A new Metallic Thermal Barrier Coating System for Rocket Engines: Failure Mechanisms and Design Guidelines

Fiedler, Torben; Rösler, Joachim; Bäker, Martin

doi:10.1007/s11666-019-00900-1

Cited by 10 publications

(14 citation statements)

References 54 publications

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“…The coatings were tested in laser-cycling experiments to investigate their performance under large heat-fluxes and thermo-shock loading. FEM simulations were used to identify critical loads for coating failure to develop guidelines for coating design [47,48]. Delamination, buckling, and diffusion pores can be avoided by following these new guidelines for coating design, vertical cracks, see Fig.…”

Section: Thermal Barrier Coatings and Component Life Predictionmentioning

confidence: 99%

Collaborative Research for Future Space Transportation Systems

Haidn

Adams

Radespiel

et al. 2020

Notes on Numerical Fluid Mechanics and Multidisciplinary Design

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This chapter book summarizes the major achievements of the five topical focus areas, Structural Cooling, Aft-Body Flows, Combustion Chamber, Thrust Nozzle, and Thrust-Chamber Assembly of the Collaborative Research Center (Sonderforschungsbereich) Transregio 40. Obviously, only sample highlights of each of the more than twenty individual projects can be given here and thus the interested reader is invited to read their reports which again are only a summary of the entire achievements and much more information can be found in the referenced publications. The structural cooling focus area included results from experimental as well as numerical research on transpiration cooling of thrust chamber structures as well as film cooling supersonic nozzles. The topics of the aft-body flow group reached from studies of classical flow separation to interaction of rocket plumes with nozzle structures for sub-, trans-, and supersonic conditions both experimentally and numerically. Combustion instabilities, boundary layer heat transfer, injection, mixing and combustion under real gas conditions and in particular the investigation of the impact of trans-critical conditions on propellant jet disintegration and the behavior under trans-critical conditions were the subjects dealt with in the combustion chamber focus area. The thrust nozzle group worked on thermal barrier coatings and life prediction methods, investigated cooling channel flows and paid special attention to the clarification and description of fluid-structure-interaction phenomena I nozzle flows. The main emphasis of the focal area thrust-chamber assembly was combustion and heat transfer investigated in various model combustors, on dual-bell nozzle phenomena and on the definition and design of three demonstrations for which the individual projects have contributed according to their research field.

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Section: Thermal Barrier Coatings and Component Life Predictionmentioning

confidence: 99%

Collaborative Research for Future Space Transportation Systems

Haidn

Adams

Radespiel

et al. 2020

Notes on Numerical Fluid Mechanics and Multidisciplinary Design

View full text Add to dashboard Cite

show abstract

“…In the past, several different TBC systems for rocket engine application were developed and tested (for a detailed review, see [10,11]). These studies show that extreme test conditions are necessary to investigate realistic coating failure.…”

Section: Introductionmentioning

confidence: 99%

“…In a third step, a detailed study of the possible failure mechanisms of the new coating system was performed, and a failure model for coating design and lifetime analysis was set up [10]. For this purpose, the laser test bed was modified to increase the heat flux density (up to 30 MW/m 2 ) and the thermomechanical loads in the coatings [11,17].…”

Section: Introductionmentioning

confidence: 99%

“…In the laser cycling experiments, four different damage mechanisms were observed [10,11,20]: Delamination cracks along the substrate/coating interface, diffusion caused interface porosity, large scale buckling, and vertical cracks in the coatings.…”

Section: Introductionmentioning

confidence: 99%

“…Delamination cracks grow due to the different coefficients of thermal expansion of substrate and coating in the roughness profile of the interface [10]. These cracks were observed after thermal cycling at interface temperatures of 700 • C and above [10,11]. The growth of delamination cracks can be hindered by a diffusion layer between coating and substrate [11].…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Mechanical Integrity of Thermal Barrier Coatings: Coating Development and Micromechanics

Fiedler

Rösler

Bäker

et al. 2020

Notes on Numerical Fluid Mechanics and Multidisciplinary Design

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To protect the copper liners of liquid-fuel rocket combustion chambers, a thermal barrier coating can be applied. Previously, a new metallic coating system was developed, consisting of a NiCuCrAl bond-coat and a Rene 80 top-coat, applied with high velocity oxyfuel spray (HVOF). The coatings are tested in laser cycling experiments to develop a detailed failure model, and critical loads for coating failure were defined. In this work, a coating system is designed for a generic engine to demonstrate the benefits of TBCs in rocket engines, and the mechanical loads and possible coating failure are analysed. Finally, the coatings are tested in a hypersonic wind tunnel with surface temperatures of 1350 K and above, where no coating failure was observed. Furthermore, cyclic experiments with a subscale combustion chamber were carried out. With a diffusion heat treatment, no large-scale coating delamination was observed, but the coating cracked vertically due to large cooling-induced stresses. These cracks are inevitable in rocket engines due to the very large thermal-strain differences between hot coating and cooled substrate. It is supposed that the cracks can be tolerated in rocket-engine application.

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High-Temperature Cycling of Plasma Sprayed Multilayered NiCrAlY/YSZ/GZO/YAG Thermal Barrier Coatings Prepared from Liquid Feedstocks

et al. 2020

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High-enthalpy hybrid water/argon-stabilized plasma (WSP-H) torch may be used for efficient deposition of coatings from dry powders, suspensions, and solutions. WSP-H torch was used to deposit two complete thermal barrier coatings (TBCs) with multilayered top-coat. NiCrAlY was used as bond - coat and deposited on nickel-based superalloy substrates. Top-coat consisted of up to three sublayers: (i) yttria-stabilized zirconia (ZrO 2 -8 wt.%Y 2 O 3 -YSZ) deposited from solution, (ii) gadolinium zirconate (Gd 2 Zr 2 O 7 -GZO) deposited from suspension, and (iii) optional yttrium aluminum garnet (Y 3 Al 5 O 12 -YAG) overlayer deposited from suspension. Each of the sublayers was intended to provide different functionalities, namely improved fracture toughness, low thermal conductivity, and high erosion resistance, respectively. High-temperature performance and thermal shock resistance of the deposited coatings were tested by thermal cycling fatigue “TCF” test (maximum temperature 1100 °C, 1 h dwell per cycle) and “laser-rig” test (maximum temperature ~ 1530 °C, 5 min dwell per cycle) exposing samples to isothermal and gradient thermal conditions, respectively. In both tests, coatings endured around 800 test cycles which shows great potential for further development of these layers and their application in demanding thermal conditions. Analysis of the samples after the test showed microstructural changes and identified reason of ultimate coating failure.

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A new Metallic Thermal Barrier Coating System for Rocket Engines: Failure Mechanisms and Design Guidelines

Cited by 10 publications

References 54 publications

Collaborative Research for Future Space Transportation Systems

Collaborative Research for Future Space Transportation Systems

Mechanical Integrity of Thermal Barrier Coatings: Coating Development and Micromechanics

High-Temperature Cycling of Plasma Sprayed Multilayered NiCrAlY/YSZ/GZO/YAG Thermal Barrier Coatings Prepared from Liquid Feedstocks

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