The Effect of Environment on Thermal Barrier Coating Lifetime

Bruce A. Pint; Kinga A. Unocic; J. Allen Haynes

doi:10.1115/1.4032438

The Effect of Environment on Thermal Barrier Coating Lifetime

Bruce A. Pint, Kinga A. Unocic, J. Allen Haynes

Oak Ridge National Laboratory

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

16 Scopus citations

Abstract

While the water vapor content of the combustion gas in natural gas-fired land-based turbines is ∼ 10%, it can be 20-85% with coal-derived (syngas or H2) fuels or innovative turbine concepts for more efficient carbon capture. Additional concepts envisage working fluids with high CO₂ contents to facilitate carbon capture and sequestration. To investigate the effects of changes in the gas composition on thermal barrier coating (TBC) lifetime, furnace cycling tests (1-h and 100-h cycles) were performed in air with 10, 50, and 90 vol. % water vapor and CO₂-10% H2O and compared to prior results in dry air or O₂. Two types of TBCs were investigated: (1) diffusion bond coatings (Pt-diffusion or Ptmodified aluminide) with commercial electron-beam physical vapor-deposited yttriastabilized zirconia (YSZ) top coatings on second-generation superalloy N5 and N515 substrates and (2) high-velocity oxygen fuel (HVOF) sprayed MCrAlYHfSi bond coatings with air plasma-sprayed YSZ top coatings on superalloys X4, 1483, or 247 substrates. For both types of coatings exposed in 1-h cycles, the addition of water vapor resulted in a decrease in coating lifetime, except for Pt-diffusion coatings which were unaffected by the environment. In 100-h cycles, environment was less critical, perhaps because coating failure was chemical (i.e., due to interdiffusion) rather than mechanical. In both 1-h and 100-h cycles, CO₂ did not appear to have any negative effect on coating lifetime.

Original language	English
Article number	082102
Journal	Journal of Engineering for Gas Turbines and Power
Volume	138
Issue number	8
DOIs	https://doi.org/10.1115/1.4032438
State	Published - Aug 1 2016

Bibliographical note

Publisher Copyright:
© 2016 by ASME.

Funding

The authors would like to thank G. W. Garner, T. M. Lowe, K. M. Cooley, H. Longmire, T. Jordan, and D. Leonard for assistance with the experimental work. Plating of Pt was conducted at Tennessee Technological University by Professor Y. Zhang. B. Hazel and B. Nagaraj at General Electric Aircraft Engines provided the N5 and N515 substrate materials and coated the specimens with EB-PVD YSZ, and Stonybrook University applied the HVOF and APS coatings. The X4 substrates were provided by K. Murphy at Alcoa Howmet, the 1483 substrates by A. Kulkarni at Siemens, and the 247 substrates by Capstone Turbine Corp. P. F. Tortorelli provided helpful comments on the manuscript. This research was sponsored by the U.S. Department of Energy, Office of Coal and Power R&D, Office of Fossil Energy (R. Dennis program manager and B. White project monitor).

Funders	Funder number
Capstone Turbine Corp
Office of Coal and Power R&D
Stonybrook University
U.S. Department of Energy
Office of Fossil Energy

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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The Effect of Environment on Thermal Barrier Coating Lifetime

Abstract

Bibliographical note

Funding

UN SDGs

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