Abstract
Thermal barrier coatings (TBCs) enable the hot section part to work at high temperatures owing to their thermal barrier effect on the base metal components. However, localized spallation in the ceramic top-coat might occur after long duration of thermal exposure or thermal cycling. To comprehensively understand the damage of the top-coat on the overall hot section part, effects of diameter and tilt angle of the spallation on the temperature redistribution of the substrate and the top-coat were investigated. The results show that the spallation diameter and tilt angle both have a significant effect on the temperature redistribution of the top-coat and the substrate. In the case of the substrate, the maximum temperature increment is located at the spallation center. Meanwhile, the surface (depth) maximum temperature increment, having nothing to do with the tilt angle, increases with the increase of the spallation diameter. In contrast, in the case of the top-coat, the maximum temperature increment was located at the sharp corner of the spallation area, and the surface (depth) maximum temperature increment increases with the increase of both the spallation diameter and the tilt angle. Based on the temperature redistribution of the substrate and the top-coat affected by the partial spallation, it is possible to evaluate the damage effect of spalled areas on the thermal capability of TBCs.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Clarke DR, Oechsner M, Padture NP. Thermal-barrier coatings for more efficient gas-turbine engines. MRS Bull 2012, 37: 891–898.
Hardwicke CU, Lau Y-C. Advances in thermal spray coatings for gas turbines and energy generation: A review. J Therm Spray Techn 2013, 22: 564–576.
Chen X, Zhang H, Zhang H, et al. Ce1−xSmxO2−x/2—A novel type of ceramic material for thermal barrier coatings. J Adv Ceram 2016, 5: 244–252.
Greil P. Generic principles of crack-healing ceramics. J Adv Ceram 2012, 1: 249–267.
Wu H, Li Q. Application of mechanochemical synthesis of advanced materials. J Adv Ceram 2012, 1: 130–137.
Levi CG. Emerging materials and processes for thermal barrier systems. Curr Opin Solid St M 2004, 8: 77–91.
Pollock TM, Tin S. Nickel-based superalloys for advanced turbine engines: chemistry, microstructure and properties. J Propul Power 2006, 22: 361–374.
Lima RS, Marple BR. Nanostructured YSZ thermal barrier coatings engineered to counteract sintering effects. Mat Sci Eng A 2008, 485: 182–193.
Caron P, Khan T. Evolution of Ni-based superalloys for single crystal gas turbine blade applications. Aerosp Sci Technol 1999, 3: 513–523.
Padture NP, Gell M, Jordan EH. Thermal barrier coatings for gas-turbine engine applications. Science 2002, 296: 280–284.
Vaßen R, Jarligo MO, Steinke T, et al. Overview on advanced thermal barrier coatings. Surf Coat Technol 2010, 205: 938–942.
Rabiei A, Evans AG. Failure mechanisms associated with the thermally grown oxide in plasma-sprayed thermal barrier coatings. Acta Mater 2000, 48: 3963–3976.
Evans AG, Mumm DR, Hutchinson JW, et al. Mechanisms controlling the durability of thermal barrier coatings. Prog Mater Sci 2001, 46: 505–553.
Schlichting KW, Padture NP, Jordan EH, et al. Failure modes in plasma-sprayed thermal barrier coatings. Mat Sci Eng A 2003, 342: 120–130.
Nissley DM. Thermal barrier coating life modeling in aircraft gas turbine engines. J Therm Spray Techn 1997, 6: 91–98.
Shinozaki M, Clyne TW. A methodology, based on sintering-induced stiffening, for prediction of the spallation lifetime of plasma-sprayed coatings. Acta Mater 2013, 61: 579–588.
Voisey KT, Clyne TW. Laser drilling of cooling holes through plasma sprayed thermal barrier coatings. Surf Coat Technol 2004, 176: 296–306.
Guinard C, Montay G, Guipont V, et al. Residual stress analysis of laser-drilled thermal barrier coatings involving various bond coats. J Therm Spray Techn 2015, 24: 252–262.
Girardot J, Schneider M, Berthe L, et al. Investigation of delamination mechanisms during a laser drilling on a cobalt-base superalloy. J Mater Process Tech 2013, 213: 1682–1691.
Kamalu J, Byrd P, Pitman A. Variable angle laser drilling of thermal barrier coated nimonic. J Mater Process Tech 2002, 122: 355–362.
Corcoran A, Sexton L, Seaman B, et al. The laser drilling of multi-layer aerospace material systems. J Mater Process Tech 2002, 123: 100–106.
Busso EP, Wright L, Evans HE, et al. A physics-based life prediction methodology for thermal barrier coating systems. Acta Mater 2007, 55: 1491–1503.
Beck T, Herzog R, Trunova O, et al. Damage mechanisms and lifetime behavior of plasma-sprayed thermal barrier coating systems for gas turbines—Part II: Modeling. Surf Coat Technol 2008, 202: 5901–5908.
Trunova O, Beck T, Herzog R, et al. Damage mechanisms and lifetime behavior of plasma sprayed thermal barrier coating systems for gas turbines—Part I: Experiments. Surf Coat Technol 2008, 202: 5027–5032.
Stowell WR, Johnson RA, Skoog AJ, et al. Method for repairing a thermal barrier coating and repaired coating formed thereby. U.S. Patent 6,413,578. 2002.
Nagaraj BA, Mannava S, Gupta BK. Method for repairing a thermal barrier coating. U.S. Patent 5,723,078. 1998.
Draghi PJ, Wrabel P. Repair of gas turbine engine component coated with a thermal barrier coating. U.S. Patent 5,972,424. 1999.
McGraw J, Van Deventer G, Anton R, et al. Advancements in gas turbine vane repair. In: Proceedings of the ASME 2006 Power Conference, 2006: 385–389.
Kelbassa I, Albus P, Dietrich J, et al. Manufacture and repair of aero engine components using laser technology. In: Proceedings of the 3rd Pacific International Conference on Application of Lasers and Optics, 2008: 208–213.
Fujii T, Takahashi T. Development of operating temperature prediction method using thermophysical properties change of thermal barrier coatings. J Eng Gas Turbines Power 2004, 126: 102–106.
Morinaga M, Fujii T, Takahashi T. Development of actual TBC exposure temperature prediction method. In: Proceedings of the ASME Turbo Expo 2004: Power for Land, Sea, and Air, 2004: 521–526.
Ellingson WA, Koehl ER, Engel HP, et al. Development of nondestructive evaluation methods for structural ceramics. In: Proceedings of the 12th Annual Conference on Fossil Energy Materials, 1998: 270–292.
Clarke DR. Materials selection guidelines for low thermal conductivity thermal barrier coatings. Surf Coat Technol 2003, 163–164: 67–74.
Asakuma Y, Yamamoto T. Thermal analysis of porous medium with ellipsoidal pores using a homogenization method. Heat Mass Transfer 2016, 52: 2113–2117.
Clyne TW, Golosnoy IO, Tan JC, et al. Porous materials for thermal management under extreme conditions. Philos T Roy Soc A 2006, 364: 125–146.
Cernuschi F, Golosnoy IO, Bison P, et al. Microstructural characterization of porous thermal barrier coatings by IR gas porosimetry and sintering forecasts. Acta Mater 2013, 61: 248–262.
Darolia R. Thermal barrier coatings technology: Critical review, progress update, remaining challenges and prospects. Int Mater Rev 2013, 58: 315–348.
Altun Ö, Böke Y. Heat transfer analyses of thermal barrier coatings on a metal substrate. J Therm Sci Tech 2013, 33: 101–109.
Wang L, Wang Y, Sun XG, et al. Influence of pores on the thermal insulation behavior of thermal barrier coatings prepared by atmospheric plasma spray. Mater Design 2011, 32: 36–47.
Acknowledgements
This work is supported by the National Basic Research Program of China (No. 2013CB035701), the National Natural Science Foundation of China (Grant No. 51671159), the Fundamental Research Funds for the Central Universities, and the National Program for Support of Top-notch Young Professionals.
Author information
Authors and Affiliations
Corresponding author
Additional information
This article is published with open access at Springerlink.com
Rights and permissions
Open Access The articles published in this journal are distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.
About this article
Cite this article
Zhang, WW., Li, GR., Zhang, Q. et al. Comprehensive damage evaluation of localized spallation of thermal barrier coatings. J Adv Ceram 6, 230–239 (2017). https://doi.org/10.1007/s40145-017-0234-4
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s40145-017-0234-4