Oxidation and degradation of a plasma-sprayed thermal barrier coating system

J. Allen Haynes; E. Douglas Rigney; Mattison K. Ferber; Wallace D. Porter

doi:10.1016/S0257-8972(96)02985-4

Oxidation and degradation of a plasma-sprayed thermal barrier coating system

J. Allen Haynes, E. Douglas Rigney, Mattison K. Ferber, Wallace D. Porter

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

126 Scopus citations

Abstract

The isothermal oxidation behavior of thermal barrier coating (TBC) specimens consisting of single-crystal superalloy substrates, vacuum plasma-sprayed Ni-22Cr-10Al-1Y bond coatings and air plasma-sprayed 7.5 wt.% yttria stabilized zirconia (YSZ) top coatings was evaluated by high-mass thermogravimetric analysis at 1150°C for up to 200 h. Coating durability was assessed by furnace cycling at 1150°C. Coatings and reaction products were characterized by X-ray diffraction, field-emission scanning electron microscopy and energy dispersive spectroscopy. No spallation of the ceramic top coatings occurred after up to 200 h isothermal exposure. Interfacial scales consisted of Al₂O₃ and Ni(Cr,Al)₂O₄ spinels. Discrete bands of Al₅Y₃O₁₂ oriented perpendicular to the bond coat surfaces were dispersed throughout the alumina scales. Coatings displayed average cyclic lifetimes of 355 1-h cycles. There were indications of interfacial scale delamination and subscale formation during thermal cycling. Results of the study are in agreement with previous findings. This work was the introductory phase of a larger study which will evaluate the oxidation behavior of electron beam-physical vapor deposition (EB-PVD) TBC systems.

Original language	English
Pages (from-to)	102-108
Number of pages	7
Journal	Surface and Coatings Technology
Volume	86-87
Issue number	PART 1
DOIs	https://doi.org/10.1016/S0257-8972(96)02985-4
State	Published - Dec 1 1996
Externally published	Yes

Funding

The authors would like to thank Dr. B. Nagaraj of G.E. Aircraft Engines, Cincinnati, OR for providing superalloy substrate material, and Mr. G. Bancke and Prof. C. Berndt of the Thermal Spray Laboratory at State University of New York, Stony Brook for coating deposition. Research was sponsored by the Assistant Secretary for Energy Efficiency and Renewable Energy, Office of Transportation Technologies, as part of the High Temperature Materials Laboratory Fellowship Program, Oak Ridge National Laboratory, managed by Lockheed Martin Energy Research Corp. for the US Department of Energy under contract number DE-AC05-960R22464.

Funders	Funder number
Lockheed Martin Energy Research Corp.
Office of Transportation Technologies
US Department of Energy	DE-AC05-960R22464
Office of Energy Efficiency and Renewable Energy
Oak Ridge National Laboratory

Keywords

Degradation
Oxidation
Thermal barrier coating

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10.1016/S0257-8972(96)02985-4

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abstract = "The isothermal oxidation behavior of thermal barrier coating (TBC) specimens consisting of single-crystal superalloy substrates, vacuum plasma-sprayed Ni-22Cr-10Al-1Y bond coatings and air plasma-sprayed 7.5 wt.% yttria stabilized zirconia (YSZ) top coatings was evaluated by high-mass thermogravimetric analysis at 1150°C for up to 200 h. Coating durability was assessed by furnace cycling at 1150°C. Coatings and reaction products were characterized by X-ray diffraction, field-emission scanning electron microscopy and energy dispersive spectroscopy. No spallation of the ceramic top coatings occurred after up to 200 h isothermal exposure. Interfacial scales consisted of Al2O3 and Ni(Cr,Al)2O4 spinels. Discrete bands of Al5Y3O12 oriented perpendicular to the bond coat surfaces were dispersed throughout the alumina scales. Coatings displayed average cyclic lifetimes of 355 1-h cycles. There were indications of interfacial scale delamination and subscale formation during thermal cycling. Results of the study are in agreement with previous findings. This work was the introductory phase of a larger study which will evaluate the oxidation behavior of electron beam-physical vapor deposition (EB-PVD) TBC systems.",

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AU - Haynes, J. Allen

AU - Rigney, E. Douglas

AU - Ferber, Mattison K.

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N2 - The isothermal oxidation behavior of thermal barrier coating (TBC) specimens consisting of single-crystal superalloy substrates, vacuum plasma-sprayed Ni-22Cr-10Al-1Y bond coatings and air plasma-sprayed 7.5 wt.% yttria stabilized zirconia (YSZ) top coatings was evaluated by high-mass thermogravimetric analysis at 1150°C for up to 200 h. Coating durability was assessed by furnace cycling at 1150°C. Coatings and reaction products were characterized by X-ray diffraction, field-emission scanning electron microscopy and energy dispersive spectroscopy. No spallation of the ceramic top coatings occurred after up to 200 h isothermal exposure. Interfacial scales consisted of Al2O3 and Ni(Cr,Al)2O4 spinels. Discrete bands of Al5Y3O12 oriented perpendicular to the bond coat surfaces were dispersed throughout the alumina scales. Coatings displayed average cyclic lifetimes of 355 1-h cycles. There were indications of interfacial scale delamination and subscale formation during thermal cycling. Results of the study are in agreement with previous findings. This work was the introductory phase of a larger study which will evaluate the oxidation behavior of electron beam-physical vapor deposition (EB-PVD) TBC systems.

AB - The isothermal oxidation behavior of thermal barrier coating (TBC) specimens consisting of single-crystal superalloy substrates, vacuum plasma-sprayed Ni-22Cr-10Al-1Y bond coatings and air plasma-sprayed 7.5 wt.% yttria stabilized zirconia (YSZ) top coatings was evaluated by high-mass thermogravimetric analysis at 1150°C for up to 200 h. Coating durability was assessed by furnace cycling at 1150°C. Coatings and reaction products were characterized by X-ray diffraction, field-emission scanning electron microscopy and energy dispersive spectroscopy. No spallation of the ceramic top coatings occurred after up to 200 h isothermal exposure. Interfacial scales consisted of Al2O3 and Ni(Cr,Al)2O4 spinels. Discrete bands of Al5Y3O12 oriented perpendicular to the bond coat surfaces were dispersed throughout the alumina scales. Coatings displayed average cyclic lifetimes of 355 1-h cycles. There were indications of interfacial scale delamination and subscale formation during thermal cycling. Results of the study are in agreement with previous findings. This work was the introductory phase of a larger study which will evaluate the oxidation behavior of electron beam-physical vapor deposition (EB-PVD) TBC systems.

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ER -

Oxidation and degradation of a plasma-sprayed thermal barrier coating system

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