Health and Durability of Protective and Thermal Barrier Coatings Monitored in Service by Visual Inspection

Szczepankowski, Andrzej; Przysowa, Radosław; Perczyński, Jerzy; Kułaszka, Artur

doi:10.3390/coatings12050624

Cited by 11 publications

(4 citation statements)

References 63 publications

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“…One non-destructive coating testing method (NDT) that may be utilized often in service is visual inspection, despite the fact that it can only identify surface issues and offers limited quantitative information. Andrzej Szczepankowski et al attempted in-service monitoring of turbine blades with multilayer coatings deposited by atmospheric plasma spraying [14]. They were validated in a test cell with five other innovations in a series of turbofan engine accelerated mission tests that used to be in the military.…”

Section: Literature Reviewmentioning

confidence: 99%

Failure analysis of gas turbine in first stage turbine blades in an urban power plant

Hassan,

Sindi,

Mohamed

et al. 2024

J., eng., them. sci.

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The Combined Cycle Power Plants (CCPP) are widely known as the most efficient power plants. The concept of CCPP represented in Brayton and Rankin cycles combined to achieve the highest efficiency in power generation. During the fact finding, while performing the major outage, at 77,521 running hours some of the turbine blades at 1st stage found suffering from severe damages and sulfuric acid thick layer accumulated in the cooling airfoils. The blades were new, also known as the most essential and costly component installed after Hot Gas Path Inspection (HGPI) at 42,000 running hours. The main objective of this work is to study the surrounding parameters that directly affect the lifetime of the turbine blades. Furthermore, XRD analysis for new and used turbine blades are studied as well as the EDS analysis for the coating layers which are used to enhance the surface life of gas turbine blades. Corrective maintenance, on the other hand, has been undertaken to overcome the performance deterioration caused by wear, which is the result of any machine or plant’s operation. A gas turbine cannot be run reliably unless wear reserves are checked and, if necessary, restored during inspections and maintenance operations. These are performed to determine the machine's condition and the necessary condition-based repairs. The principal types of gas turbine inspection have been investigated and presented, including minor inspection, hot gas inspection, extended-scope hot gas path examination, and major inspection. Lifetime extension (LTE) measures are derived from these inspection types and go beyond the scope of a major inspection. Nondestructive testing is performed on the gas turbine’s key components. Furthermore, due to the high degree of contamination in the fuel, the turbine section must be cleaned at regular intervals. As a result of the examinations, replacement, and refurbishment intervals for important components, as well as outage time, could be recommended.

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Section: Literature Reviewmentioning

confidence: 99%

Failure analysis of gas turbine in first stage turbine blades in an urban power plant

Hassan,

Sindi,

Mohamed

et al. 2024

J., eng., them. sci.

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“…Despite such a difference, both processes are designed to apply a coating that protects the component against high-temperature corrosion, oxidation and erosion, especially in harsh environments [5,8].…”

Section: Deposition Of Tbc Layersmentioning

confidence: 99%

Thermal Barrier Coatings for High-Temperature Performance of Nickel-Based Superalloys: A Synthetic Review

et al. 2023

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With the rising demands of industry to increase the working temperature of gas turbine blades and internal combustion engines, thermal barrier coatings (TBC) were found to be an effective way to further enhance the lifetime of aero components through the improvement of mechanical properties and oxidation-resistance. Thus, this paper aims to review coating technologies with special emphasis on plasma-sprayed thermal barrier coatings (PS), and those produced by physical vapor deposition (PVD) and chemical vapor deposition (CVD) methods. Each technology was assessed in terms of its effectiveness to enhance the mechanical response and oxidation resistance of nickel-based parts working at high temperature. The effect of coating technology on mechanical strength, hardness, fatigue and creep of nickel alloys was discussed to reveal the potential candidates for future applications in aggressive environments.

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“…However, research results have shown that some of the above technologies have limitations, such as low deposition efficiency, poor substrate and coating bonding, and poor process stability. Szczepankowski et al [11] reported the gradual oxidation and depletion of Al, as well as the effects of environmental particles, as the reason for reducing the efficiency of thermal barrier coatings. Wang et al [12] introduced the formation of NiMoO 4 and MoO 3 lubricants in NiCoCrAlY-Cr 2 O 3-AgMo coating sprayed on GH4169 superalloy as a factor in reducing the coefficient of friction (COF) and increasing wear resistance.…”

Section: Introductionmentioning

confidence: 99%

The Effect of an Ultrasonic Field on the Microstructure and Tribological Behavior of ZrB2/ZrC+Ni60A/WC Composite Coating Applied by Laser Cladding

Wei,

Najafi,

Taheri

et al. 2023

Coatings

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Ni60A/WC composite coating reinforced with ZrB2/ZrC was layered on GTD-111 superalloy by laser cladding. The effect of an ultrasonic field on coating formation, microstructure, microhardness, and wear was investigated and analyzed. The results showed that the resulting coating had pores and microcracks, which were removed when using an ultrasonic field. Ultrasonic fields increased the heat input and increased the dimensions of the coating pool by creating a cavitation effect. The dendrites of the coating microstructure were mainly composed of Zr(B, C) and ZrC blocks and small α-Zr dendrites. The mechanical vibrations resulting from the application of ultrasonic fields caused the crushing of the growing dendrites, and as a result, the grains and dendrites crumbled. By decreasing the grain size, the average hardness increases from 312 HV for coating without an ultrasonic field to 617 HV for coating with 300 W ultrasonic power. The results of the wear test also showed that the sample coated with 300 W of ultrasonic power, with a coefficient of friction of 0.41 and scar wear of 6.8 µm, has the highest wear resistance due to the removal of porosity and the presence of equiaxed grains on the top and bottom of the clad zone.

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Health and Durability of Protective and Thermal Barrier Coatings Monitored in Service by Visual Inspection

Cited by 11 publications

References 63 publications

Failure analysis of gas turbine in first stage turbine blades in an urban power plant

Failure analysis of gas turbine in first stage turbine blades in an urban power plant

Thermal Barrier Coatings for High-Temperature Performance of Nickel-Based Superalloys: A Synthetic Review

The Effect of an Ultrasonic Field on the Microstructure and Tribological Behavior of ZrB2/ZrC+Ni60A/WC Composite Coating Applied by Laser Cladding

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