institute of Energy Technology Evaluation and Planning (KETEP) grant funded by the Korean Government Ministry of Knowledge Economy (No. 2013101010170C). This work was also supported by “Human Resources Program in Energy Technology” of the KETEP and MOTIE of the Republic of Korea (No. 20174030201460).

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Correspondence to Kwang-Yong Park or Yeon-Gil Jung.

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Park, KY., Yang, Bi., Jeon, Sh. et al. Variation of Thermal Barrier Coating Lifetime Characteristics with Thermal Durability Evaluation Methods. J Therm Spray Tech 27, 1436–1446 (2018). https://doi.org/10.1007/s11666-018-0784-1

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  • DOI: https://doi.org/10.1007/s11666-018-0784-1

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