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Fatigue Performance of TBCs on Hastelloy X Substrate During Cyclic Bending

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Abstract

Our previous experiments with low-cost steel substrates confirmed that individual steps of conventional thermal barrier coating (TBC) deposition may influence fatigue properties of the coated samples differently. In the presented study, testing was carried out for TBC samples deposited on industrially more relevant Hastelloy X substrates. Samples were tested after each step of the TBC deposition process: as-received (non-coated), grit-blasted, bond-coated (NiCoCrAlY), and bond-coated + top-coated yttria-stabilized zirconia (YSZ). Conventional atmospheric plasma spraying (APS) was used for deposition of bond coat and top coat. In addition, for one half of the samples, dual-layer bond coat was prepared by combination of high-velocity air-fuel (HVAF) and APS processes. Samples were tested in the as-sprayed condition and after 100 hours annealing at 980 °C, which simulated application-relevant in-service conditions. Obtained results showed that each stage of the TBC manufacturing process as well as the simulated in-service heat exposure may significantly influence the fatigue properties of the TBC coated part. HVAF grit-blasting substantially increased the fatigue performance of the uncoated substrates. This beneficial effect was suppressed by deposition of APS bond coat but not by deposition of dual-layer HVAF + APS bond coat. All heat-treated samples showed again enhanced fatigue performance.

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Acknowledgment

The financial support of this study through project 14-36566G (Czech Science Foundation) is gratefully acknowledged.

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Author notes

  1. Nicholas Curry

    Present address: University West, 461 86, Trollhättan, Sweden

Authors and Affiliations

  1. Department of Materials Engineering, Institute of Plasma Physics AS CR, v.v.i., Za Slovankou 3, 182 00, Praha 8, Czech Republic

    Radek Musalek, Jan Medricky & Zdenek Pala

  2. Faculty of Nuclear Sciences and Physical Engineering, Department of Materials, Czech Technical University in Prague, Trojanova 13, 120 00, Praha 2, Czech Republic

    Ondrej Kovarik, Libor Tomek, Jan Medricky & Petr Hausild

  3. Faculty of Nuclear Sciences and Physical Engineering, Department of Solid State Engineering, Czech Technical University in Prague, Trojanova 13, 120 00, Praha 2, Czech Republic

    Jiri Capek & Kamil Kolarik

  4. University West, 461 86, Trollhättan, Sweden

    Stefan Bjorklund

  5. Treibacher Industrie AG, Auer-von-Welsbach-Straße 1, 9330, Althofen, Austria

    Nicholas Curry

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  1. Radek Musalek
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Correspondence to Radek Musalek.

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This article is an invited paper selected from presentations at the 2015 International Thermal Spray Conference, held May 11-14, 2015, in Long Beach, California, USA, and has been expanded from the original presentation.

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Musalek, R., Kovarik, O., Tomek, L. et al. Fatigue Performance of TBCs on Hastelloy X Substrate During Cyclic Bending. J Therm Spray Tech 25, 231–243 (2016). https://doi.org/10.1007/s11666-015-0321-4

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