Characterization of the Benefit of APS Flash Coatings in Improving TBC Lifetime

Bruce A. Pint; Michael J. Lance; Ercan Cakmak; Kenneth A. Kane; J. Allen Haynes; Edward J. Gildersleeve; Sanjay Sampath

doi:10.1007/978-3-030-51834-9_71

Characterization of the Benefit of APS Flash Coatings in Improving TBC Lifetime

Bruce A. Pint, Michael J. Lance, Ercan Cakmak, Kenneth A. Kane, J. Allen Haynes, Edward J. Gildersleeve, Sanjay Sampath

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

3 Scopus citations

Abstract

The addition of an air plasma sprayed (APS) “flash” layer on top of a high velocity oxygen fuel (HVOF) bond coating has been shown to extend the lifetime of thermal barrier coatings. A series of furnace cycle tests (FCTs) has been conducted at 1100 °C in air + 10% H₂O to study the benefit of flash coatings on rod and disk alloy 247 specimens and provide a better mechanistic understanding of their benefit. Flash coatings of NiCoCrAlY and NiCoCrAlYHfSi both improved the FCT lifetime of rod specimens tested in 100-h cycles and disk specimens tested in 1-h cycles. In 1-h cycles, the NiCoCrAlY flash coating significantly outperformed an HVOF-only NiCoCrAlYHfSi bond coating and a NiCoCrAlYHfSi flash coating. Both flash coatings increased the bond coating roughness compared to HVOF. During exposure, the flash layer formed an intermixed alumina-metal layer that appeared to inhibit crack formation. Using a time series of observations, the lower Y + Hf content in the Y-only flash coating appeared to reduce Al consumption. The HVOF layer acted as a source of Al for the adjacent mixed zone. A second series of specimens included a fully APS bond coating where oxide had penetrated through the entire coating to the substrate after only 100, 1-h cycles and lifetime was similar to an HVOF-only bond coating. The inner HVOF layer with the outer APS flash coating prevented this complete penetration from occurring.

Original language	English
Title of host publication	Superalloys 2020 - Proceedings of the 14th International Symposium on Superalloys
Editors	Sammy Tin, Mark Hardy, Justin Clews, Jonathan Cormier, Qiang Feng, John Marcin, Chris O'Brien, Akane Suzuki
Publisher	Springer Science and Business Media Deutschland GmbH
Pages	739-746
Number of pages	8
ISBN (Print)	9783030518332
DOIs	https://doi.org/10.1007/978-3-030-51834-9_71
State	Published - 2020
Event	14th International Symposium on Superalloys, Superalloys 2021 - Seven Springs, United States Duration: Sep 12 2021 → Sep 16 2021

Publication series

Name	Minerals, Metals and Materials Series
ISSN (Print)	2367-1181
ISSN (Electronic)	2367-1696

Conference

Conference	14th International Symposium on Superalloys, Superalloys 2021
Country/Territory	United States
City	Seven Springs
Period	09/12/21 → 09/16/21

Funding

Notice: This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the US Department of Energy. The US Government retains and the publisher, by accepting the article for publication, acknowledges that the US Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan). Acknowledgements G. Garner, T. Lowe, T. Jordan, V. Cox assisted with the experimental work at ORNL. This research was sponsored by the US Department of Energy, Office of Fossil Energy, Advanced Turbine Program (R. Dennis program manager and P. Burke project monitor). G. Garner, T. Lowe, T. Jordan, V. Cox assisted with the experimental work at ORNL. This research was sponsored by the US Department of Energy, Office of Fossil Energy, Advanced Turbine Program (R. Dennis program manager and P. Burke project monitor).

Funders	Funder number
U.S. Department of Energy
Office of Fossil Energy
Oak Ridge National Laboratory

Keywords

APS flash coating
Furnace cycle testing
Thermal barrier coatings

Access to Document

10.1007/978-3-030-51834-9_71

Cite this

Pint, B. A., Lance, M. J., Cakmak, E., Kane, K. A., Haynes, J. A., Gildersleeve, E. J., & Sampath, S. (2020). Characterization of the Benefit of APS Flash Coatings in Improving TBC Lifetime. In S. Tin, M. Hardy, J. Clews, J. Cormier, Q. Feng, J. Marcin, C. O'Brien, & A. Suzuki (Eds.), Superalloys 2020 - Proceedings of the 14th International Symposium on Superalloys (pp. 739-746). (Minerals, Metals and Materials Series). Springer Science and Business Media Deutschland GmbH. https://doi.org/10.1007/978-3-030-51834-9_71

Pint, Bruce A. ; Lance, Michael J. ; Cakmak, Ercan et al. / Characterization of the Benefit of APS Flash Coatings in Improving TBC Lifetime. Superalloys 2020 - Proceedings of the 14th International Symposium on Superalloys. editor / Sammy Tin ; Mark Hardy ; Justin Clews ; Jonathan Cormier ; Qiang Feng ; John Marcin ; Chris O'Brien ; Akane Suzuki. Springer Science and Business Media Deutschland GmbH, 2020. pp. 739-746 (Minerals, Metals and Materials Series).

@inproceedings{ab0d14bce5a045da870a65309671e75f,

title = "Characterization of the Benefit of APS Flash Coatings in Improving TBC Lifetime",

abstract = "The addition of an air plasma sprayed (APS) “flash” layer on top of a high velocity oxygen fuel (HVOF) bond coating has been shown to extend the lifetime of thermal barrier coatings. A series of furnace cycle tests (FCTs) has been conducted at 1100 °C in air + 10% H2O to study the benefit of flash coatings on rod and disk alloy 247 specimens and provide a better mechanistic understanding of their benefit. Flash coatings of NiCoCrAlY and NiCoCrAlYHfSi both improved the FCT lifetime of rod specimens tested in 100-h cycles and disk specimens tested in 1-h cycles. In 1-h cycles, the NiCoCrAlY flash coating significantly outperformed an HVOF-only NiCoCrAlYHfSi bond coating and a NiCoCrAlYHfSi flash coating. Both flash coatings increased the bond coating roughness compared to HVOF. During exposure, the flash layer formed an intermixed alumina-metal layer that appeared to inhibit crack formation. Using a time series of observations, the lower Y + Hf content in the Y-only flash coating appeared to reduce Al consumption. The HVOF layer acted as a source of Al for the adjacent mixed zone. A second series of specimens included a fully APS bond coating where oxide had penetrated through the entire coating to the substrate after only 100, 1-h cycles and lifetime was similar to an HVOF-only bond coating. The inner HVOF layer with the outer APS flash coating prevented this complete penetration from occurring.",

keywords = "APS flash coating, Furnace cycle testing, Thermal barrier coatings",

author = "Pint, {Bruce A.} and Lance, {Michael J.} and Ercan Cakmak and Kane, {Kenneth A.} and Haynes, {J. Allen} and Gildersleeve, {Edward J.} and Sanjay Sampath",

note = "Publisher Copyright: {\textcopyright} 2020, The Minerals, Metals & Materials Society.; 14th International Symposium on Superalloys, Superalloys 2021 ; Conference date: 12-09-2021 Through 16-09-2021",

year = "2020",

doi = "10.1007/978-3-030-51834-9_71",

language = "English",

isbn = "9783030518332",

series = "Minerals, Metals and Materials Series",

publisher = "Springer Science and Business Media Deutschland GmbH",

pages = "739--746",

editor = "Sammy Tin and Mark Hardy and Justin Clews and Jonathan Cormier and Qiang Feng and John Marcin and Chris O'Brien and Akane Suzuki",

booktitle = "Superalloys 2020 - Proceedings of the 14th International Symposium on Superalloys",

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Pint, BA , Lance, MJ , Cakmak, E, Kane, KA, Haynes, JA, Gildersleeve, EJ & Sampath, S 2020, Characterization of the Benefit of APS Flash Coatings in Improving TBC Lifetime. in S Tin, M Hardy, J Clews, J Cormier, Q Feng, J Marcin, C O'Brien & A Suzuki (eds), Superalloys 2020 - Proceedings of the 14th International Symposium on Superalloys. Minerals, Metals and Materials Series, Springer Science and Business Media Deutschland GmbH, pp. 739-746, 14th International Symposium on Superalloys, Superalloys 2021, Seven Springs, United States, 09/12/21. https://doi.org/10.1007/978-3-030-51834-9_71

Characterization of the Benefit of APS Flash Coatings in Improving TBC Lifetime. / Pint, Bruce A.; Lance, Michael J.; Cakmak, Ercan et al.
Superalloys 2020 - Proceedings of the 14th International Symposium on Superalloys. ed. / Sammy Tin; Mark Hardy; Justin Clews; Jonathan Cormier; Qiang Feng; John Marcin; Chris O'Brien; Akane Suzuki. Springer Science and Business Media Deutschland GmbH, 2020. p. 739-746 (Minerals, Metals and Materials Series).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

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AU - Pint, Bruce A.

AU - Lance, Michael J.

AU - Cakmak, Ercan

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N2 - The addition of an air plasma sprayed (APS) “flash” layer on top of a high velocity oxygen fuel (HVOF) bond coating has been shown to extend the lifetime of thermal barrier coatings. A series of furnace cycle tests (FCTs) has been conducted at 1100 °C in air + 10% H2O to study the benefit of flash coatings on rod and disk alloy 247 specimens and provide a better mechanistic understanding of their benefit. Flash coatings of NiCoCrAlY and NiCoCrAlYHfSi both improved the FCT lifetime of rod specimens tested in 100-h cycles and disk specimens tested in 1-h cycles. In 1-h cycles, the NiCoCrAlY flash coating significantly outperformed an HVOF-only NiCoCrAlYHfSi bond coating and a NiCoCrAlYHfSi flash coating. Both flash coatings increased the bond coating roughness compared to HVOF. During exposure, the flash layer formed an intermixed alumina-metal layer that appeared to inhibit crack formation. Using a time series of observations, the lower Y + Hf content in the Y-only flash coating appeared to reduce Al consumption. The HVOF layer acted as a source of Al for the adjacent mixed zone. A second series of specimens included a fully APS bond coating where oxide had penetrated through the entire coating to the substrate after only 100, 1-h cycles and lifetime was similar to an HVOF-only bond coating. The inner HVOF layer with the outer APS flash coating prevented this complete penetration from occurring.

AB - The addition of an air plasma sprayed (APS) “flash” layer on top of a high velocity oxygen fuel (HVOF) bond coating has been shown to extend the lifetime of thermal barrier coatings. A series of furnace cycle tests (FCTs) has been conducted at 1100 °C in air + 10% H2O to study the benefit of flash coatings on rod and disk alloy 247 specimens and provide a better mechanistic understanding of their benefit. Flash coatings of NiCoCrAlY and NiCoCrAlYHfSi both improved the FCT lifetime of rod specimens tested in 100-h cycles and disk specimens tested in 1-h cycles. In 1-h cycles, the NiCoCrAlY flash coating significantly outperformed an HVOF-only NiCoCrAlYHfSi bond coating and a NiCoCrAlYHfSi flash coating. Both flash coatings increased the bond coating roughness compared to HVOF. During exposure, the flash layer formed an intermixed alumina-metal layer that appeared to inhibit crack formation. Using a time series of observations, the lower Y + Hf content in the Y-only flash coating appeared to reduce Al consumption. The HVOF layer acted as a source of Al for the adjacent mixed zone. A second series of specimens included a fully APS bond coating where oxide had penetrated through the entire coating to the substrate after only 100, 1-h cycles and lifetime was similar to an HVOF-only bond coating. The inner HVOF layer with the outer APS flash coating prevented this complete penetration from occurring.

KW - APS flash coating

KW - Furnace cycle testing

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Y2 - 12 September 2021 through 16 September 2021

ER -

Pint BA , Lance MJ , Cakmak E, Kane KA, Haynes JA, Gildersleeve EJ et al. Characterization of the Benefit of APS Flash Coatings in Improving TBC Lifetime. In Tin S, Hardy M, Clews J, Cormier J, Feng Q, Marcin J, O'Brien C, Suzuki A, editors, Superalloys 2020 - Proceedings of the 14th International Symposium on Superalloys. Springer Science and Business Media Deutschland GmbH. 2020. p. 739-746. (Minerals, Metals and Materials Series). doi: 10.1007/978-3-030-51834-9_71

Characterization of the Benefit of APS Flash Coatings in Improving TBC Lifetime

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