Improved Performance Thermal Barrier Coatings Using … Library/Events/2016/utsr/Wednesday... ·...
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Improved Performance Thermal Barrier Coatings Using The Solution Precursor Plasma Spray Process Maurice Gell*, Eric Jordan*, Jeffrey Roth, Rishi Kumar University of Connecticut + + - UTSR SBI STTR Phase IIA Presentation November 4, 2015 Jiwen Wang, Chen Jiang Balky Nair* HiFunda LLC
Transcript of Improved Performance Thermal Barrier Coatings Using … Library/Events/2016/utsr/Wednesday... ·...
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Improved Performance Thermal Barrier Coatings Using The Solution Precursor Plasma Spray Process
Maurice Gell*, Eric Jordan*, Jeffrey Roth, Rishi KumarUniversity of Connecticut
+
+-
UTSR SBI
STTR Phase IIA PresentationNovember 4, 2015
Jiwen Wang, Chen Jiang Balky Nair*
HiFunda LLC
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BACKGROUND
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TBC Applications
Combustor Case
Blades and Vanes
TBC Applications
Combustor Case
Blades and Vanes
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TGO
100 m
Tem
pera
ture
Hot GasSuperalloy BondCoatEB-PVD
7YSZ
Gas Film
Topcoat requirements:
Low thermal conductivity,
High use temperature,
High durability:
Microstructure & Requirements
Toughness Strain tolerance
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Liquid reservoir
Plasma gun Droplets CoatingSubstrate
Temperaturecontrol unit
Solution Precursor Plasma Spray (SPPS) Process
A B
Liquid injector
Solution Precursors
A, B or A+B
Multiple composition
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Solution Precursor Plasma Spray:Unique Microstructural Features
100 m
1 m
Through-thickness vertical cracks
Varied nano/micro-scale porosity:0~40%
Splat diameter < 2 mSplat thickness < 1 mSplat area is 1/2500 of that in APS TBCs
Layered porosity: inter-pass boundaries.
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SPPS
500 m
Thick SPPS Thermal Barrier Coatings
Substrate
4mm
Surface
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0
0.2
0.4
0.6
0.8
0 0.5 1.0 1.5 2.0 2.5 3.0
Thermal Cycle:1121C/1 hour
0
100
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0 1 2 3
Substrate A Substrate B
Coating Thickness (mm)
Spal
latio
n Li
fe,
Cyc
les
Nor
mal
ized
C
rack
Spa
cing
Coating Thickness (mm)
Effect of SPPS TBC Thickness On Durability
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In-Plane Fracture Toughness
In P
lane
Fra
ctur
e To
ughn
ess (
MPa
m1/
2 )
400 m 100 m
APSTBC
SPPSTBC
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SPPS YSZ With IPBS: Thermal Conductivity
50% Reduction Demonstrated
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Engineered SPPS YSZ TBC Architecture
10 m
Vertical cracks for strain tolerance/thermal cycle durability
Planar pores (IPBs) for low thermal conductivity
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SPPS can Make Thin Dense Layers 10 Micron
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YAG A CHALLNAGE AND OPPROTUNITY
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Properties Of YSZ and YAGMaterial Property YSZ YAG
Melting Point (oC) 2680 1950
Maximum Operating Temperature (oC) 1200-1300 1800
Thermal Conductivity at 1350 oC (W/mol-K) 2.0-3.0 (measured) 2.5 (extrapolated)
Thermal ExpansionCoefficient (ppm/K)
Density (g/cc) 6.10 4.55
Vickers Hardness 1200 1700
Fracture Toughness Highest Less
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3 SPPS TBCs DevelopedSPPS TBC Benefits
YSZ High Durability
YSZ with IPBs Lower KHigh Durability
YAG Higher Temp.Similar KHigh DurabilityLower Density
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SPPS YAG TBCs: Project Objectives
Develop a Higher Temperature (+200oC), Lower Thermal Conductivity Thermal Barrier Coating Using Yttrium Alumina Garnet (YAG) and the Solution Precursor Plasma Spray Process (SPPS)
Phase IIa Objective Improve Performance/Cost
Lower Thermal Conductivity Increse deposition rate $ and efficiency Radically improve CMAS resistance
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Anticipated Benefits
A New TBC That Can Tolerate Surface Temperatures of 1500oC Can Be Game-Changing For the Gas Turbine Industry Due to Higher Turbine Efficiencies and Lower Fuel Consumption
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Yttria-Alumina Phase Diagram
M. Shojaie-Bahaabad et al, Ceramics Intl.,Vol 35, 2009
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Thermal Spray Optimization Many Variables
Stand off Distance Precursor Composition Atomizing Gas Pressure Scan Speed and Step Height Injection Method, Stream vs. Atomizing Feed Rate Gun Power Gas Mix Gun Type
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SD = 1.375 1.425 1.5 1.625
6/27/2013 spray trials, 10 psi atomizing pressure
382
290226
161
0
100
200
300
400
500
06272013AA 06272013AB 06272013AC 06272013AD
Microh
ardnes
s (HV)
Increased Spray Distance at Lower Atomizing Pressure
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Performance
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SPPS YAG TBCs: Standard Microstructure--Used for Engine-Critical Properties Tests--
SPPS YAG
APS YSZ
Bond Coat
Superalloy
Vickers Hardness: 200-400 Porosity: 15-20%
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800 microns (33 mils) thick strain-tolerant microstructure Can be used for vanes, combustors and turbine outer air seals
Thick SPPS YAG TBCs Can Be Readily Fabricated
Proprietary & Confidential
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0
10000
20000
30000
40000
50000
60000
70000
80000
20 25 30 35 40 45 50 55 60 65 70
M: YAMP: YAP
MP
As-Sprayed SPPS YAG
0
20000
40000
60000
80000
100000
120000
140000
20 25 30 35 40 45 50 55 60 65 70
2 ()
Intensi
ty
As-Sprayed SPPS YAG with Excess Al3+ in precursor
Predominantly YAG Phase with Minor Amounts of YAM and YAP
Pure YAG phase
Stoichiometric YAG Deposited By SPPS Process
Inte
nsity
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9933
7131
6695
7892
9391
9381
7631
5503
3743
2716
2247
1975
1857
1711
1710
1552
1540
1484
1368
1376
1349
1356
1312
1339
1308
1333
1266
1250
1223
1241
1228
1216
1211
1247
1225
1288
1248
1251
1218
1235
1257
1217
1212
1245
1270
1251
1240
1267
1233
1262
1337
1241
1252
1258
1290
1286
1293
1360
1230
1286
1253
1266
1262
1277
1301
1298
1256
1273
1252
1260
1327
1354
1416
1352
1322
1347
1326
1287
1324
1376
1311
1362
1365
1395
1455
1348
1423
1453
1531
1510
1588
1678
1701
1793
1820
1881
1980
2061
2232
2322
2440
2643
2597
2749
3042
3341
3788
4713
6102
8865
14021
22788
32126
35465
30169
21143
14291
11862
13471
17118
19334
17865
13212
8544
5552
4076
3309
2771
2460
2242
2106
1987
1868
1837
1651
1684
1562
1548
1572
1465
1427
1386
1434
1399
1396
1457
1450
1417
1490
1507
1451
1435
1500
1477
1493
1497
1617
1613
1600
1634
1631
1690
1764
1885
2149
2592
3577
5204
7206
8841
8299
6588
4680
3704
3691
4254
5007
5223
4586
3591
2603
2087
1855
1673
1618
1588
1600
1479
1526
1439
1426
1396
1451
1470
1390
1378
1447
1372
1463
1486
1494
1473
1595
1608
1653
1724
1759
1850
1906
1936
2048
2199
2227
2375
2420
2540
2734
2987
3477
4086
5292
7506
11464
18183
25034
28198
25126
18255
12302
9674
10083
12288
15040
14981
12712
8819
5899
4020
3126
2744
2356
2109
1971
1766
1644
1626
1590
1551
1470
1392
1362
1372
1271
1274
1249
1292
1227
1201
1220
1227
1184
1179
1226
1178
1180
1204
1251
1197
1184
1178
1191
1177
1208
1179
1166
1145
1134
1208
1134
1229
1181
1177
1204
1169
1172
1143
1166
1132
1170
1173
1182
1182
1229
1158
1180
1169
1219
1246
1179
1138
1174
1204
1125
1175
1150
1155
1122
1106
1113
1148
1176
1109
1109
1091
1175
1133
1202
1176
1173
1177
1147
1100
1149
1143
1100
1173
1139
1171
1206
1143
1156
1155
1126
1178
1107
1154
1117
1129
1135
1146
1134
1141
1093
1113
1132
1170
1149
1124
1166
1138
1178
1137
1198
1132
1115
1108
1121
1133
1184
1177
1196
1227
1127
1131
1119
1113
1124
1203
1255
1237
1262
1257
1314
1284
1271
1324
1320
1357
1295
1366
1427
1471
1558
1683
1961
2590
3505
4462
4964
4571
3578
2761
2353
2193
2486
2992
3068
2939
2595
1978
1683
1552
1373
1357
1315
1253
1242
1250
1283
1254
1242
1278
1297
1266
1252
1239
1300
1289
1300
1339
1346
1423
1464
1436
1421
1503
1494
1638
1632
1632
1663
1801
1694
1889
2064
2394
2912
3686
5410
8139
11243
12684
11613
8939
6308
4723
4255
4798
6012
7079
6801
5836
4284
3037
2332
2012
1697
1554
1523
1430
1340
1388
1310
1287
1210
1245
1205
1179
1157
1188
1031
1175
1143
1124
1110
1175
1196
1235
1220
1218
1164
1106
1092
1067
1064
1090
1118
1067
1120
1181
1214
1324
1381
1441
1408
1399
1296
1215
1172
1189
1241
1284
1274
1238
1222
1181
1130
1069
1093
1078
1056
1104
1060
1033
1006
1059
1004
1071
1052
1032
1039
1039
1030
1098
1093
1098
1061
1012
1071
1062
1068
1084
1115
1030
982
1076
1079
1036
1100
1063
1094
1100
1097
1152
1198
1289
1326
1224
1240
1133
1150
1146
1164
1154
1203
1294
1160
1173
1110
1196
1257
1355
1230
1230
1176
1148
1083
1057
1045
1034
1088
1066
1024
1068
1088
1068
1097
1000
1045
1084
1030
1058
1070
1043
1003
1054
961
1080
1037
1035
1062
1033
1124
1147
1130
1322
1477
1525
1567
1523
1374
1270
1206
1150
1270
1286
1346
1317
1298
1235
1125
1081
1094
1082
998
1018
997
1003
995
1012
1055
1039
1022
982
1032
991
1082
1022
989
1027
1057
996
1110
964
1008
1030
1077
1071
1074
1075
1101
1071
1112
1096
1182
1275
1386
1629
1907
1847
1757
1505
1320
1204
1230
1252
1284
1386
1388
1410
1349
1186
1138
1018
992
1010
1011
1072
984
987
980
1046
985
1025
984
1025
1026
1081
1052
1052
968
1019
1211
1091
995
1039
1001
1013
1046
1008
1022
961
953
957
1022
1029
1047
1071
1078
1179
1148
1115
1083
1092
1001
1020
1014
1026
1077
1189
1052
1076
999
1031
1053
1046
1015
986
958
998
1024
1024
994
1021
997
1028
1012
988
991
979
1020
987
962
924
948
936
970
988
993
974
998
1001
999
988
980
1007
956
992
1021
1025
1026
964
1027
990
1030
1002
986
1011
989
979
1018
980
990
998
1053
994
984
1003
1016
1012
1018
1032
1010
1018
973
976
965
952
987
1043
993
1032
999
970
980
1014
981
969
951
998
986
1013
1029
1091
1056
1095
1106
1251
1387
1416
1563
1577
1379
1246
1177
1119
1126
1217
1200
1255
1277
1257
1242
1205
1086
1117
1070
1079
993
1077
1055
1109
1055
1094
1095
1102
1101
1111
1112
1139
1142
1153
1163
1284
1253
1264
1266
1303
1310
1338
1375
1435
1539
1687
1946
2352
2990
4184
5679
6889
7135
6327
5132
3769
2954
2638
2647
3007
3612
4170
4128
3724
3010
2312
1833
1555
1439
1303
1285
1219
1178
1138
1044
1108
1084
1096
1089
1046
1017
1007
1035
1102
1010
1057
1043
1050
1060
989
1089
1033
1065
1057
1074
1014
1027
1059
1016
1046
1019
1056
1054
1027
982
1066
1114
1059
1060
1039
1063
1049
1058
1056
1036
1032
1083
1061
1109
1041
1085
1128
1115
1165
1125
1186
1220
1245
1268
1292
1379
1391
1495
1504
1499
1514
1642
1628
1592
1776
1923
2033
2229
2539
2979
3724
4933
7208
10164
13581
15616
15170
13098
9567
6652
5194
4662
5060
6148
7412
8479
8613
7719
5820
4309
3103
2335
1942
1746
1628
1486
1461
1437
1359
1330
1328
1222
1247
1254
1171
1133
1123
1113
1157
1131
1160
1214
1195
1156
1134
1172
1179
1294
1356
1483
1681
1960
2454
2924
3131
3098
2661
2180
1791
1586
1472
1606
1760
1913
2105
2144
2029
1718
1444
1324
1173
1150
1115
1096
1096
1104
1060
1088
1143
1112
1108
1106
1101
1117
1116
1130
1143
1158
1208
1133
1145
1101
1197
1231
1300
1396
1457
1649
1898
2410
3161
3982
4694
4931
4544
3809
2860
2311
1928
1919
2060
2448
2731
2989
3077
2695
2217
1769
1488
1363
1261
1191
1152
1026
1111
1048
1019
1058
1048
1075
1059
1029
1042
996
959
1000
1016
1018
1039
1023
1044
1040
1035
1045
1015
1051
1112
1173
1292
1396
1533
1636
1456
1441
1275
1197
1124
1160
1128
1165
1272
1254
1310
1230
1214
1123
1034
1017
1037
1012
975
960
954
944
988
903
958
946
968
946
921
947
965
971
900
943
948
992
974
942
972
985
965
890
971
958
941
942
891
961
895
961
929
948
900
932
968
969
1007
919
975
951
1009
978
906
967
926
946
930
966
934
919
937
956
1020
1001
1012
970
1046
994
1069
970
1039
1053
1031
1037
1121
1075
1154
1177
1255
1292
1518
1697
2007
2444
2857
3147
3032
2619
2144
1846
1563
1534
1520
1658
1830
1966
2174
2112
1930
1673
1549
1302
1290
1260
1191
1198
1097
1124
1046
997
976
1079
1001
975
990
1002
934
931
883
969
908
967
934
938
937
926
991
978
1015
1004
1034
1053
1067
1019
997
1022
1006
1039
1000
1012
961
974
1018
978
1031
1001
964
962
911
965
959
1009
956
921
927
940
906
956
978
914
973
958
997
987
977
1022
993
1009
1029
1008
966
1045
1024
1082
1060
1128
1269
1346
1596
1719
1974
2005
1841
1604
1344
1230
1144
1153
1206
1198
1302
1346
1362
1391
1315
1204
1069
1083
1018
985
985
913
978
943
938
957
936
944
969
953
913
932
908
890
906
944
971
952
880
937
912
904
899
841
874
885
928
880
913
954
910
915
891
915
899
904
979
2 ()
Intensity
SPPS YAG Stream 5wt% AlN
[Data]
AnglePSD
20.00161501
20.02181468
20.04211480
20.06231468
20.08251507
20.10281500
20.1231503
20.14321518
20.16351480
20.18371534
20.20391557
20.22411593
20.24441561
20.26461531
20.28481454
20.30511524
20.32531457
20.34551577
20.36581604
20.3861533
20.40621511
20.42641593
20.44671514
20.46691517
20.48711635
20.50741587
20.52761540
20.54781595
20.56811569
20.58831504
20.60851547
20.62871550
20.6491596
20.66921566
20.68941687
20.70971570
20.72991617
20.75011658
20.77041696
20.79061735
20.81081710
20.83111830
20.85132022
20.87152200
20.89172715
20.9123476
20.93224594
20.95245927
20.97277462
20.99297576
21.01317099
21.03346052
21.05364846
21.07383637
21.0942718
21.11432167
21.13451972
21.15471849
21.1751696
21.19521673
21.21541572
21.23571575
21.25591601
21.27611507
21.29631601
21.31661655
21.33681518
21.3571481
21.37731600
21.39751484
21.41771507
21.4381488
21.45821497
21.47841466
21.49861510
21.51891476
21.53911452
21.55931449
21.57961541
21.59981496
21.621496
21.64031496
21.66051435
21.68071409
21.7011403
21.72121424
21.74141472
21.76161466
21.78191510
21.80211464
21.82231431
21.84261428
21.86281459
21.8831375
21.90331478
21.92351448
21.94371482
21.96391463
21.98421495
22.00441460
22.02461437
22.04491467
22.06511427
22.08531464
22.10561428
22.12581492
22.1461380
22.16621400
22.18651437
22.20671453
22.22691465
22.24721444
22.26741433
22.28761416
22.30791433
22.32811401
22.34831430
22.36851472
22.38881511
22.4091427
22.42921452
22.44951445
22.46971488
22.48991465
22.51021464
22.53041466
22.55061464
22.57081448
22.59111421
22.61131391
22.63151495
22.65181427
22.6721462
22.69221424
22.71251373
22.73271518
22.75291460
22.77321423
22.79341468
22.81361418
22.83381448
22.85411410
22.87431466
22.89451468
22.91481382
22.9351379
22.95521356
22.97551382
22.99571374
23.01591427
23.03611456
23.05641421
23.07661439
23.09681385
23.11711417
23.13731368
23.15751302
23.17781381
23.1981362
23.21821373
23.23841369
23.25871332
23.27891430
23.29911377
23.31941413
23.33961421
23.35981361
23.38011428
23.40031439
23.42051415
23.44071451
23.4611415
23.48121306
23.50141406
23.52171381
23.54191411
23.56211438
23.58241422
23.60261335
23.62281315
23.64311407
23.66331413
23.68351399
23.70371389
23.7241399
23.74421385
23.76441364
23.78471364
23.80491422
23.82511363
23.84541437
23.86561291
23.88581404
23.9061410
23.92631358
23.94651342
23.96671359
23.9871390
24.00721356
24.02741363
24.04771362
24.06791371
24.08811415
24.10831376
24.12861335
24.14881395
24.1691361
24.18931399
24.20951315
24.22971396
24.251327
24.27021387
24.29041358
24.31061422
24.33091319
24.35111400
24.37131413
24.39161388
24.41181430
24.4321409
24.45231446
24.47251350
24.49271365
24.5131440
24.53321339
24.55341370
24.57361425
24.59391374
24.61411416
24.63431458
24.65461420
24.67481373
24.6951393
24.71531454
24.73551383
24.75571307
24.77591359
24.79621329
24.81641377
24.83661399
24.85691356
24.87711456
24.89731421
24.91761381
24.93781434
24.9581404
24.97821398
24.99851402
25.01871458
25.03891454
25.05921381
25.07941513
25.09961567
25.11991629
25.14011585
25.16031493
25.18051481
25.20081499
25.2211406
25.24121415
25.26151402
25.28171340
25.30191415
25.32221407
25.34241418
25.36261417
25.38291443
25.40311410
25.42331408
25.44351396
25.46381387
25.4841402
25.50421338
25.52451405
25.54471414
25.56491429
25.58521451
25.60541383
25.62561415
25.64581396
25.66611431
25.68631433
25.70651499
25.72681389
25.7471423
25.76721426
25.78751407
25.80771378
25.82791417
25.84811421
25.86841382
25.88861396
25.90881405
25.92911379
25.94931417
25.96951414
25.98981447
26.011415
26.03021410
26.05041457
26.07071376
26.09091353
26.11111312
26.13141286
26.15161380
26.17181453
26.19211383
26.21231412
26.23251355
26.25271417
26.2731389
26.29321485
26.31341497
26.33371469
26.35391539
26.37411456
26.39441331
26.41461388
26.43481334
26.45511435
26.47531329
26.49551428
26.51571380
26.5361407
26.55621397
26.57641390
26.59671523
26.61691508
26.63711396
26.65741407
26.67761450
26.69781438
26.7181545
26.73831621
26.75851520
26.77871615
26.7991617
26.81921637
26.83941775
26.85971861
26.87991957
26.90011922
26.92031894
26.94061763
26.96081669
26.9811619
27.00131575
27.02151535
27.04171595
27.0621572
27.08221532
27.10241493
27.12261454
27.14291473
27.16311577
27.18331545
27.20361555
27.22381514
27.2441542
27.26431601
27.28451622
27.30471620
27.3251603
27.34521613
27.36541664
27.38561632
27.40591685
27.42611734
27.44631678
27.46661793
27.48681728
27.5071794
27.52731803
27.54751837
27.56771842
27.58791894
27.60821992
27.62842091
27.64862123
27.66892262
27.68912417
27.70932741
27.72963145
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