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Surface roughness affects metastable non-wetting behavior of silicate melts on thermal barrier coatings

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Abstract

Airborne silicate pollutants in flight corridors pose a serious threat to aviation safety whose severity is directly linked to the wettability of molten silicates on thermal barrier coatings (TBCs) at high temperatures (1200–2000 °C). Despite its importance, the wettability of silicate melt on TBCs has not been well investigated. In particular, the surface morphology characteristics of TBCs can be expected to have a first-order effect on the wettability of silicate melt on such TBCs. Here, a series of atmospheric plasma spray (APS) yttria-stabilized zirconia (YSZ) TBCs with varying surface roughness were generated through the application of mechanical polishing. The metastable non-wetting behavior of three representative types of airborne silicate ash (volcanic ash, fly ash and a synthetic calcium–magnesium–aluminum–silicates (CMAS) powder) on these TBCs with varying surface roughness was investigated. It was observed that the smoother the surface of TBCs was, the larger the contact angle was with the molten silicate melts, and consequently, the smaller the area of damage was on the TBCs. Thus, the reduction in TBCs surface roughness (here via mechanical polishing) led to an improvement in the wetting and spreading resistance of TBCs to silicate melts at high temperature. In support of these observations and conclusions, the surface morphology of the TBC (both before and after polishing) had been characterized, and the mechanism of the surface roughness-dependence of wettability had been discussed. These results should contribute to reducing the deposition rate of silicate melt on TBCs, thus extending the lifetime of turbine blades and reducing maintenance costs.

摘要

大气中的硅酸盐污染物 (Calcium–magnesium–aluminum–silicates, CMAS, 来自 于火山喷发, 沙尘暴、工业燃料燃烧、汽车尾气排放与PM2.5) 对航空安全构成了严重威胁, 这种熔融硅酸盐对航空发动机的破坏程度是由其在高温下 (1200–2000 ℃) 对热障涂层 (TBCs) 的润湿性决定的提高TBCs 的物理抗CMAS 润湿性的方法亟待深入研究。本文采用机械抛光的方法制备了一系列具有不同表面粗糙度的大气等离子喷涂 (APS) 氧化钇稳定氧化锆 (YSZ)TBCs, 并研究了三类代表性的硅酸盐粉末 (火山灰、粉煤灰和合成CMAS粉末) 在不同表面粗糙度TBCs上的润湿行为。试验结果表明, TBCs表面粗糙度的降低, 使其与硅酸盐熔体的接触角增大, 润湿和铺展面积减小, TBCs粗糙度对三类硅酸盐粉末熔体的润湿性的影响具有一致规律。通过对TBCs抛光前后的表面形貌表征与理论分析, 探讨了TBCs 表面粗糙度的降低对其高温抗CMAS性能提升的影响机理。本文的结论将为降低硅酸盐熔体在TBCs上的沉积率提供定量的理论和数据支撑, 为有效延长涡轮叶片的使用寿命, 降低维护成本打下基础。

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Acknowledgements

This study was financially supported by the National Science and Technology Major Project (No. 2017-VI-0010-0081), the Program of the Ministry of Education of China for Introducing Talents of Discipline to Universities (No. B17002), the National Natural Science Foundation of China (No. 51901011), the “Freigeist” Fellowship of the Volkswagenstiftung on “Volcanic Ash Deposition in Jet Engines” (VADJEs, No. 89705) and China Scholarship Council (CSC). We are grateful to U. Küppers for providing the volcanic ash material, to C. Cimarelli for assistance with the SEM analyses.

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Authors and Affiliations

  1. School of Materials Science and Engineering, Beihang University, Beijing, 100191, China

    Shan-Jie Yang & Hong-Bo Guo

  2. Department of Earth and Environmental Sciences, Ludwig-Maximilians-Universität München, Munich, 80333, Germany

    Wen-Jia Song & Donald B. Dingwell

  3. Research Institute for Frontier Science, Beihang University, Beijing, 100191, China

    Jian He

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  1. Shan-Jie Yang
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Yang, SJ., Song, WJ., Dingwell, D.B. et al. Surface roughness affects metastable non-wetting behavior of silicate melts on thermal barrier coatings. Rare Met. 41, 469–481 (2022). https://doi.org/10.1007/s12598-021-01773-6

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