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Computational Methods to Accelerate Development of Corrosion Resistant Coatings for Industrial Gas Turbines

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Superalloys 2020

Part of the book series: The Minerals, Metals & Materials Series ((MMMS))

Abstract

Oxidation resistant overlay coatings protect the underlying superalloy component in industrial gas turbines from oxidation attack. Rate of depletion of the Al-rich β-phase in the bond coat governs the lifetime of these coatings. The applicability of a computational method in accelerating the development of corrosion resistant coatings and significantly reducing the extensive experimental effort to predict coating lifetimes and microstructural changes in three-coated Ni-based superalloys for real operational durations (20–40 kh) was undertaken in the present study. Scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), and electron microprobe analysis (EPMA) were employed to characterize MCrAlY-coated superalloy substrates (1483, 247 and X4) after exposure at 900 °C in air + 10% H2O for up to 20,000 h. The model predicted the longest coating lifetime for the coating on X4 substrate. Precipitation of γ′ in the coatings was correctly predicted for all three coating systems. Additionally, the model was able to predict the formation of topologically close packed (TCP)-phases in the investigated coating systems.

This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).

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Acknowledgements

G. Garner assisted with the experimental work at ORNL. T. Lowe and M. Romedenne are thanked for helping with microstructural characterization. This research was sponsored by the U.S. Department of Energy, Office of Fossil Energy, Advanced Turbine Program (R. Dennis program manager). The authors would like to thank K. Murphy at Howmet and A. Kulkarni at Siemens for providing superalloys.

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Authors and Affiliations

  1. Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, 37831-6156, USA

    R. Pillai, K. Kane, M. Lance & B. A. Pint

Authors
  1. R. Pillai
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  2. K. Kane
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  3. M. Lance
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  4. B. A. Pint
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Corresponding author

Correspondence to R. Pillai .

Editor information

Editors and Affiliations

  1. Illinois Institute of Technology, Chicago, IL, USA

    Sammy Tin

  2. Rolls-Royce, Derby, UK

    Mark Hardy

  3. PCC Structurals, Portland, OR, USA

    Justin Clews

  4. ISAE-ENSMA, Chasseneuil-du-Poitou, France

    Jonathan Cormier

  5. University of Science and Technology, Beijing, China

    Qiang Feng

  6. Collins Aerospace, Windsor Locks, CT, USA

    John Marcin

  7. ATI Specialty Materials, Monroe, NC, USA

    Chris O'Brien

  8. GE Global Research, Niskayuna, NY, USA

    Akane Suzuki

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Pillai, R., Kane, K., Lance, M., Pint, B.A. (2020). Computational Methods to Accelerate Development of Corrosion Resistant Coatings for Industrial Gas Turbines. In: Tin, S., et al. Superalloys 2020. The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-030-51834-9_81

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