The Effect of APS-HVOF Bond Coating Thickness Ratio on TBC Furnace Cycle Lifetime

M. J. Lance; K. A. Kane; B. A. Pint

doi:10.1007/s11085-022-10127-1

The Effect of APS-HVOF Bond Coating Thickness Ratio on TBC Furnace Cycle Lifetime

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

Abstract

Combinations of NiCoCrAlY APS and high-velocity oxygen fuel (HVOF) bond coatings were deposited on alloy 247 disk substrates with APS yttria-stabilized zirconia (YSZ) top coatings to assess the benefit of air plasma sprayed (APS) ‘flash’ bond coatings. Using 1-h cycles at 1100 ℃ in air with 10% H₂O and HVOF-only and APS-only bond coatings as a baseline, it was found that APS flash coatings extended the average coating lifetime by 16% to 35% with the thicker flash coating performing best. Principal component analysis and energy dispersive spectroscopy (EDS) compositional mapping on coatings characterized after 0, 100, 300 and 500 cycles and after failure showed that the Al in the bond coatings was depleted due to both oxidation and back diffusion into the substrate. The APS-only bond coating had significant oxidation throughout the bond coating and was so depleted in Al, that Al diffused from the substrate to the coating. Residual stress maps of the thermally-grown alumina scale were obtained every 100 cycles using photo-stimulated luminescence piezospectroscopy (PLPS) revealing that the Thick Flash coating had the slowest rate of damage accumulation in the oxide scale.

Original language	English
Pages (from-to)	385-397
Number of pages	13
Journal	Oxidation of Metals
Volume	98
Issue number	3-4
DOIs	https://doi.org/10.1007/s11085-022-10127-1
State	Published - Oct 2022

Funding

The authors would like to thank Prof. S. Sampath and E. Gildersleeve at Stony Brook University's Center for Thermal Spray Research for the coating fabrication. At ORNL, G. Garner, and T. Geer assisted with the experimental work and J. A Haynes, Y.-F. Su and E. Lara-Curzio provided helpful comments on the manuscript. This research was sponsored by the U.S. Department of Energy, Office of Fossil Energy and Carbon Management, Turbine Program (R. Dennis program manager and P. Burke project manager). This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States 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 United States 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).

Funders	Funder number
Office of Fossil Energy and Carbon Management, Turbine Program
U.S. Department of Energy

Keywords

APS flash coating
Alumina scale
Furnace cycle testing (FCT)
HVOF bond coating
Principal component analysis (PCA)
TBC

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10.1007/s11085-022-10127-1

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title = "The Effect of APS-HVOF Bond Coating Thickness Ratio on TBC Furnace Cycle Lifetime",

abstract = "Combinations of NiCoCrAlY APS and high-velocity oxygen fuel (HVOF) bond coatings were deposited on alloy 247 disk substrates with APS yttria-stabilized zirconia (YSZ) top coatings to assess the benefit of air plasma sprayed (APS) {\textquoteleft}flash{\textquoteright} bond coatings. Using 1-h cycles at 1100 ℃ in air with 10% H2O and HVOF-only and APS-only bond coatings as a baseline, it was found that APS flash coatings extended the average coating lifetime by 16% to 35% with the thicker flash coating performing best. Principal component analysis and energy dispersive spectroscopy (EDS) compositional mapping on coatings characterized after 0, 100, 300 and 500 cycles and after failure showed that the Al in the bond coatings was depleted due to both oxidation and back diffusion into the substrate. The APS-only bond coating had significant oxidation throughout the bond coating and was so depleted in Al, that Al diffused from the substrate to the coating. Residual stress maps of the thermally-grown alumina scale were obtained every 100 cycles using photo-stimulated luminescence piezospectroscopy (PLPS) revealing that the Thick Flash coating had the slowest rate of damage accumulation in the oxide scale.",

keywords = "APS flash coating, Alumina scale, Furnace cycle testing (FCT), HVOF bond coating, Principal component analysis (PCA), TBC",

author = "Lance, {M. J.} and Kane, {K. A.} and Pint, {B. A.}",

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AB - Combinations of NiCoCrAlY APS and high-velocity oxygen fuel (HVOF) bond coatings were deposited on alloy 247 disk substrates with APS yttria-stabilized zirconia (YSZ) top coatings to assess the benefit of air plasma sprayed (APS) ‘flash’ bond coatings. Using 1-h cycles at 1100 ℃ in air with 10% H2O and HVOF-only and APS-only bond coatings as a baseline, it was found that APS flash coatings extended the average coating lifetime by 16% to 35% with the thicker flash coating performing best. Principal component analysis and energy dispersive spectroscopy (EDS) compositional mapping on coatings characterized after 0, 100, 300 and 500 cycles and after failure showed that the Al in the bond coatings was depleted due to both oxidation and back diffusion into the substrate. The APS-only bond coating had significant oxidation throughout the bond coating and was so depleted in Al, that Al diffused from the substrate to the coating. Residual stress maps of the thermally-grown alumina scale were obtained every 100 cycles using photo-stimulated luminescence piezospectroscopy (PLPS) revealing that the Thick Flash coating had the slowest rate of damage accumulation in the oxide scale.

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The Effect of APS-HVOF Bond Coating Thickness Ratio on TBC Furnace Cycle Lifetime

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