A thermal barrier coated (TBC) turbine component design system, including an accurate TBC life prediction model, is needed to realize the full potential of available TBC engine performance and/or durability benefits. The objective of this work, which was sponsored in part by NASA under the Hot Section Technology (HOST) Program (Contract NAS3-23944), was to generate a life prediction model for electron beam-physical vapor deposited (EB-PVD) zirconia TBC. Specific results include EB-PVD zirconia mechanical and physical properties, coating adherence strength measurements, interfacial oxide growth characteristics, quantitative cyclic thermal spallation life data, and a spallation life model.

Thermal barrier coatings (TBCs) have been used for almost three decades to extend the life of combustors and augmentors and, more recently, stationary turbine components. Plasma-sprayed yttria-stabilized zirconia TBC currently is bill-of-material on many commercial jet engine parts. A more durable electron beam-physical vapor deposited (EB-PVD) ceramic coating recently has been developed for more demanding rotating as well as stationary turbine components. This ceramic EB-PVD is bill-of-material on turbine blades and vanes in current high thrust engine models and is being considered for newer developmental engines as well. To take maximum advantage of potential TBC benefits, the thermal effect of the TBC ceramic layer must become an integral element of the hot section component design system. To do this with acceptable reliability requires a suitable analytical life prediction model calibrated to engine experience. The latest efforts in thermal barrier coatings are directed toward correlating such models to measured engine performance.

Thertn1l1 barrier coatings hnve been used for over 20 yet1rs 10 extend the durability of aircraft gus turbine engine combustors. Improvements to the chemiall composition of the ceramic and to the composition Qnd microstructure of the underlying bond coat have Ill/owed the application of thermal barrier coating technology to turbine components, with similar benefits. Recent ceramic process improvements have led to the incorporation of very durable electron beamphysical vapor deposited coatings 0" the most demJ1nding of statiol1Jlry und rotating turbine components.

Thermal barrier coatings (TBCs) have been used for almost three decades to extend the life of combustors and augmentors and, more recently, stationary turbine components. Plasma sprayed yttria stabilized zirconia TBC currently is bill-of-material on many commercial jet engine parts. A more durable electron beam-physical vapor deposited (EB-PVD) ceramic coating recently has been developed for more demanding rotating as well as stationary turbine components. This ceramic EB-PVD is bill-of-material on turbine blades and vanes in current high thrust engine models and is being considered for newer developmental engines as well. To take maximum advantage of potential TBC benefits, the thermal effect of the TBC ceramic layer must become an integral element of the hot section component design system. To do this with acceptable reliability requires a suitable analytical life prediction model calibrated to engine experience. The latest efforts in thermal barrier coatings are directed toward correlating such models to measured engine performance.

A thermal barrier coated (TBC) turbine component design system, including an accurate TBC life prediction model, is needed to realize the full potential of available TBC engine performance and/or durability benefits. The objective of this work, which was sponsored in part by NASA under the Hot Section Technology (HOST) Program (Contract NAS3-23944), was to generate a life prediction model for electron beam - physical vapor deposited (EB-PVD) zirconia TBC. Specific results include EB-PVD zirconia mechanical and physical properties, coating adherence strength measurements, interfacial oxide growth characteristics, quantitative cyclic thermal spallation life data, and a spallation life model.