Effect of APS flash bond coatings and curvature on TBC performance on rod specimens

M. J. Lance; B. P. Thiesing; J. A. Haynes; E. J. Gildersleeve; S. Sampath; B. A. Pint

doi:10.1016/j.surfcoat.2019.124940

Effect of APS flash bond coatings and curvature on TBC performance on rod specimens

M. J. Lance, B. P. Thiesing, J. A. Haynes, E. J. Gildersleeve, S. Sampath, B. A. Pint

Research output: Contribution to journal › Article › peer-review

10 Scopus citations

Abstract

The addition of an air plasma sprayed (APS) “flash” bond coating layer on top of a high velocity oxy-fuel (HVOF) bond coating significantly extended the lifetime of APS yttria stabilized zirconia (YSZ) thermal barrier coatings (TBC) on rod specimens of superalloy 247 tested using 100-h cycles in air+10%H₂O at 1100 °C. The flash bond coatings of both NiCoCrAlY and NiCoCrAlYHfSi powder were compared to an HVOF-only and a vacuum plasma sprayed (VPS) NiCoCrAlYHfSi bond coating. The flash coatings appear to form a mixed oxide-metal zone, which likely inhibits crack formation and therefore extends lifetime compared to conventional bond coatings. The underlying dense HVOF layer appeared to act as a source of Al for this intermixed zone and prevented the oxide from penetrating deeper into the bond coating. Residual stress in the thermally-grown Al₂O₃ scale was measured using photo-luminescence piezospectroscopy (PLPS) as a function of time for each coating variation, including a comparison of concave and convex surfaces on a specially designed rod.

Original language	English
Article number	124940
Journal	Surface and Coatings Technology
Volume	378
DOIs	https://doi.org/10.1016/j.surfcoat.2019.124940
State	Published - Nov 25 2019

Funding

The authors would like to thank G. Garner, M. Stephens, T. Lowe, T. Geer, and T. Jordan for assistance with the experimental work and K. A. Kane, A. A. Wereszczak and E. Lara-Curzio for helpful comments on the manuscript and Mitsubishi Hitachi Power Systems (MHPS) for providing the bond coating powder and St. Gobain for top coat powder. This research was sponsored by the U.S. Department of Energy , Office of Fossil Energy , Turbine Program (R. Dennis program manager and P. Burke project manager). The authors would like to thank G. Garner, M. Stephens, T. Lowe, T. Geer, and T. Jordan for assistance with the experimental work and K. A. Kane, A. A. Wereszczak and E. Lara-Curzio for helpful comments on the manuscript and Mitsubishi Hitachi Power Systems (MHPS) for providing the bond coating powder and St. Gobain for top coat powder. This research was sponsored by the U.S. Department of Energy, Office of Fossil Energy, Turbine Program (R. Dennis program manager and P. Burke project manager).

Funders	Funder number
Mitsubishi Hitachi Power Systems
U.S. Department of Energy
Office of Fossil Energy

Keywords

APS flash bond coating
Alumina scale
Furnace cycle testing (FCT)
HVOF bond coating
Photo-stimulated luminescence piezospectroscopy (PLPS)
TBC
VPS bond coating

Access to Document

10.1016/j.surfcoat.2019.124940

Cite this

@article{0841831ab18943aaaa15d2bc60a350dc,

title = "Effect of APS flash bond coatings and curvature on TBC performance on rod specimens",

abstract = "The addition of an air plasma sprayed (APS) “flash” bond coating layer on top of a high velocity oxy-fuel (HVOF) bond coating significantly extended the lifetime of APS yttria stabilized zirconia (YSZ) thermal barrier coatings (TBC) on rod specimens of superalloy 247 tested using 100-h cycles in air+10%H2O at 1100 °C. The flash bond coatings of both NiCoCrAlY and NiCoCrAlYHfSi powder were compared to an HVOF-only and a vacuum plasma sprayed (VPS) NiCoCrAlYHfSi bond coating. The flash coatings appear to form a mixed oxide-metal zone, which likely inhibits crack formation and therefore extends lifetime compared to conventional bond coatings. The underlying dense HVOF layer appeared to act as a source of Al for this intermixed zone and prevented the oxide from penetrating deeper into the bond coating. Residual stress in the thermally-grown Al2O3 scale was measured using photo-luminescence piezospectroscopy (PLPS) as a function of time for each coating variation, including a comparison of concave and convex surfaces on a specially designed rod.",

keywords = "APS flash bond coating, Alumina scale, Furnace cycle testing (FCT), HVOF bond coating, Photo-stimulated luminescence piezospectroscopy (PLPS), TBC, VPS bond coating",

author = "Lance, {M. J.} and Thiesing, {B. P.} and Haynes, {J. A.} and Gildersleeve, {E. J.} and S. Sampath and Pint, {B. A.}",

note = "Publisher Copyright: {\textcopyright} 2019 Elsevier B.V.",

year = "2019",

month = nov,

day = "25",

doi = "10.1016/j.surfcoat.2019.124940",

language = "English",

volume = "378",

journal = "Surface and Coatings Technology",

issn = "0257-8972",

publisher = "Elsevier",

}

TY - JOUR

T1 - Effect of APS flash bond coatings and curvature on TBC performance on rod specimens

AU - Lance, M. J.

AU - Thiesing, B. P.

AU - Haynes, J. A.

AU - Gildersleeve, E. J.

AU - Sampath, S.

AU - Pint, B. A.

PY - 2019/11/25

Y1 - 2019/11/25

N2 - The addition of an air plasma sprayed (APS) “flash” bond coating layer on top of a high velocity oxy-fuel (HVOF) bond coating significantly extended the lifetime of APS yttria stabilized zirconia (YSZ) thermal barrier coatings (TBC) on rod specimens of superalloy 247 tested using 100-h cycles in air+10%H2O at 1100 °C. The flash bond coatings of both NiCoCrAlY and NiCoCrAlYHfSi powder were compared to an HVOF-only and a vacuum plasma sprayed (VPS) NiCoCrAlYHfSi bond coating. The flash coatings appear to form a mixed oxide-metal zone, which likely inhibits crack formation and therefore extends lifetime compared to conventional bond coatings. The underlying dense HVOF layer appeared to act as a source of Al for this intermixed zone and prevented the oxide from penetrating deeper into the bond coating. Residual stress in the thermally-grown Al2O3 scale was measured using photo-luminescence piezospectroscopy (PLPS) as a function of time for each coating variation, including a comparison of concave and convex surfaces on a specially designed rod.

AB - The addition of an air plasma sprayed (APS) “flash” bond coating layer on top of a high velocity oxy-fuel (HVOF) bond coating significantly extended the lifetime of APS yttria stabilized zirconia (YSZ) thermal barrier coatings (TBC) on rod specimens of superalloy 247 tested using 100-h cycles in air+10%H2O at 1100 °C. The flash bond coatings of both NiCoCrAlY and NiCoCrAlYHfSi powder were compared to an HVOF-only and a vacuum plasma sprayed (VPS) NiCoCrAlYHfSi bond coating. The flash coatings appear to form a mixed oxide-metal zone, which likely inhibits crack formation and therefore extends lifetime compared to conventional bond coatings. The underlying dense HVOF layer appeared to act as a source of Al for this intermixed zone and prevented the oxide from penetrating deeper into the bond coating. Residual stress in the thermally-grown Al2O3 scale was measured using photo-luminescence piezospectroscopy (PLPS) as a function of time for each coating variation, including a comparison of concave and convex surfaces on a specially designed rod.

KW - APS flash bond coating

KW - Alumina scale

KW - Furnace cycle testing (FCT)

KW - HVOF bond coating

KW - Photo-stimulated luminescence piezospectroscopy (PLPS)

KW - TBC

KW - VPS bond coating

UR - http://www.scopus.com/inward/record.url?scp=85072164175&partnerID=8YFLogxK

U2 - 10.1016/j.surfcoat.2019.124940

DO - 10.1016/j.surfcoat.2019.124940

M3 - Article

AN - SCOPUS:85072164175

SN - 0257-8972

VL - 378

JO - Surface and Coatings Technology

JF - Surface and Coatings Technology

M1 - 124940

ER -

Effect of APS flash bond coatings and curvature on TBC performance on rod specimens

Abstract

Funding

Keywords

Access to Document

Other files and links

Fingerprint

Cite this