Evaluation and Characterization of a Durable Composite Phase Thermal Barrier Coating in Solid Particle Erosion and Burner Rig Tests

Abstract

A new concept of composite phase ceramic had been proposed for the topcoat of a durable thermal barrier coating (TBC) system which is one of the critical technologies for advanced turbine engines. The composite phase TBCs showed promising performance related benefits over conventional single phase TBCs, including durability, material affordability, thermal stability and low thermal conductivity. The present work is to continue the effort to exploring the TBC behaviors of erosive wear by solid particle erosion test and thermal cyclic shock by special burner rig test. In the erosion test, the investigation was focused on the most important characteristics of erosion test results using different characterization methods, including the variations of erosion damages with impingement angle and finally the effect of high temperature sintering. In the burner rig test, the TBC was exposed to a rapidly thermal cycling condition introduced by a high heat flux and high-velocity combustion torch. The TBC damages and failure modes were identified and explained in terms of microstructural observation and mechanism discussion. The composite phase c ? t 0 TBC demonstrated improved erosion resistance relative to a Gd 2 Zr 2 O 7 TBC and equivalent thermal shock resistance to a conventional 8YSZ TBC. Keywords air plasma spray Á burner rig test Á coating characterization Á erosion test Á thermal barrier coating This article is an invited paper selected from abstracts submitted for the 2020 International Thermal Spray Conference, ITSC2020 that was to be held from June 10-12, 2020, in Vienna, Austria. The conference was cancelled due to the coronavirus (COVID-19) pandemic. The paper has been expanded from the planned presentation.

Evaluation of environmental barrier coatings: A review

“…Combustion of high-pressure acetylene, propane, liquefied petroleum gas, or any other flammable gases can provide not only a high temperature to direct heating up samples but also a high-speed gas flow, which is more close to the condition in the real application. 83,84 Samples are directly faced and exposed to flame with high gas flow, as shown in Figure 6A. The heating temperature is controlled by adjusting the flow of oxygen and flammable gas.…”

“…Due to the heating approach, the heating rate of most traditional furnaces is limited and cannot be too fast. Combustion of high‐pressure acetylene, propane, liquefied petroleum gas, or any other flammable gases can provide not only a high temperature to direct heating up samples but also a high‐speed gas flow, which is more close to the condition in the real application 83,84 . Samples are directly faced and exposed to flame with high gas flow, as shown in Figure 6A.…”

Novel Thermal Barrier Coatings with Phase Composite Structures for Extreme Environment Applications: Concept, Process, Evaluation and Performance

“…The aforementioned examination of TBC research and development highlighted key aspects of producing novel TBCs designed for high-temperature, extreme environments. We have suggested the concept of using phase composite ceramics as the topcoat for these innovative TBC systems, which were applied in the fabrication of dual-phase and tri-phase TBCs using the air plasma spray process [26][27][28]. The phase composite TBCs have been proven to offer many advantages over conventional single-phase TBCs, in terms of coating durability, phase thermal stability, thermal shock resistance, solid particle resistance, and low thermal conductivity, as well as CMAS corrosion resistance.…”

Study on hydrodynamic characteristics of swirl burner based on CFD

“…Therefore, many burners use swirl to control mixing and flame structure. The annular re-circulation zone formed by swirling combustion in the combustion center is a good mixing zone for hot combustion products, which plays the role of storing heat and chemically active substances, so that heat and quality can be effectively transferred from combustion products to new combustible mixture through high turbulence, so as to fully burn the fuel [5]. Therefore, the re-circulation zone in the swirl burner due to strong fluid rotation plays an important role in stabilizing the flame.…”