Skip to main content
SpringerLink
Log in

Environmental degradation of thermal-barrier coatings by molten deposits

  • Thermal-barrier coatings for more efficient gas-turbine engines
  • Published:
MRS Bulletin Aims and scope Submit manuscript

Abstract

Molten deposits based on calcium-magnesium alumino-silicates (CMAS), originating from siliceous debris ingested with the intake air, represent a fundamental threat to progress in gas turbine technology by limiting the operating surface temperature of coated components. The thermomechanical and thermochemical aspects of the CMAS interactions with thermal-barrier coatings, as well as the current status of mitigating strategies, are discussed in this article. Key challenges and research needs for developing adequate solutions are highlighted.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Figure 1
Figure 2
Figure 3
Figure 8
Figure 4
Figure 5
Figure 6
Figure 7

Similar content being viewed by others

References

  1. D.W. McKee, P.A. Siemers, Thin Solid Films 73, 439 (1980).

    Article  CAS  Google Scholar 

  2. A.S. Nagelberg, J. Electrochem. Soc. 132 (10), 2502 (1985).

  3. R.L. Jones, C.E. Williams, Surf. Coat. Technol. 349 (1987).

  4. C. Leyens, I.G. Wright, B.A. Pint, Oxid. Met. 54 (5/6), 401 (2000).

  5. T.E. Strangman, Thin Solid Films 127, 93 (1985).

  6. T.E. Strangman, J. Neumann, A. Liu, “Thermal Barrier Coating Life—Prediction Model Development; Final Report” (NASA–Lewis Research Center, 1987).

  7. R.L. Jones, “Experiences in Seeking Stabilizers for Zirconia having Hot Corrosion-Resistance and High Temperature Tetragonal (t’) Stability” (NRL/MR/6170–96–7841, Naval Research Laboratory, 1996).

  8. S. Raghavan, M.J. Mayo, Surf. Coat. Technol. 160, 187 (2002).

  9. F.M. Pitek, C.G. Levi, Surf. Coat. Technol. 201, 6044 (2007).

  10. M.A. Alvin, F.S. Pettit, G.H. Meier, N.M. Yanar, M. Chyu, D. Mazzotta, W. Slaughter, V. Karaivanov, B. Kang, C. Feng, R. Chen, T.C. Fu, in 5th International Conference on Advances in Materials Technology for Fossil Power Plants, R. Viswanathan, D. Gandy, K. Coleman, Eds. (Electric Power Research Institute, Inc., Marco Island, FL, 2008), pp. 413–423.

  11. J.L. Smialek, F.A. Archer, R.G. Garlick, JOM 46 (12), 39 (1994).

  12. F.H. Stott, D.J. de Wet, R. Taylor, MRS Bull. 19 (10), 46 (1994).

  13. M.P. Borom, C.A. Johnson, L.A. Peluso, Surf. Coat. Technol. 86–87, 116 (1996).

  14. S. Krämer, J.Y. Yang, C.A. Johnson, C.G. Levi, J. Am. Ceram. Soc. 89 (10), 3167 (2006).

  15. K.M. Grant, S. Krämer, J.P.A. Löfvader, C.G. Levi, Surf. Coat. Technol. 202, 653 (2007).

  16. K.M. Grant, S. Krämer, G.G.E. Seward, C.G. Levi, J. Am. Ceram. Soc. 93 (10), 3504 (2010).

  17. J.L. Smialek, “The Chemistry of Saudi Arabian Sand: A Deposition Problem on Helicopter Turbine Airfoils” (NASA TM-105234, NASA Lewis Research Center, 1991).

  18. W. Braue, J. Mater. Sci. 44, 1664 (2009).

  19. A.G. Evans, D.R. Clarke, C.G. Levi, J. Eur. Ceram. Soc. 28 (7), 1405 (2008).

  20. C. Mercer, S. Faulhaber, A.G. Evans, R. Darolia, Acta Mater. 53 (4), 1029 (2005).

  21. S. Krämer, S. Faulhaber, M. Chambers, D.R. Clarke, C.G. Levi, J.W. Hutchinson, A.G. Evans, Mater. Sci. Eng., A 490, 26 (2008).

  22. V.K. Tolpygo, private communication.

  23. K.M. Wessels, R.W. Jackson, D.G. Konitzer, T.M. Pollock, C.G. Levi, presented at the International Conference on Metallurgical Coatings and Thin Films, San Diego, CA, 2012.

  24. L. Li, D.R. Clarke, Int. J. Appl. Ceram. Technol. 5 (3), 278 (2008).

  25. J. Wu, H.B. Guo, Y.Z. Gao, S.K. Gong, J. Eur. Ceram. Soc. 31, 1881 (2011).

  26. W. Braue, P. Mechnich, J. Am. Ceram. Soc. 94 (12), 4483 (2011).

  27. M.J. Maloney, in Turbine Forum (Forum of Technology, Germany, Nice-Port St. Laurent, France, 2006).

  28. A.G. Evans, J.W. Hutchinson, Surf. Coat. Technol. 201, 7905 (2007).

  29. S. Sundaram, D.M. Lipkin, C.A. Johnson, J.W. Hutchinson, J. Appl. Mech. (2012), in press.

  30. A. Aygun, A.L. Vasiliev, N.P. Padture, X. Ma, Acta Mater. 55 (20), 6734 (2007).

  31. A.D. Gledhill, K.M. Reddy, J.M. Drexler, K. Shinoda, S. Sampath, N.P. Padture, Mater. Sci. Eng., A 528, 7214 (2011).

  32. P. Mechnich, W. Braue, U. Schulz, J. Am. Ceram. Soc. 94 (3), 925 (2011).

  33. M.-P. Bacos, J.-M. Dorvaux, O. Lavigne, R. Mévrel, M. Poulain, C. Rio, M.-H. Vidal-Setif, in Aerospace Lab: The ONERA Journal (ONERA, Chatillon, France, 2011), issue 3.

  34. R.A. Miller, J.L. Smialek, R.G. Garlick, in Science and Technology of Zirconia, A.H. Heuer, L.W. Hobbs, Eds. (The American Ceramic Society, Columbus, OH, 1981), vol. 3, pp. 241–253.

  35. J.A. Krogstad, S. Krämer, D.M. Lipkin, C.A. Johnson, D.R.G. Mitchell, J.M. Cairney, C.G. Levi, J. Am. Ceram. Soc. 94 (S1), S168 (2011).

  36. D.M. Lipkin, J.A. Krogstad, Y. Gao, C.A. Johnson, W.A. Nelson, C.G. Levi, J. Am. Ceram. Soc. (2012), in press.

  37. M.J. Maloney, US Patent 6,177,200, 2001.

  38. R. Vassen, A. Stuke, D. Stöver, J. Therm. Spray Technol. 18 (2), 181 (2009).

  39. T.E. Strangman, D. Raybould, A. Jameel, W. Baker, Surf. Coat. Technol. 202, 658 (2007).

  40. W.E. Ford, in Dana’s Textbook of Mineralogy with an Extended Treatise on Crystallography and Physical Mineralogy, 4th Edition (Wiley, New York, 1954).

  41. PTI, “Material Safety Data Sheet: Airport Runway Sand” (2007); www.powdertechnologyinc.com/secondary/msds.php.

  42. H.E. Taylor, F.E. Lichte, Geophys. Res. Lett. 7 (11), 949 (1980).

  43. W. Chesner, R. Collins, M. MacKay, J. Emery, “User Guidelines for Waste and Byproduct Materials in Pavement Construction” (Federal Highway Administration, Washington, DC, 1997).

  44. N. Chellah, M.-H. Vidal-Sétif, C. Petitjean, P.-J. Panteix, C. Rapin, M. Vilasi, in 8th International Symposium on High Temperature Corrosion and Protection of Materials (HTCPM8) (Les Embiez, France, 2012).

  45. T. Steinke, D. Sebold, D.E. Mack, R. Vaßen, D. Stöver, Surf. Coat. Technol. 205, 2287 (2010).

  46. A.K. Rai, R.S. Bhattacharya, D.E. Wolfe, T.J. Eden, Int. J. Appl. Ceram. Technol. 7 (5), 662 (2010).

  47. J.M. Drexler, K. Shinoda, A.L. Ortiz, D. Li, A.L. Vasiliev, A.D. Gledhill, S. Sampath, N.P. Padture, Acta Mater. 58 6835 (2010).

  48. J.M. Drexler, A.L. Ortiz, N.P. Padture, Acta Mater. 60 5437 (2012).

  49. M.-P. Bacos, J.-M. Dorvaux, S. Landais, O. Lavigne, R. Mévrel, M. Poulain, C. Rio, M.-H. Vidal-Sétif, in Aerospace Lab: The ONERA Journal (ONERA, Chatillon, France, 2011), issue 3.

  50. W.C. Hasz, C.A. Johnson, M.P. Borom, US Patent 5,660,885 (1997).

  51. M. Fu, R. Darolia, M.D. Gorman, B.A. Nagaraj, US Patent 8,062,759 (2007).

  52. N.P. Padture, K.W. Schlichting, T. Bhatia, A. Ozturk, B. Cetegen, E.H. Jordan, M. Gell, S. Jiang, T.D. Xiao, P.R. Strutt, E. Garcia, P. Miranzo, M.I. Osendi, Acta Mater. 49, 2251 (2001).

  53. S. Krämer, J.Y. Yang, C.G. Levi, J. Am. Ceram. Soc. 91 (2), 576 (2008).

  54. J.M. Drexler, C.H. Chen, A.D. Gledhill, K. Shinoda, S. Sampath, N.P. Padture Surf. Coat. Technol. 206, 3911 (2012).

  55. R.G. Wellman, J.R. Nicholls, Tribol. Int. 41, 657 (2008).

  56. R.V. Hillery, B.H. Pilsner, R.L. McKnight, T.S. Cook, M.S. Hartle, “Thermal Barrier Coating Life Prediction Model Development” (NASA CR 180807, General Electric, 1988).

  57. E. Zaleski, R.W. Jackson, C. Ensslen, C.G. Levi, 8th International Symposium on High Temperature Corrosion and Protection of Materials (HTCPM8) (Les Embiez, France, 2012).

  58. J.M. Drexler, A. Aygun, D. Li, R. Vaßen, T. Steinke, N.P. Padture, Surf. Coat. Technol. 204 (16–17), 2683 (2010).

  59. R.W. Jackson, E.M. Zaleski, M.R. Begley, C.G. Levi, in International Conference on Metallurgical Coatings and Thin Films (San Diego, CA, 2012).

  60. M.D. Novak, F.W. Zok, Rev. Sci. Instrum. 82 (115101) (2012).

  61. NRC, “Integrated Computational Materials Engineering: A Transformational Discipline for Improved Competitiveness and National Security” (9780309119993, The National Academies Press, Washington, DC, 2008).

Download references

Acknowledgments

This article draws on lessons from research supported by the Office of Naval Research (CGL) and the French Defense Research Organization (MHVS). The authors are indebted to Dr. M.J. Maloney (PWA) for use of the illustration in Figure 2, as well as to Drs. O. Lavigne (ONERA), D. Konitzer, and D. Lipkin (GE) and Professors N.P. Padture (Brown) and M.R. Begley (UCSB) for helpful discussions. The contributions of Drs. R.W. Jackson and S. Krämer at UCSB are gratefully acknowledged.

Author information

Authors and Affiliations

  1. Materials Department, University of California, Santa Barbara, USA

    Carlos G. Levi

  2. School of Engineering and Applied Sciences, Harvard University, USA

    John W. Hutchinson

  3. Department of Metallic Materials and Structures, Onera, French Aerospace Lab, France

    Marie Hélène Vidal-Sétif

  4. GE Global Research and Center for Thermal Spray Research, Stony Brook University, USA

    Curtis A. Johnson

Authors
  1. Carlos G. Levi
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. John W. Hutchinson
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Marie Hélène Vidal-Sétif
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Curtis A. Johnson
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Carlos G. Levi.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Levi, C.G., Hutchinson, J.W., Vidal-Sétif, M.H. et al. Environmental degradation of thermal-barrier coatings by molten deposits. MRS Bulletin 37, 932–941 (2012). https://doi.org/10.1557/mrs.2012.230

Download citation

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1557/mrs.2012.230

Search

Navigation