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Technical and Economical Aspects of Current Thermal Barrier Coating Systems for Gas Turbine Engines by Thermal Spray and EBPVD: A Review

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Abstract

The most advanced thermal barrier coating (TBC) systems for aircraft engine and power generation hot section components consist of electron beam physical vapor deposition (EBPVD) applied yttria-stabilized zirconia and platinum modified diffusion aluminide bond coating. Thermally sprayed ceramic and MCrAlY bond coatings, however, are still used extensively for combustors and power generation blades and vanes. This article highlights the key features of plasma spray and HVOF, diffusion aluminizing, and EBPVD coating processes. The coating characteristics of thermally sprayed MCrAlY bond coat as well as low density and dense vertically cracked (DVC) Zircoat TBC are described. Essential features of a typical EBPVD TBC coating system, consisting of a diffusion aluminide and a columnar TBC, are also presented. The major coating cost elements such as material, equipment and processing are explained for the different technologies, with a performance and cost comparison given for selected examples.

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Acknowledgments

The authors would like to thank Dan Fillenwarth, Dan Helm, and Daming Wang for their input and valuable discussions.

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Authors and Affiliations

  1. Praxair Surface Technologies, Inc., Indianapolis, IN, USA

    Albert Feuerstein, James Knapp, Thomas Taylor, Adil Ashary & Neil Hitchman

  2. Rolls Royce Corporation, Indianapolis, IN, USA

    Ann Bolcavage

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  1. Albert Feuerstein
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  2. James Knapp
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  3. Thomas Taylor
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  4. Adil Ashary
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  5. Ann Bolcavage
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  6. Neil Hitchman
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Correspondence to Albert Feuerstein.

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Feuerstein, A., Knapp, J., Taylor, T. et al. Technical and Economical Aspects of Current Thermal Barrier Coating Systems for Gas Turbine Engines by Thermal Spray and EBPVD: A Review. J Therm Spray Tech 17, 199–213 (2008). https://doi.org/10.1007/s11666-007-9148-y

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