Advertisement

Journal of Thermal Spray Technology

, Volume 20, Issue 1–2, pp 108–115 | Cite as

Next Generation Thermal Barrier Coatings for the Gas Turbine Industry

  • Nicholas Curry
  • Nicolaie Markocsan
  • Xin-Hai Li
  • Aurélien Tricoire
  • Mitch Dorfman
Peer Reviewed

Abstract

The aim of this study is to develop the next generation of production ready air plasma sprayed thermal barrier coating with a low conductivity and long lifetime. A number of coating architectures were produced using commercially available plasma spray guns. Modifications were made to powder chemistry, including high purity powders, dysprosia stabilized zirconia powders, and powders containing porosity formers. Agglomerated & sintered and homogenized oven spheroidized powder morphologies were used to attain beneficial microstructures. Dual layer coatings were produced using the two powders. Laser flash technique was used to evaluate the thermal conductivity of the coating systems from room temperature to 1200 °C. Tests were performed on as-sprayed samples and samples were heat treated for 100 h at 1150 °C. Thermal conductivity results were correlated to the coating microstructure using image analysis of porosity and cracks. The results show the influence of beneficial porosity on reducing the thermal conductivity of the produced coatings.

Keywords

APS coatings coatings for gas turbine components porosity of coatings TBC topcoats 

Notes

Acknowledgments

The authors acknowledge the financial support of the KK foundation, Mr. S. Björklund for thermal spray experiments, Mr. J. Wigren and L. Östergren from Volvo Aero for the valuable discussions during the study. Thanks to Miss C. Goddard and Mr. V. Matikainen for their work.

References

  1. 1.
    R. Miller, Thermal Barrier Coatings For Aircraft Engines: History and Directions, J. Therm. Spray Tech., 1997, 6, p 35-42CrossRefGoogle Scholar
  2. 2.
    X. Cao, R. Vassen, and D. Stöver, Ceramic Materials for Thermal Barrier Coatings, J. Eur. Ceram. Soc., 2004, 24, p 1-10CrossRefGoogle Scholar
  3. 3.
    I. Golosnoy, S. Tsipas, and T. Clyne, An Analytical Model for Simulation of Heat Flow in Plasma-Sprayed Thermal Barrier Coatings, J. Therm. Spray Tech., 2005, 14, p 205-214CrossRefGoogle Scholar
  4. 4.
    I. Golosnoy, A. Cipitria, and T. Clyne, Heat Transfer Through Plasma-Sprayed Thermal Barrier Coatings in Gas Turbines: A Review of Recent Work, J. Therm. Spray Tech., 2009, 18, p 809-821CrossRefGoogle Scholar
  5. 5.
    F. Cernuschi, L. Lorenzoni, S. Ahmaniemi, P. Vuoristo, and T. Mäntylä, Studies of the Sintering Kinetics of Thick Thermal Barrier Coatings by Thermal Diffusivity Measurements, J. Eur. Ceram. Soc., 2005, 25, p 393-400CrossRefGoogle Scholar
  6. 6.
    D. Zhu and R. Miller, Thermal Conductivity and Elastic Modulus Evolution of Thermal Barrier Coatings Under High Heat Flux Conditions, J. Therm. Spray Tech., 2000, 9, p 175-180CrossRefGoogle Scholar
  7. 7.
    N. Markocsan, P. Nylen, and J. Wigren, Low Thermal Conductivity Coatings for Gas Turbine Applications, J. Therm. Spray Tech., 2007, 16, p 498-505CrossRefGoogle Scholar
  8. 8.
    R. Vaßen, N. Czech, W. Malléner, W. Stamm, and D. Stöver, Influence of Impurity Content and Porosity of Plasma-Sprayed Yttria-Stabilized Zirconia Layers on the Sintering Behaviour, Surf. Coat. Technol., 2001, 141, p 135-140CrossRefGoogle Scholar
  9. 9.
    L. Xie, M. Dorfman, A. Cipitria, S. Paul, I. Golosnoy, and T. Clyne, Properties and Performance of High-Purity Thermal Barrier Coatings, J. Therm. Spray Tech., 2007, 16, p 804-808CrossRefGoogle Scholar
  10. 10.
    S. Tsipas, Effect of Dopants on the Phase Stability of Zirconia-Based Plasma Sprayed Thermal Barrier Coatings, J. Eur. Ceram. Soc., 2010, 30, p 61-72CrossRefGoogle Scholar
  11. 11.
    S. Paul, A. Cipitria, S. Tsipas, and T. Clyne, Sintering Characteristics of Plasma Sprayed Zirconia Coatings Containing Different Stabilisers, Surf. Coat. Technol., 2009, 203, p 1069-1074CrossRefGoogle Scholar
  12. 12.
    G. Bertrand, P. Bertrand, P. Roy, C. Rio, and R. Mevrel, Low Conductivity Plasma Sprayed Thermal Barrier Coating Using Hollow psz Spheres: Correlation Between Thermophysical Properties And Microstructure, Surf. Coat. Technol., 2008, 202, p 1994-2001CrossRefGoogle Scholar
  13. 13.
    J. Wigren, “High Insulation Thermal Barrier Systems—HITS Brite Euram Project BE96-3226,” 2002.Google Scholar
  14. 14.
    R.E. Taylor, Thermal Conductivity Determinations of Thermal Barrier Coatings, Mater. Sci. Eng. A, 1998, 245, p 160-167CrossRefGoogle Scholar

Copyright information

© ASM International 2010

Authors and Affiliations

  • Nicholas Curry
    • 1
  • Nicolaie Markocsan
    • 1
  • Xin-Hai Li
    • 2
  • Aurélien Tricoire
    • 3
  • Mitch Dorfman
    • 4
  1. 1.University WestTrollhättanSweden
  2. 2.Siemens Industrial Turbomachinery ABFinspongSweden
  3. 3.Volvo AeroTrollhättanSweden
  4. 4.Sulzer MetcoWestburyUSA

Personalised recommendations