, Volume 9, Issue 2, pp 175-180

Thermal conductivity and elastic modulus evolution of thermal barrier coatings under high heat flux conditions

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Abstract

Laser high heat flux test approaches have been established to obtain critical properties of ceramic thermal barrier coatings (TBCs) under near-realistic temperature and thermal gradients that may be encountered in advanced engine systems. Thermal conductivity change kinetics of a thin ceramic coating were continuously monitored in real time at various test temperatures. A significant thermal conductivity increase was observed during the laser-simulated engine heat flux tests. For a 0.25 mm thick ZrO2-8% Y2O3 coating system, the overall thermal conductivity increased from the initial value of 1.0 W/m K to 1.15, 1.19, and 1.5 W/m K after 30 h of testing at surface temperatures of 990, 1100, and 1320 °C, respectively, Hardness and elastic modulus gradients across a 1.5 mm thick TBC system were also determined as a function of laser testing time using the laser sintering/creep and microindentation techniques. The coating Knoop hardness values increased from the initial hardness value of 4 GPa to 5 GPa near the ceramic/bond coat interface and to 7.5 GPa at the ceramic coating surface after 120 h of testing. The ceramic surface modulus increased from an initial value of about 70 GPa to a final value of 125 GPa. The increase in thermal conductivity and the evolution of significant hardness and modulus gradients in the TBC systems are attributed to sintering-induced microporosity gradients under the laser-imposed high thermal gradient conditions. The test techniques provide a viable means for obtaining coating data for use in design, development, stress modeling, and life prediction for various TBC applications.