With the development of aero-engine,gas import temperatures of hot section structural materials are increasingly higher.Metal alloy materials due to the rapidly decreased mechanical properties at relative high tempera...With the development of aero-engine,gas import temperatures of hot section structural materials are increasingly higher.Metal alloy materials due to the rapidly decreased mechanical properties at relative high temperature are gradually replaced with silicon-based non-oxide silicon carbide ceramics.However,silicon carbide ceramic materials tend to spall and deform in engine combustion environment,need environmental barrier coatings for the protection of the matrix.The preparation of Si/mullite/Yb2Si2O7 environmental barrier coatings onto silicon carbide was realized with plasma spraying and sol-gel method.Coatings structure,surface morphology and layer components were principally discussed through the test of X-ray diffraction(XRD),thermogravimetric analysis(TG) and scanning electron microscopy(SEM).This paper explored how to match coefficient of thermal expansion(CTE) and enhance chemical compatibility effectively.The results showed that most areas of the environmental barrier coatings were uniform,close-grained and crack-free,which could maintain excellent adherence.Their oxidation resistance would be better with the increase of dipping time and spraying time in preparation.展开更多
Thermal/environmental barrier coatings(T/EBCs)play important roles in jet and/or gas turbine engines to protect the Ni-based superalloys and/or ceramic matrix composite substrates from the high-temperature airflow dam...Thermal/environmental barrier coatings(T/EBCs)play important roles in jet and/or gas turbine engines to protect the Ni-based superalloys and/or ceramic matrix composite substrates from the high-temperature airflow damage.Great efforts have been contributed to searching for enhanced T/EBC materials to improve the efficiency of the engines,which is the key of improving thrust-to-weight ratio and energy saving.The practical candidates,rare earth-contained materials,are widely used for T/EBCs in gas turbines due to their excellent properties such as low thermal conductivity,high melting point,hightemperature strength and durability as exhibited in yttriastabilized zirconia,pyrochlore oxides and rare earth silicates.In addition to the intrinsic properties,the microstructures obtained by different synthesis processes and the service performances,as well as the underlying failure mechanism,are also significant to this specific application.However,the main challenges for T/EBCs developments are T/EBC materials selection with balanced properties and their anti-corrosion performances at higher operating temperature.In this review,we summarized the progress in their fabrication techniques and mechanical/thermal properties of typically rare earth-contained T/EBCs,together with their anti-corrosion performance under the condition of molten salts or oxides(such as Na2SO4,V2O5and NaVO3),calcium–magnesium–alumina–silicate(CMAS)and high-temperature water vapor.展开更多
An environmental barrier coating(EBC) consisting of a silicon bond coat and an Yb2-SiO5 top-coat was sprayed on a carbon fibers reinforced SiC ceramic matrix composite(CMC) by atmospheric plasma spray(APS). The micros...An environmental barrier coating(EBC) consisting of a silicon bond coat and an Yb2-SiO5 top-coat was sprayed on a carbon fibers reinforced SiC ceramic matrix composite(CMC) by atmospheric plasma spray(APS). The microstructure of the coating annealed at 1300 ℃ and its high-temperature oxidation behavior at 1350 ℃ were investigated. The significant mass loss of silica during the plasma spray process led to the formation of Yb2SiO5 and Yb2O3 binary phases in the top-coat. Eutectics of Yb2SiO5 and Yb2O3 were precipitated in the top-coat, and channel cracks were formed in the top-coat after 20 h annealing because of the mismatch between the coefficients of thermal expansion(CTEs) of Yb2SiO5 and the SiC substrate. The EBC effectively improved the oxidation resistance of the CMC substrate. The channel cracks in the Yb2SiO5 top-coat provided inward diffusion channels for oxygen and led to the formation of oxidation delamination cracks in the bond coat, finally resulting in spallation failure of the coating after 80 h oxidation.展开更多
In this work,the microstructure evolution,thermal expansion,thermal conductivity,and thermal shock resistance properties of the plasma-sprayed Xl-Gd_(2)SiO_(5),X2-Y_(2)SiO_(5),and X2-Er_(2)SiO_(5)coatings were evaluat...In this work,the microstructure evolution,thermal expansion,thermal conductivity,and thermal shock resistance properties of the plasma-sprayed Xl-Gd_(2)SiO_(5),X2-Y_(2)SiO_(5),and X2-Er_(2)SiO_(5)coatings were evaluated and compared by experimental measurement and theoretical exploration.Results showed that significant microstructure evolution such as crystallization of amorphous phase,grain growth,and defects reduction was observed in the RE_(2)SiO_(5)coatings after thermal aging at 1400℃.The Xl-Gd_(2)SiO_(5)coating exhibited higher CTE values than the X2-Y_(2)SiO_(5)and X2-Er_(2)SiO_(5)coatings,which was related to their crystal structure.The thermal conductivity of thermal-aged RE_(2)SiO_(5)coating was much higher than that of the as-sprayed RE_(2)SiO_(5)coating,and thermal conductivity was determined not only by crystal structure but also mainly by the microstructure of the coatings.The X2-Y_(2)SiO_(5)and X2-Er_(2)SiO_(5)coatings with lower thermal mismatch stre s ses presented much better thermal shock resistance than the X1-Gd_(2)SiO_(5)coating.展开更多
Avirtual wall thicknessmethod is developed to simulate the temperature field of turbine bladeswith thermal barrier coatings(TBCs),to simplify the modeling process and improve the calculation efficiency.The results sho...Avirtual wall thicknessmethod is developed to simulate the temperature field of turbine bladeswith thermal barrier coatings(TBCs),to simplify the modeling process and improve the calculation efficiency.The results show that the virtualwall thickness method can improve themesh quality by 20%,reduce the number ofmeshes by 76.7%and save the calculation time by 35.5%,compared with the traditional real wall thickness method.The average calculation error of the two methods is between 0.21%and 0.93%.Furthermore,the temperature at the blade leading edge is the highest and the average temperature of the blade pressure surface is higher than that of the suction surface under a certain service condition.The blade surface temperature presents a high temperature at both ends and a low temperature in themiddle height when the temperature of incoming gas is uniformand constant.The thermal insulation effect of TBCs is the worst near the air film hole,and the best at the blade leading edge.According to the calculated temperature field of the substrate-coating system,the highest thermal insulation temperature of the TC layer is 172.01 K,and the thermal insulation proportions of TC,TGO and BC are 93.55%,1.54%and 4.91%,respectively.展开更多
The surface fracture toughness is an important mechanical parameter for studying the failure behavior of air plasma sprayed(APS)thermal barrier coatings(TBCs).As APS TBCs are typical multilayer porous ceramic material...The surface fracture toughness is an important mechanical parameter for studying the failure behavior of air plasma sprayed(APS)thermal barrier coatings(TBCs).As APS TBCs are typical multilayer porous ceramic materials,the direct applications of the traditional single edge notched beam(SENB)method that ignores those typical structural characters may cause errors.To measure the surface fracture toughness more accurately,the effects of multilayer and porous characters on the fracture toughness of APS TBCs should be considered.In this paper,a modified single edge V-notched beam(MSEVNB)method with typical structural characters is developed.According to the finite element analysis(FEA),the geometry factor of the multilayer structure is recalculated.Owing to the narrower V-notches,a more accurate critical fracture stress is obtained.Based on the Griffith energy balance,the reduction of the crack surface caused by micro-defects is corrected.The MSEVNB method can measure the surface fracture toughness more accurately than the SENB method.展开更多
Thermal barrier coating (TBC) revolutionized the industry by allowing higher operating temperatures for equipment, such as gas turbines in the aeronautical industry. However, at high temperatures, the TBC is exposed t...Thermal barrier coating (TBC) revolutionized the industry by allowing higher operating temperatures for equipment, such as gas turbines in the aeronautical industry. However, at high temperatures, the TBC is exposed to the attack of molten silicates, known as CMAS (Calcium-Magnesium-Alumino-Silicate), which are particles from the environment that infiltrate the TBC, causing delamination. In this study, samples coated with TBC by thermal spray and covered with CMAS were evaluated at temperatures of 1200˚C and 1250˚C. For each temperature, exposure times of 1 h and 5 h were used. Samples with longer exposure time had a considerable volume increase. The main contribution of this work was to demonstrate the non-wettability of the CMAS, even in the 5-h heat treatments, which prevented its infiltration in the deeper regions. The conditions to guarantee the formation of the silicate and its consequent wettability are also discussed.展开更多
Environmental barrier coatings(EBCs)effectively protect the ceramic matrix composites(CMCs)from harsh engine environments,especially steam and molten salts.However,open pores inevitably formed during the deposition pr...Environmental barrier coatings(EBCs)effectively protect the ceramic matrix composites(CMCs)from harsh engine environments,especially steam and molten salts.However,open pores inevitably formed during the deposition process provide the transport channels for oxidants and corrosives,and lead to premature failure of EBCs.This research work proposed a method of pressure infiltration densification which blocked these open pores in the coatings.These results showed that it was difficult for aluminum to infiltrate spontaneously,but with the increase of external gas pressure and internal vacuum simultaneously,the molten aluminum obviously moved forward,and finally stopped infiltrating at a depth of a specific geometry.Based on the wrinkled zigzag pore model,a mathematical relationship between the critical pressure with the infiltration depth and the pore intrinsic geometry was established.The infiltration results confirmed this relationship,indicating that for a given coating,a dense thick film can be obtained by adjusting the internal and external gas pressures to drive a melt infiltration.展开更多
LaMgAl_(11)O_(19) thermal barrier coatings(TBCs) were applied to carbon steels with a NiCoCrAlY bond coat by plasma spraying. The effects of heat treatment on the corrosion resistance of carbon steel coated with LaMgA...LaMgAl_(11)O_(19) thermal barrier coatings(TBCs) were applied to carbon steels with a NiCoCrAlY bond coat by plasma spraying. The effects of heat treatment on the corrosion resistance of carbon steel coated with LaMgAl_(11)O_(19) TBCs were investigated in 3.5wt% Na Cl solution using polarization curves, electrochemical impedance spectroscopy(EIS), scanning electron microscopy(SEM), and X-ray diffraction(XRD). The results show that a large number of cracks are found in the LaMgAl_(11)O_(19) TBCs after the samples are heat-treated, including some through-thickness cracks. The corrosion forms of the as-sprayed and heat-treated TBCs are uniform corrosion and pitting corrosion, respectively. The as-sprayed TBCs exhibit three EIS time constants after being immersed for less than 7 d, and then a new time constant appears because of steel substrate corrosion. When the immersion time is increased to 56 d, a Warburg impedance(W) component appears in the EIS data. The EIS data for the heat-treated TBCs exhibit only two time constants after the samples are immersed for less than 14 d, and a new time constant appears when the immersion time is increased further. The heat treatment reduces the corrosion resistance of carbon steel coated with LaMgAl_(11)O_(19) TBCs. The corrosion products are primarily γ-Fe OOH and Fe3O4.展开更多
Determining the interfacial properties of thermal barrier coatings(TBCs) is imperative for their durability evaluation and further improvements. A ceramic coating(topcoat) and a NiCoCrALY bondcoat were atmospheric-pla...Determining the interfacial properties of thermal barrier coatings(TBCs) is imperative for their durability evaluation and further improvements. A ceramic coating(topcoat) and a NiCoCrALY bondcoat were atmospheric-plasma-sprayed(APS) on a stainless steel substrate. A modified three-point bending test was adopted to initiate and propagate the topcoat/bondcoat(TC/BC)interfacial crack. After a complete delamination, the fracture surfaces were examined by an optical microscope, which shows that the cracking plane was merely on the TC/BC interface. Based on the experimental results of load–displacement and crack length–displacement,the strain energy release rate G for crack propagation was calculated, and the averaged magnitude was 77.1 J/m^2.Repeatable results have indicated that the method can be used for the evaluation of interfacial fracture toughness in thermal barrier coatings and other multi-layer structures.展开更多
Laboratory experiments were conducted to study the spallation behaviour of thermal barrier coatings(TBCs) on aero-engine turbine blades manufactured by the electron-beam physical vapour deposition technique(EB-PVD). I...Laboratory experiments were conducted to study the spallation behaviour of thermal barrier coatings(TBCs) on aero-engine turbine blades manufactured by the electron-beam physical vapour deposition technique(EB-PVD). Intact blades were heated at temperature 1135℃ in a furnace for certain time and then cooled to the room temperature in the laboratory condition. It was found that no spallation occurred during cooling, but spallation happened at constant room temperature after cooling. The spallation mechanism is studied by using the mechanical model developed(Harvey 2017 and Wang 2017), which are based on the hypothesis of pockets of energy concentration(PECs). Some observations of the spallation behaviour are well predicted by the model.展开更多
The functionally graded thermal barrier coatings （FG-TBCs） with 80%ZrO2-13%CeO2-7%Y2O3 （C-YSZ）/NiCoCrAlY were prepared using a recently developed supersonic plasma spraying（S-PS） with dual powder feed ports syst...The functionally graded thermal barrier coatings （FG-TBCs） with 80%ZrO2-13%CeO2-7%Y2O3 （C-YSZ）/NiCoCrAlY were prepared using a recently developed supersonic plasma spraying（S-PS） with dual powder feed ports system. The thermal shock experiment of FG-TBCs specimens was carried out by means of the automatic thermal cycle device, in which the samples were heated to 1200℃ by oxygen-acetylene flame jet then water-quenched to ambient temperature. The temperature—time curves of specimens and photographs can be watched on-line and recorded by a computer during the test. The results show that the totally 1mm-thick FG-TBCs have excellent thermal shock resistance due to the fact that the coatings have no any peeling-off after 200 thermal cycles. The microstructures and morphologies of FG-TBCs were characterized and analyzed by SEM.展开更多
In this study, an etched-SiO-film grating fabrication technique based on solute-solvent separation soft lithography is developed. By using this new technique, high temperature grating with frequency of 600 lines/mm is...In this study, an etched-SiO-film grating fabrication technique based on solute-solvent separation soft lithography is developed. By using this new technique, high temperature grating with frequency of 600 lines/mm is successfully fabricated on the surface of thermal barrier coatings(TBCs). During the fabrication process, the microstructure and chemical compositions of ceramic coating before and after polishing is analyzed with a digital microscope and the energy dispersive X-ray spectroscope(EDS) in scanning electron microscope(SEM). And then the grating on TBCs is heated at the temperature ranging from 300℃ to 1000℃ for examining the high temperature resistance. In the practical application, the displacement and strain field around the crack on the ceramic surface are investigated with geometry phase analysis(GPA). The successful results verify that the etched-SiO-film grating has a good oxidation resistance and can be applied to high temperature deformation measurement of TBCs.展开更多
Interface fracture toughness and fracture mechanisms of plasma-/sprayed thermal barrier coatings(TBCs) were investigated by interfacial indentation test(IIT) in combination with acoustic emission(AE) measurement.Criti...Interface fracture toughness and fracture mechanisms of plasma-/sprayed thermal barrier coatings(TBCs) were investigated by interfacial indentation test(IIT) in combination with acoustic emission(AE) measurement.Critical load and AE energy were employed to calculate interface fracture toughness.The critical point at which crack appears at the interface was determined by the IIT.AE signals produced during total indentation test not only are used to investigate the interface cracking behavior by Fast Fourier Transform(FFT) and wavelet transforms but also supply the mechanical information.The result shows that the AE signals associated with coating plastic deformation during indentation are of a more continuous type with a lower characteristic frequency content(30-60 kHz),whereas the instantaneous relaxation associated with interface crack initiation produces burst type AE signals with a characteristic frequency in the range 70- 200 kHz.The AE signals energy is concentrated on different scales for the coating plastic deformation,interface crack initiation and interface crack propagation.Interface fracture toughness calculated by AE energy was 1.19 MPam^(1/2) close to 1.58 MPam calculated by critical load.It indicates that the acoustic emission energy is suitable to reflect the interface fracture toughness.展开更多
Pyrochlore oxides of general compositions, A2Zr2O7, where A is a 3+ cation (La to Lu), are promising candidate materials for applications as high temperature thermal barrier coatings because of their high melting poin...Pyrochlore oxides of general compositions, A2Zr2O7, where A is a 3+ cation (La to Lu), are promising candidate materials for applications as high temperature thermal barrier coatings because of their high melting points, high thermal expansion coefficients, and low thermal conductivities. In this study, oxides of Sm2Zr2O7, (Sm0.75La0.25)2Zr2O7, (Sm0,5 La0.5)2 Zr2O7, (Sm0.25La0.75)2Zr2O7 and La2Zr2O7 were prepared by solid reactions at 1600 °C for 10 h using Sm2O3, La2O3 and ZrO2 as the reactants. The phase compositions of these ceramic materials were analyzed by X-ray diffractometer (XRD) and fourier transform infrared spectroscopy (FT-IR) methods, respectively. The micro-structure was observed by scanning electronl microscope (SEM). The thermal conductivities of these ceramic materials were measured using laser-flash method. XRD and FT-IR results showed that pure ceramic materials with pyrochlore structure were prepared successfully. SEM results indicated that microstructures of these ceramic materials were dense and grain boundaries were very clean. The La2O3 doped Sm2Zr2O7 pyrochlores (Sm0.75 La0.25)2Zr2O7 and (Sm0.5 La0.5)2 Zr2O7 had lower thermal conductivity than the undoped Sm2Zr2O7. The thermal conductivity of (Sm0.25La0.75)2Zr2O7 was found to be lower than that of La2Zr2O7. The results showed that these ceramic materials had the potential to be used as candidate materials for TBCs.展开更多
ZrO_(2)-YO_(1.5)-TaO_(2.5)(ZYTO)is a promising top-coat material for thermal barrier coatings(TBCs).The bulk properties of ZYTO have been reported by several studies,but its performances as TBCs are less-well understo...ZrO_(2)-YO_(1.5)-TaO_(2.5)(ZYTO)is a promising top-coat material for thermal barrier coatings(TBCs).The bulk properties of ZYTO have been reported by several studies,but its performances as TBCs are less-well understood.In this work,ZYTO TBCs were prepared by air plasma spraying(APS)and their thermal cycling performances were investigated at 1150℃.Despite of the good bulk properties,APS ZYTO TBCs present an extremely short thermal fatigue life.This is attributed to the non-equilibrium grain-boundary segregation of TaO_(2.5) induced by limited solubility and rapid quenching during APS process,resulting in a tetragonal(t)to cubic(c)and metastable-tetragonal(tm)phase transformation in ZYTO TBCs.The volume shrinkage(~0.74vol%)of phase transformation leads to many cracks at the c/tm phase boundaries after deposition.On the other hand,the formation of cubic phase with massive grain-boundary Ta segregation induces a large intergranular embrittlement and a weak bonding strength(~5.3 MPa),resulting in the premature failure of the ZYTO TBCs.展开更多
Research is being conducted to study the effects of particulate deposition from contaminants in coal synthesis gas (syngas) on the mechanical properties of thermal barrier coatings (TBC) employed on integrated gasific...Research is being conducted to study the effects of particulate deposition from contaminants in coal synthesis gas (syngas) on the mechanical properties of thermal barrier coatings (TBC) employed on integrated gasification combined cycle (IGCC) turbine hot section airfoils. West Virginia University (WVU) had been working with US Department of Energy, National Energy Technology Laboratory (NETL) to simulate deposition on the pressure side of an IGCC turbine first stage vane. To model the deposition, coal fly ash was injected into the flow of a combustor facility and deposited onto TBC coated, angled film-cooled test articles in a high pressure (approximately 4 atm) and a high temperature (1560 K) environment. To investigate the interaction between the deposition and the TBC, a load-based multiple-partial unloading micro-indentation technique was used to quantitatively evaluate the mechanical properties of materials. The indentation results showed the Young’s Modulus of the ceramic top coat was higher in areas with deposition formation due to the penetration of the fly ash. This corresponds with the reduction of strain tolerance of the 7% yttria-stabilized zirconia (7YSZ) coatings.展开更多
NiCoCrAlTaY bond coat was deposited on pure nickel substrate by low pressure plasma spraying(LPPS), and ZrO2-8%Y2O3 (mass fraction) nanostructured and ZrO2-7%Y2O3 (mass fraction) conventional thermal barrier coatings(...NiCoCrAlTaY bond coat was deposited on pure nickel substrate by low pressure plasma spraying(LPPS), and ZrO2-8%Y2O3 (mass fraction) nanostructured and ZrO2-7%Y2O3 (mass fraction) conventional thermal barrier coatings(TBCs) were deposited by air plasma spraying(APS). The thermal shock behaviors of the nanostructured and conventional TBCs were investigated by quenching the coating samples in cold water from 1 150, 1 200 and 1 250 ℃, respectively. Scanning electron microscopy(SEM) was used to examine the microstructures of the samples after thermal shock testing. Energy dispersive analysis of X-ray(EDAX) was used to analyze the interface diffusion behavior of the bond coat elements. X-ray diffractometry(XRD) was used to analyze the constituent phases of the samples. Experimental results indicate that the nanostructured TBC is superior to the conventional TBC in thermal shock performance. Both the nanostructured and conventional TBCs fail along the bond coat/substrate interface. The constituent phase of the as-sprayed conventional TBC is diffusionless-transformed tetragonal(t′). However, the constituent phase of the as-sprayed nanostructured TBC is cubic(c). There is a difference in the crystal size at the spalled surfaces of the nanostructured and conventional TBCs. The constituent phases of the spalled surfaces are mainly composed of Ni2.88Cr1.12 and oxides of bond coat elements.展开更多
基金supported by the National Basic Research Program of China (2010CB934700)
文摘With the development of aero-engine,gas import temperatures of hot section structural materials are increasingly higher.Metal alloy materials due to the rapidly decreased mechanical properties at relative high temperature are gradually replaced with silicon-based non-oxide silicon carbide ceramics.However,silicon carbide ceramic materials tend to spall and deform in engine combustion environment,need environmental barrier coatings for the protection of the matrix.The preparation of Si/mullite/Yb2Si2O7 environmental barrier coatings onto silicon carbide was realized with plasma spraying and sol-gel method.Coatings structure,surface morphology and layer components were principally discussed through the test of X-ray diffraction(XRD),thermogravimetric analysis(TG) and scanning electron microscopy(SEM).This paper explored how to match coefficient of thermal expansion(CTE) and enhance chemical compatibility effectively.The results showed that most areas of the environmental barrier coatings were uniform,close-grained and crack-free,which could maintain excellent adherence.Their oxidation resistance would be better with the increase of dipping time and spraying time in preparation.
基金financially supported by the National Natural Science Foundation of China(Nos.51602188,51602187,51572166 and 51402183)the Program for Professor of Special Appointment(Young Eastern Scholar and Eastern Scholar)at Shanghai Institutions of Higher Learning(Nos.QD2015028,TP2015040 and TP2014041)the Yunnan Province Science and Technology Major Project(No.2018ZE009)。
文摘Thermal/environmental barrier coatings(T/EBCs)play important roles in jet and/or gas turbine engines to protect the Ni-based superalloys and/or ceramic matrix composite substrates from the high-temperature airflow damage.Great efforts have been contributed to searching for enhanced T/EBC materials to improve the efficiency of the engines,which is the key of improving thrust-to-weight ratio and energy saving.The practical candidates,rare earth-contained materials,are widely used for T/EBCs in gas turbines due to their excellent properties such as low thermal conductivity,high melting point,hightemperature strength and durability as exhibited in yttriastabilized zirconia,pyrochlore oxides and rare earth silicates.In addition to the intrinsic properties,the microstructures obtained by different synthesis processes and the service performances,as well as the underlying failure mechanism,are also significant to this specific application.However,the main challenges for T/EBCs developments are T/EBC materials selection with balanced properties and their anti-corrosion performances at higher operating temperature.In this review,we summarized the progress in their fabrication techniques and mechanical/thermal properties of typically rare earth-contained T/EBCs,together with their anti-corrosion performance under the condition of molten salts or oxides(such as Na2SO4,V2O5and NaVO3),calcium–magnesium–alumina–silicate(CMAS)and high-temperature water vapor.
基金sponsored by the National Natural Science Foundation of China (NSFC) under grant Nos. 51590894, 51425102, and 51231001
文摘An environmental barrier coating(EBC) consisting of a silicon bond coat and an Yb2-SiO5 top-coat was sprayed on a carbon fibers reinforced SiC ceramic matrix composite(CMC) by atmospheric plasma spray(APS). The microstructure of the coating annealed at 1300 ℃ and its high-temperature oxidation behavior at 1350 ℃ were investigated. The significant mass loss of silica during the plasma spray process led to the formation of Yb2SiO5 and Yb2O3 binary phases in the top-coat. Eutectics of Yb2SiO5 and Yb2O3 were precipitated in the top-coat, and channel cracks were formed in the top-coat after 20 h annealing because of the mismatch between the coefficients of thermal expansion(CTEs) of Yb2SiO5 and the SiC substrate. The EBC effectively improved the oxidation resistance of the CMC substrate. The channel cracks in the Yb2SiO5 top-coat provided inward diffusion channels for oxygen and led to the formation of oxidation delamination cracks in the bond coat, finally resulting in spallation failure of the coating after 80 h oxidation.
基金financially supported by the National Key R&D Program of China(No.2018YFB0704400)the National Science and Technology Major Project(No.2017-VI-0020-0092)+2 种基金the Shanghai Technical Platform for Testing on Inorganic Materials(No.19DZ2290700)the Shanghai Sailing Program(No.19YF1453900)the Natural Science Foundation of Shanghai(No.20ZR1465700)。
文摘In this work,the microstructure evolution,thermal expansion,thermal conductivity,and thermal shock resistance properties of the plasma-sprayed Xl-Gd_(2)SiO_(5),X2-Y_(2)SiO_(5),and X2-Er_(2)SiO_(5)coatings were evaluated and compared by experimental measurement and theoretical exploration.Results showed that significant microstructure evolution such as crystallization of amorphous phase,grain growth,and defects reduction was observed in the RE_(2)SiO_(5)coatings after thermal aging at 1400℃.The Xl-Gd_(2)SiO_(5)coating exhibited higher CTE values than the X2-Y_(2)SiO_(5)and X2-Er_(2)SiO_(5)coatings,which was related to their crystal structure.The thermal conductivity of thermal-aged RE_(2)SiO_(5)coating was much higher than that of the as-sprayed RE_(2)SiO_(5)coating,and thermal conductivity was determined not only by crystal structure but also mainly by the microstructure of the coatings.The X2-Y_(2)SiO_(5)and X2-Er_(2)SiO_(5)coatings with lower thermal mismatch stre s ses presented much better thermal shock resistance than the X1-Gd_(2)SiO_(5)coating.
基金supported by the National Science and Technology Major Project(J2019-IV-0003-0070)the National Natural Science Foundation of China(Grant No.12102320)+1 种基金the Advanced Aviation Power Innovation Workstation Project(HKCX2019-01-003)China Postdoc-toral Science Foundation(2021M692571).
文摘Avirtual wall thicknessmethod is developed to simulate the temperature field of turbine bladeswith thermal barrier coatings(TBCs),to simplify the modeling process and improve the calculation efficiency.The results show that the virtualwall thickness method can improve themesh quality by 20%,reduce the number ofmeshes by 76.7%and save the calculation time by 35.5%,compared with the traditional real wall thickness method.The average calculation error of the two methods is between 0.21%and 0.93%.Furthermore,the temperature at the blade leading edge is the highest and the average temperature of the blade pressure surface is higher than that of the suction surface under a certain service condition.The blade surface temperature presents a high temperature at both ends and a low temperature in themiddle height when the temperature of incoming gas is uniformand constant.The thermal insulation effect of TBCs is the worst near the air film hole,and the best at the blade leading edge.According to the calculated temperature field of the substrate-coating system,the highest thermal insulation temperature of the TC layer is 172.01 K,and the thermal insulation proportions of TC,TGO and BC are 93.55%,1.54%and 4.91%,respectively.
基金Project supported by the National Natural Science Foundation of China(Nos.12172048 and 12027901)the National Science and Technology Major Project of China(Nos.2019-Ⅶ-0007-0147 and 2017-Ⅵ-0020-0093)。
文摘The surface fracture toughness is an important mechanical parameter for studying the failure behavior of air plasma sprayed(APS)thermal barrier coatings(TBCs).As APS TBCs are typical multilayer porous ceramic materials,the direct applications of the traditional single edge notched beam(SENB)method that ignores those typical structural characters may cause errors.To measure the surface fracture toughness more accurately,the effects of multilayer and porous characters on the fracture toughness of APS TBCs should be considered.In this paper,a modified single edge V-notched beam(MSEVNB)method with typical structural characters is developed.According to the finite element analysis(FEA),the geometry factor of the multilayer structure is recalculated.Owing to the narrower V-notches,a more accurate critical fracture stress is obtained.Based on the Griffith energy balance,the reduction of the crack surface caused by micro-defects is corrected.The MSEVNB method can measure the surface fracture toughness more accurately than the SENB method.
文摘Thermal barrier coating (TBC) revolutionized the industry by allowing higher operating temperatures for equipment, such as gas turbines in the aeronautical industry. However, at high temperatures, the TBC is exposed to the attack of molten silicates, known as CMAS (Calcium-Magnesium-Alumino-Silicate), which are particles from the environment that infiltrate the TBC, causing delamination. In this study, samples coated with TBC by thermal spray and covered with CMAS were evaluated at temperatures of 1200˚C and 1250˚C. For each temperature, exposure times of 1 h and 5 h were used. Samples with longer exposure time had a considerable volume increase. The main contribution of this work was to demonstrate the non-wettability of the CMAS, even in the 5-h heat treatments, which prevented its infiltration in the deeper regions. The conditions to guarantee the formation of the silicate and its consequent wettability are also discussed.
基金supported by the National Natural Science Foundation of China(No.51901175)the Guangdong Province Outstanding Youth Foundation(No.2021B1515020038)+3 种基金the Guangzhou Technical Research Program(No.201906010015)the Industry University Research Project funded by Aero Engine Corporation of China(No.HFZL2019CXY015)the Postdoctoral Research Foundation of China(Nos.2020T130499 and 2019M653602)the National Program for Support of Top-notch Young Professionals.
文摘Environmental barrier coatings(EBCs)effectively protect the ceramic matrix composites(CMCs)from harsh engine environments,especially steam and molten salts.However,open pores inevitably formed during the deposition process provide the transport channels for oxidants and corrosives,and lead to premature failure of EBCs.This research work proposed a method of pressure infiltration densification which blocked these open pores in the coatings.These results showed that it was difficult for aluminum to infiltrate spontaneously,but with the increase of external gas pressure and internal vacuum simultaneously,the molten aluminum obviously moved forward,and finally stopped infiltrating at a depth of a specific geometry.Based on the wrinkled zigzag pore model,a mathematical relationship between the critical pressure with the infiltration depth and the pore intrinsic geometry was established.The infiltration results confirmed this relationship,indicating that for a given coating,a dense thick film can be obtained by adjusting the internal and external gas pressures to drive a melt infiltration.
基金financially supported by the Fundamental Research Funds for the Central Universities of China(No.FRF-AS-11-015B)the Science Research Program of Beijing Municipal Commission of Education(No.00012087)
文摘LaMgAl_(11)O_(19) thermal barrier coatings(TBCs) were applied to carbon steels with a NiCoCrAlY bond coat by plasma spraying. The effects of heat treatment on the corrosion resistance of carbon steel coated with LaMgAl_(11)O_(19) TBCs were investigated in 3.5wt% Na Cl solution using polarization curves, electrochemical impedance spectroscopy(EIS), scanning electron microscopy(SEM), and X-ray diffraction(XRD). The results show that a large number of cracks are found in the LaMgAl_(11)O_(19) TBCs after the samples are heat-treated, including some through-thickness cracks. The corrosion forms of the as-sprayed and heat-treated TBCs are uniform corrosion and pitting corrosion, respectively. The as-sprayed TBCs exhibit three EIS time constants after being immersed for less than 7 d, and then a new time constant appears because of steel substrate corrosion. When the immersion time is increased to 56 d, a Warburg impedance(W) component appears in the EIS data. The EIS data for the heat-treated TBCs exhibit only two time constants after the samples are immersed for less than 14 d, and a new time constant appears when the immersion time is increased further. The heat treatment reduces the corrosion resistance of carbon steel coated with LaMgAl_(11)O_(19) TBCs. The corrosion products are primarily γ-Fe OOH and Fe3O4.
基金financial support from the National Natural Science Foundation of China(11232008,11372118,and 11672345)the Natural Science Foundation of Jiangsu Province(BK20161341)the Six Talent Peaks Project in Jiangsu Province(2016-HKHT-004)
文摘Determining the interfacial properties of thermal barrier coatings(TBCs) is imperative for their durability evaluation and further improvements. A ceramic coating(topcoat) and a NiCoCrALY bondcoat were atmospheric-plasma-sprayed(APS) on a stainless steel substrate. A modified three-point bending test was adopted to initiate and propagate the topcoat/bondcoat(TC/BC)interfacial crack. After a complete delamination, the fracture surfaces were examined by an optical microscope, which shows that the cracking plane was merely on the TC/BC interface. Based on the experimental results of load–displacement and crack length–displacement,the strain energy release rate G for crack propagation was calculated, and the averaged magnitude was 77.1 J/m^2.Repeatable results have indicated that the method can be used for the evaluation of interfacial fracture toughness in thermal barrier coatings and other multi-layer structures.
文摘Laboratory experiments were conducted to study the spallation behaviour of thermal barrier coatings(TBCs) on aero-engine turbine blades manufactured by the electron-beam physical vapour deposition technique(EB-PVD). Intact blades were heated at temperature 1135℃ in a furnace for certain time and then cooled to the room temperature in the laboratory condition. It was found that no spallation occurred during cooling, but spallation happened at constant room temperature after cooling. The spallation mechanism is studied by using the mechanical model developed(Harvey 2017 and Wang 2017), which are based on the hypothesis of pockets of energy concentration(PECs). Some observations of the spallation behaviour are well predicted by the model.
文摘The functionally graded thermal barrier coatings （FG-TBCs） with 80%ZrO2-13%CeO2-7%Y2O3 （C-YSZ）/NiCoCrAlY were prepared using a recently developed supersonic plasma spraying（S-PS） with dual powder feed ports system. The thermal shock experiment of FG-TBCs specimens was carried out by means of the automatic thermal cycle device, in which the samples were heated to 1200℃ by oxygen-acetylene flame jet then water-quenched to ambient temperature. The temperature—time curves of specimens and photographs can be watched on-line and recorded by a computer during the test. The results show that the totally 1mm-thick FG-TBCs have excellent thermal shock resistance due to the fact that the coatings have no any peeling-off after 200 thermal cycles. The microstructures and morphologies of FG-TBCs were characterized and analyzed by SEM.
基金financially supported by the National Natural Science Foundation of China(11672153,11232008)
文摘In this study, an etched-SiO-film grating fabrication technique based on solute-solvent separation soft lithography is developed. By using this new technique, high temperature grating with frequency of 600 lines/mm is successfully fabricated on the surface of thermal barrier coatings(TBCs). During the fabrication process, the microstructure and chemical compositions of ceramic coating before and after polishing is analyzed with a digital microscope and the energy dispersive X-ray spectroscope(EDS) in scanning electron microscope(SEM). And then the grating on TBCs is heated at the temperature ranging from 300℃ to 1000℃ for examining the high temperature resistance. In the practical application, the displacement and strain field around the crack on the ceramic surface are investigated with geometry phase analysis(GPA). The successful results verify that the etched-SiO-film grating has a good oxidation resistance and can be applied to high temperature deformation measurement of TBCs.
文摘Interface fracture toughness and fracture mechanisms of plasma-/sprayed thermal barrier coatings(TBCs) were investigated by interfacial indentation test(IIT) in combination with acoustic emission(AE) measurement.Critical load and AE energy were employed to calculate interface fracture toughness.The critical point at which crack appears at the interface was determined by the IIT.AE signals produced during total indentation test not only are used to investigate the interface cracking behavior by Fast Fourier Transform(FFT) and wavelet transforms but also supply the mechanical information.The result shows that the AE signals associated with coating plastic deformation during indentation are of a more continuous type with a lower characteristic frequency content(30-60 kHz),whereas the instantaneous relaxation associated with interface crack initiation produces burst type AE signals with a characteristic frequency in the range 70- 200 kHz.The AE signals energy is concentrated on different scales for the coating plastic deformation,interface crack initiation and interface crack propagation.Interface fracture toughness calculated by AE energy was 1.19 MPam^(1/2) close to 1.58 MPam calculated by critical load.It indicates that the acoustic emission energy is suitable to reflect the interface fracture toughness.
基金supported by Doctoral Fund of Henan Institute of Engineering (D2007012)
文摘Pyrochlore oxides of general compositions, A2Zr2O7, where A is a 3+ cation (La to Lu), are promising candidate materials for applications as high temperature thermal barrier coatings because of their high melting points, high thermal expansion coefficients, and low thermal conductivities. In this study, oxides of Sm2Zr2O7, (Sm0.75La0.25)2Zr2O7, (Sm0,5 La0.5)2 Zr2O7, (Sm0.25La0.75)2Zr2O7 and La2Zr2O7 were prepared by solid reactions at 1600 °C for 10 h using Sm2O3, La2O3 and ZrO2 as the reactants. The phase compositions of these ceramic materials were analyzed by X-ray diffractometer (XRD) and fourier transform infrared spectroscopy (FT-IR) methods, respectively. The micro-structure was observed by scanning electronl microscope (SEM). The thermal conductivities of these ceramic materials were measured using laser-flash method. XRD and FT-IR results showed that pure ceramic materials with pyrochlore structure were prepared successfully. SEM results indicated that microstructures of these ceramic materials were dense and grain boundaries were very clean. The La2O3 doped Sm2Zr2O7 pyrochlores (Sm0.75 La0.25)2Zr2O7 and (Sm0.5 La0.5)2 Zr2O7 had lower thermal conductivity than the undoped Sm2Zr2O7. The thermal conductivity of (Sm0.25La0.75)2Zr2O7 was found to be lower than that of La2Zr2O7. The results showed that these ceramic materials had the potential to be used as candidate materials for TBCs.
基金financially supported by the National Natural Science Foundation of China (Nos. 51971139 and 51875341)the National Science and Technology Major Project of China (No. 2017-VI-0011-0083)
文摘ZrO_(2)-YO_(1.5)-TaO_(2.5)(ZYTO)is a promising top-coat material for thermal barrier coatings(TBCs).The bulk properties of ZYTO have been reported by several studies,but its performances as TBCs are less-well understood.In this work,ZYTO TBCs were prepared by air plasma spraying(APS)and their thermal cycling performances were investigated at 1150℃.Despite of the good bulk properties,APS ZYTO TBCs present an extremely short thermal fatigue life.This is attributed to the non-equilibrium grain-boundary segregation of TaO_(2.5) induced by limited solubility and rapid quenching during APS process,resulting in a tetragonal(t)to cubic(c)and metastable-tetragonal(tm)phase transformation in ZYTO TBCs.The volume shrinkage(~0.74vol%)of phase transformation leads to many cracks at the c/tm phase boundaries after deposition.On the other hand,the formation of cubic phase with massive grain-boundary Ta segregation induces a large intergranular embrittlement and a weak bonding strength(~5.3 MPa),resulting in the premature failure of the ZYTO TBCs.
文摘Research is being conducted to study the effects of particulate deposition from contaminants in coal synthesis gas (syngas) on the mechanical properties of thermal barrier coatings (TBC) employed on integrated gasification combined cycle (IGCC) turbine hot section airfoils. West Virginia University (WVU) had been working with US Department of Energy, National Energy Technology Laboratory (NETL) to simulate deposition on the pressure side of an IGCC turbine first stage vane. To model the deposition, coal fly ash was injected into the flow of a combustor facility and deposited onto TBC coated, angled film-cooled test articles in a high pressure (approximately 4 atm) and a high temperature (1560 K) environment. To investigate the interaction between the deposition and the TBC, a load-based multiple-partial unloading micro-indentation technique was used to quantitatively evaluate the mechanical properties of materials. The indentation results showed the Young’s Modulus of the ceramic top coat was higher in areas with deposition formation due to the penetration of the fly ash. This corresponds with the reduction of strain tolerance of the 7% yttria-stabilized zirconia (7YSZ) coatings.
基金Project(1343-77212) supported by the Innovation Program for Graduate Students of Central South University, China
文摘NiCoCrAlTaY bond coat was deposited on pure nickel substrate by low pressure plasma spraying(LPPS), and ZrO2-8%Y2O3 (mass fraction) nanostructured and ZrO2-7%Y2O3 (mass fraction) conventional thermal barrier coatings(TBCs) were deposited by air plasma spraying(APS). The thermal shock behaviors of the nanostructured and conventional TBCs were investigated by quenching the coating samples in cold water from 1 150, 1 200 and 1 250 ℃, respectively. Scanning electron microscopy(SEM) was used to examine the microstructures of the samples after thermal shock testing. Energy dispersive analysis of X-ray(EDAX) was used to analyze the interface diffusion behavior of the bond coat elements. X-ray diffractometry(XRD) was used to analyze the constituent phases of the samples. Experimental results indicate that the nanostructured TBC is superior to the conventional TBC in thermal shock performance. Both the nanostructured and conventional TBCs fail along the bond coat/substrate interface. The constituent phase of the as-sprayed conventional TBC is diffusionless-transformed tetragonal(t′). However, the constituent phase of the as-sprayed nanostructured TBC is cubic(c). There is a difference in the crystal size at the spalled surfaces of the nanostructured and conventional TBCs. The constituent phases of the spalled surfaces are mainly composed of Ni2.88Cr1.12 and oxides of bond coat elements.
