THERMAL BARRIER COATINGS

Department of Metallurgical and Materials Engineering National Institute of Technology , Rourkela

introduction structure of thermal barrier coatings principal requirements of TBC coating materials importance of YSZ processing methods applications disadvantages prevention of failure of TBC conclusion

INTRODUCTION
Whats a TBC?

Highly advanced 3 layered thermal insulation A thousandth of an inch => 15F to 25F Ceramic based composites of Ti,Alumina ,Zirconia Oxidation ,hot corrosion resistant, durable Why is a TBC important? Fuel efficiency High temperature

STRUCTURE OF A TBC

 CERAMIC TOP COAT-250 m

YSZ (170C for a 150m thickness)

Few new developments: La2Zr2O7, BaZrO3, Metal-Glass-Composites,

Graded coatings,Multilayer coatings METALLIC BOND COATING Empirically represented as MCrAlY M=Ni,Co or Fe Oxidation,hot corrosion resistant Adherence to superalloy substrate THERMALLY GROWN OXIDE Alumina layer-TGO

PRINCIPAL REQUIREMENTS
HARDNESS
EROSION RESISTANT ADHESION STRENGTH

STRAIN COMPLIANCE LIGHT WEIGHT THERMAL CONDUCTIVITY

COATING MATERIALS
Zirconates
Garnets(Y3Al5O12) Corderite( MgO Al2O3. SiO2)

Forsterite( MgOSiO2)
Spinel(MgO.Al2O3) Mullite

Applied on SiC

WHY YSZ IS PREFFERED?

No phase

transformation Lowest thermal conductivity High coeff . of thermal expansion Low density Hard

Plasma spray process

Power level-3080 kW Powder velocity300-550 m/s Temperature30,000C Coating thickness-0.050.5 mm

Electron Beam Physical Vapor Deposition

Schematic microstructure of a thermal barrier coating (TBC) obtained by air plasma spray (APS).

Schematic microstructure of a thermal barrier coating (TBC) obtained by electron beam physical vapour deposition (EBPVD). The columnar microstructure considerably enhances the strain resistance and therefore thermal cycling life.

APPLICATIONS
Gas Turbine Engine Applications Jet Engine Turbine Cutting Tool Applications Furnace Components

Rocket Motor Nozzles

Exhaust manifolds Nuclear Power Plant

Components

FAILURE MECHANISMS
Rumpling of TGO layer Presence of interfacial voids Repulsion between S and O atoms Phase Transformation of Yittria and

YVO4 crystal formation

How to Cope?
Inhibit TGO growth Increase adhesion of TGO to BC Hf,Y segregation to grain boundaries Rare earth metals or early transition metals prevent GB sliding because of strong O bonds Pt promotes point defect,diffusivity of Al is more than Ni which prevent Ni aluminate spinel

formation

References
http://ipm.virginia.edu/research/PVD/Pubs/thesis6/chapt

er2.pdf http://dauskardt.stanford.edu/joanna_mroz/Thermal.html http://en.wikipedia.org/wiki/Thermal_barrier_coating D.R. Clarke and C.G. Levi, materials design for the next generation thermal barrier coatings, Annu. Rev. Mater. Res. 2003. 33:383417 Gregoire Witz, Valery Shklover, and Walter Steurer, Phase Evolution in Yttria-Stabilized Zirconia Thermal Barrier Coatings, Journal of the American Ceramic SocietyWitz et al., Vol. 90, No. 9 Saremi Mohsen,Afrasiabi Abbas,Kobayashi Akira, Bond coat oxidation and hot corrosion behaviour of plasma sprayed YSZ coating on Ni superalloy,Transactions of JWRI,Vol.36(2009),No.1

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