Epri 2002 1006608

Blade Life Management: Coating Systems
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Technical Report
Blade Life Management:
Coating Systems
1006608
Final Report, February 2002
EPRI Project Manager

R. Viswanathan
EPRI • 3412 Hillview Avenue, Palo Alto, California 94304 • PO Box 10412, Palo Alto, California 94303 • USA
800.313.3774 • 650.855.2121 • askepri@epri.com • www.epri.com
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CITATIONS
This report was prepared by
Southwest Research Institute

6220 Culebra Road
San Antonio, TX 78284
Principal Investigators
N. Sastry Cheruvu
K. S. Chan
G. R. Leverant
This report describes research sponsored by EPRI.
The report is a corporate document that should be cited in the literature in the following manner:
Blade Life Management: Coating Systems, EPRI, Palo Alto, CA: 2002. 1006608.
iii
REPORT SUMMARY
Dramatically high replacement costs make it crucial that generating companies with high-firing-
temperature gas turbines know the life span of turbine blades and the timeframe for recoating
them with either a sacrificial metallic coating (for protection from oxidation) or a thermal barrier
coating (for protection from very high temperatures). This is the final report in a four-year EPRI
program to develop tools and methods for predicting service life of first-stage blades (buckets)
for the GE Frame 7FA and 9FA gas turbines.
Background
O&M costs for newer, higher-firing-temperature gas turbines are more sensitive to replacement
part costs than previous models. The replacement cost of the hot section components alone can
exceed 35% of the cost of a new unit. The first-stage turbine blades are a major concern because
of their short life (20,000 hours) and high replacement cost ($3 million). Life consumption
mechanisms include 1) creep rupture due to high-firing temperature, 2) thermomechanical
fatigue (TMF) due to start/stop cycles, and 3) coating degradation due to the high-temperature,
oxidizing environment and temperature cycles. This report summarizes the status of research to
meet the challenges associated with higher firing temperatures and coating degradation.
Objectives
To develop algorithms for tracking and predicting turbine blade life, including coating oxidation
and TMF; to develop a microstructural basis for estimating local blade operating temperature.
Approach
Investigators obtained data to calibrate the EPRI COATLFE model (product number 1001145)
for use with simple and duplex coatings to predict oxidation life. They conducted carefully
controlled, accelerated laboratory cyclic oxidation tests on coatings used or considered for use on
combustion turbine blades of Frames 7FA and 9FA engines. These coatings include GT29+
(CoCrAlY with a top aluminide coating) and GT33+ (NiCoCrAlY with a top aluminide coating).
Next, investigators incorporated the COATLIFE algorithm into a user-friendly spreadsheet
format, initially for computing coating oxidation life and then for TMF life. They also performed
TMF tests on directionally solidified GTD-111, with GT33+ and GT29+ coatings to support
TMF algorithm development for peaking mode operation. Where possible, they validated the
oxidation and TMF models with field components operating at known metal temperatures. In the
final year of the project, investigators developed a life prediction model for spallation of thermal
barrier coatings and acquired laboratory data for model calibration.
v
Results
In this project, researchers extended the previously developed EPRI COATLIFE model to a user-
friendly spreadsheet format. The spreadsheet is capable of computing the original or remaining
oxidation life and the TMF life of several coatings—including GT29+ and GT33+—on GTD-
111DS buckets. The user simply enters the average operating hours per start and the number of
start/stop cycles (including trips) and obtains bucket temperature and strain range input data from
pull-down tables. The output provides information on percent of life consumed and remaining
life in terms of number of starts. The code also handles variable turbine operating conditions.
In instances where the local bucket temperature is unknown, the temperature can be estimated. The method for such
calculations involves using the width of the interdiffusion zone between the coating and base metal to develop time–
temperature relationships for estimating the local blade temperature for several coating/blade alloy combinations.
Good correlations between pyrometer-measured and predicted temperatures, as well as temperature profiles,
demonstrated the validity of using interdiffusion zone widths to establish actual local blade operating temperatures.
The TMF design curves for GT29+ and GT33+ coatings on GTD-111DS were developed based
on TMF project testing. The design curves were validated by examination of cracked 7FA and
9FA buckets coated with GT29+ and a cracked 7FA bucket coated with GT33+. Limited testing
on GT33 without the aluminide overlayer indicated improved TMF resistance compared to
GT33+. This is important for peaking unit operation.
EPRI Perspective
In order to achieve combined-cycle thermal efficiencies approaching 60%, the major turbine
manufacturers are aggressively transitioning aircraft gas turbine design and materials
technologies to advanced combustion turbines for power generation. The advanced turbines fire
at higher temperatures and utilize optimum cooling of hot section components. Consequently, the
performance and durability of the coating system has now become a prime life-limiting factor for
hot section components, including those in Frames 7FA and 9FA turbines. Turbine blades are the
most critical and expensive parts of these components since the reliability and availability of a
turbine often depends on blade life, which in turn depends on the coating life. The development
of advanced coatings as well as methods for estimating operating metal temperature and more
accurately predicting coating life is essential to assess and extend blade service life.
Keywords
Coatings
Gas turbines
Temperature
Thermal fatigue
vi
EPRI Licensed Material
ABSTRACT
This final report briefly summarizes previous progress on this project and then details the
accomplishments achieved during the past year. Recent progress has included development of
thermomechanical fatigue (TMF) data for GTD-111DS coated with GT29+ and GT33+, and
limited data for GT33. The TMF design curves for GT29+ and GT33+ coated GTD-111DS have
been incorporated into the COATLIFE-3 spreadsheet. Validation of these design curves was
obtained by examination of cracked Frame 7FA and 9FA buckets coated with GT29+ and a
cracked 7FA bucket coated with GT33+.
Detailed analysis of a Frame 7EA bucket was performed to further validate the previously
developed temperature estimation method in combination with oxidation life predictions
in COATLIFE-3. Temperatures were estimated at several locations on the bucket by measuring
the size of the interdiffusion zone between the GT29+ coating and the GTD-111 substrate.
These temperatures were then used to predict the remaining aluminum content and volume
fraction of β-phase in the coating. Agreement between measured and predicted values was very
good.
Work was also initiated in the development of life prediction algorithms for air-plasma-sprayed
(APS) thermal barrier coatings (TBC’s). Model development was completed. Initial isothermal
and cyclic laboratory tests were conducted at temperatures ranging from 1850°F (1010°C)
to 2100°F (1150°C) on GTD-111DS coated with a NiCoCrAlY bond coat and an APS TBC.
Visual and metallographic examinations were used to document the cracking and spallation
behavior. This data, in conjunction with additional data to be obtained later, will be used to
calibrate the life model algorithms for eventual incorporation into the COATLIFE spreadsheet.
vii
CONTENTS
1 INTRODUCTION ....................................................................................................................1-1
2 SUMMARY OF PRIOR WORK ON THIS PROJECT .............................................................2-1
3 THERMAL BARRIER COATING LIFING...............................................................................3-1

Development of a Thermal Barrier Coating Life Model .........................................................3-1
Calculation of Interface Temperature ....................................................................................3-2
Mechanical Strain Range ......................................................................................................3-3
Oxidation Kinetics .................................................................................................................3-4
Time-Dependent Fatigue Strength Coefficient and Young’s Modulus ..................................3-4
TBC Life Equation .................................................................................................................3-5
Parametric Calculations ........................................................................................................3-5
Isothermal and Thermal Cycling Tests of Coated First Stage Bucket Material .....................3-7
Specimen Material and Design.........................................................................................3-7
Coatings and Test Conditions ..........................................................................................3-9
As-Coated Microstructure of Bond and Top TBC Coatings..............................................3-9
Isothermal Test Results..................................................................................................3-11
Thermal Cycling Test Results.........................................................................................3-15
Metallography .................................................................................................................3-17
Characterization of TGO Scale.......................................................................................3-24
Calibration of Model ............................................................................................................3-29
4 THERMOMECHANICAL FATIGUE (TMF) TESTING OF FIRST STAGE BUCKET

MATERIAL ................................................................................................................................4-1
Materials and Coatings .........................................................................................................4-1
Review of Test Conditions and Prior Test Results ................................................................4-2
Test Results ..........................................................................................................................4-3
Fractographic and Metallographic Examinations ..................................................................4-6
Calibration of Model ............................................................................................................4-14
ix
TMF Model Validation Frame 7FA/9FA Blades...................................................................4-16

Guidelines on Metal Temperatures and TMF Strain Ranges ..............................................4-24
5 FURTHER VALIDATION OF COATLIFE OXIDATION MODEL ............................................5-1

Background ...........................................................................................................................5-1
Metallography and Temperature Estimation .........................................................................5-2
Temperature Estimation ........................................................................................................5-6
COATLIFE Validation ............................................................................................................5-7
6 GUIDELINES FOR TURBINE OPERATORS.........................................................................6-1

Bucket Coating Oxidation Life ...............................................................................................6-1
Bucket Thermomechanical Fatigue (TMF) Life .....................................................................6-1
7 PROJECT SUMMARY ...........................................................................................................7-1
8 REFERENCES .......................................................................................................................8-1
x
LIST OF FIGURES
Figure 3-1 Summary of the TBCLIFE code................................................................................3-1

Figure 3-2 TBC life diagram computed via the TBCLIFE code. .................................................3-2
Figure 3-3 Effects of peak temperature on the calculated TBC life. ..........................................3-6
Figure 3-4 Effect of TBC fatigue strength coefficient on the calculated TBC life. ......................3-6
Figure 3-5 Effect of sintering and time-dependent fatigue strength on the TBC life. Both
sintering and time-dependent degradation of fatigue strength are treated through a
power law with a time exponent p. .....................................................................................3-7
Figure 3-6 Effect of substrate curvature on the calculated TBC life...........................................3-7
Figure 3-7 Isothermal exposure test specimen geometry and dimensions................................3-8
Figure 3-8 Thermal cycling exposure test specimens: (a) 0.18 inch (4.57 mm) diameter,
(b) 0.36 inch (91.4 mm) diameter. ......................................................................................3-8
Figure 3-9 Structure of APS TBC in the as-coated condition...................................................3-10
Figure 3-10 Optical micrographs of as-sprayed bond and TBC coatings. Arrows point to
microcracks (or delamination) parallel to and near or at the bond coat/TBC interface ....3-10
Figure 3-11 EDS results obtained (a) from the bond coating and (b) from the top TBC
coating..............................................................................................................................3-11
Figure 3-12 Photographs of TBC-coated specimens after 4006 hours exposure at
1850°F (1010°C). Note there were no visible cracks. ......................................................3-12
Figure 3-13 Photographs of TBC-coated specimen after 1500 hours exposure at 1950°F
(1066°C). Arrows point to TBC cracks. ............................................................................3-13
(1079°C)...........................................................................................................................3-13
(1093°C)...........................................................................................................................3-14
(1121°C)...........................................................................................................................3-14
Figure 3-17 Photographs of a large TBC-coated specimen after 395 one-hour cycle
exposures at a peak temperature of 1950°F (1066°C). ...................................................3-16
Figure 3-18 Photographs of a small TBC-coated specimen after 395 one-hour thermal
cycle exposures at a peak temperature of 1950°F (1066°C). Arrow points to a crack
away from the hole...........................................................................................................3-16
Figure 3-19 Photographs of a small TBC-coated specimen after 395 one-hour cycle
exposures at a peak temperature of 1950°F (1066°C). Arrow points to a crack that
had not initiated from the hole..........................................................................................3-16
xi
Figure 3-20 Photographs of a large TBC-coated specimen after 395 cycles at a peak
temperature of 1950°F (1066°C)......................................................................................3-17
Figure 3-21 Optical micrographs of the TBC/bond coat interface after (a) 1000 hours and
(b) 4006 hours exposure at 1850°F (1010°C) showing variation of TGO scale
thickness. Note cracks in the TBC and TGO and interface delamination. .......................3-19
Figure 3-22 Optical micrographs of the TBC/bond coat interface after (a) 500 hours,
(b) 1500 hours exposure at 1950°F (1066°C). Note cracks in the TBC and TGO
scale. Arrows point to cracks. ..........................................................................................3-19
Figure 3-23 Optical micrographs of the TBC/bond coat interface of the specimens after
(a) 1000 hours, (b) 2000 hours, and (c) 3500 hours exposure at 1850°F (1010°C)
showing variation of cracking near the TBC/TGO interface. ............................................3-20
Figure 3-24 Optical micrographs of the TBC/bond coat interfaces of the specimens after
(a) 500 hours, and (b) 1000 hours exposure at 1950°F (1066°C) showing variation
of cracking near the interface...........................................................................................3-21
Figure 3-25 Variation of crack length with exposure time. .......................................................3-21
Figure 3-26 Optical micrographs of the interface bond coat/substrate of specimens after
(a) 106 hours, (b) 304 hours, and (c) 375 hours exposure at 1975°F (1079°C)
showing variation of voids at the interface. Arrows point to delamination. .......................3-22
Figure 3-27 Optical micrographs showing bond coat delamination in specimens after
(a) 498 hours exposure at 2000°F (1093°C), (b) 160 hours exposure at 2050°F
(1121°C)...........................................................................................................................3-23
Figure 3-28 Optical micrographs showing voids at the bond coat/substrate interface of
specimens after (a) 4006 hours at 1850°F (1010°C), (b) 2000 hours at 1950°F
((1066°C), (c) 225 hours at 2000°F (1093°C), (d) 24 hours at 2050°F (1121°C). ............3-23
Figure 3-29 Photographs of a spalled TBC flake collected from a specimen after 160
hours exposure at 2050°F (1121°C). EDS was performed at multiple locations on
the inner surface (TGO). ..................................................................................................3-24
Figure 3-30 Typical EDS spectrum obtained from a location on the inner surface of the
flake collected from a specimen after 160 hours exposure at 2050°F (1121°C)..............3-25
Figure 3-31 EDS spectrum obtained from a location on the inner surface of a TBC flake
spalled from a specimen after 2500 hours exposure at 1950°F (1066°C). ......................3-25
Figure 3-32 (a) SEM back-scattered electron image of the bond coat/TBC interface of
specimen after 4006 hours exposure at 1850°F (1010°C) showing morphology of
interfacial oxide. The numbers denote the locations for the EDS analysis; (b) EDS
spectrum obtained from Location 2, (c) EDS spectrum obtained from Location 3. ..........3-26
Figure 3-33 (a) SEM back-scattered electron image of the bond coat/TBC interface of
specimen after 1500 hours exposure at 1950°F (1066°C) showing morphology of
interfacial oxide scale. The numbers on the photograph denote the locations for the
EDS analysis; (b) EDS spectrum obtained from Location 1, (c) EDS spectrum
obtained from Location 2, (d) EDS spectrum obtained from Location 4...........................3-27
Figure 3-34 SEM back-scattered image of the bond coat/TBC interface of a specimen
after 304 hours exposure at 1975°F (1079°C) showing morphology of interfacial
oxide scale. Note the dark Al-rich, Al2O3 scale is not continuous. EDS analysis was
performed on area shown by an arrow. ...........................................................................3-28
xii
Figure 3-35 Plot of oxide thickness versus √t, where t is time of oxidation, for
determining the parabolic oxidation rate constant, kp, for a given temperature.
(1066°C = 1950°F). ..........................................................................................................3-30
Figure 3-36 Plot of kp as a function of the reciprocal temperature for determining the
activation energy, Qox, for TGO formation at the TBC/bond coat interface.......................3-30
Figure 3-37 A comparison of calculated and measured oxide thickness as a function of
exposure time at 1850°F (1010°C)...................................................................................3-31
Figure 3-38 A comparison of calculated and measured oxide thickness as a function of
exposure time at 1950°F (1066°C)...................................................................................3-31
Figure 3-39 Calculated TBC life diagram compared against experimental data for 1950°F
(1066°C)...........................................................................................................................3-32
Figure 3-40 Computed TBC life curve compared against experimental data for 1850°F
(1010°C)...........................................................................................................................3-33
Figure 3-41 Computed TBC life curve compared against experimental data for 1975°F
(1079°C)...........................................................................................................................3-33
Figure 3-42 Calculated TBC life compared against burner-rig and furnace data from the
HOST program [8]............................................................................................................3-34
Figure 3-43 Linear approximation of the coating life curve for APS TBC. (1066°C =
1950°F). ...........................................................................................................................3-34
Figure 3-44 TBC life curves for APS TBC at various temperatures. ........................................3-35
Figure 4-1 TMF specimen geometry and dimensions. (All dimensions are in inches;
1 inch = 2.54 cm.)...............................................................................................................4-1
Figure 4-2 Influence of temperature range on TMF life of GT33+ coated GTD-111DS
material. (600°F-1850°F = 316°C-1010°C; 600°F-1650°F = 316°C-899°C). .....................4-4
Figure 4-3 Influence of aluminized layer on TMF life of GT33 coated GTD-111DS
material. .............................................................................................................................4-5
Figure 4-4 Comparison of TMF results of over aluminized NiCoCrAlY (GT33+) and
CoCrAlY (GT29+) coatings. ...............................................................................................4-5
Figure 4-5 Fractographs of fracture surfaces of TMF specimens showing multiple crack
initiation sites: (a) Specimen C-1, (b) Specimen N-2, and (c) Specimen N-3. Arrows
point to the crack initiation sites. ........................................................................................4-6
Figure 4-6 SEM fractograph of fracture surface of Specimen C-2 near an initiation site.
Note the fracture mode is transgranular.............................................................................4-7
Figure 4-7 SEM image of fracture surface of TMF Specimen C-3 showing transgranular
fracture mode near a crack initiation area..........................................................................4-7
Figure 4-8 SEM fractographs of fracture surface of TMF Specimen N-2 showing
transgranular mode near a crack initiation area. ................................................................4-8
Figure 4-9 SEM fractograph of TMF Specimen N-5 showing transgranular fracture mode
near a crack initiation area. ................................................................................................4-8
Figure 4-10 Photograph of longitudinal section of coated TMF Specimen C-2. Showing
secondary cracks below the fracture surface. ....................................................................4-9
Figure 4-11 Photograph of a longitudinal section of GT33+ coated TMF Specimen N-2
showing secondary cracks below fracture surface...........................................................4-10
xiii
Figure 4-12 Optical photographs of secondary cracks below the fracture surface of
GT33+ coated specimens (a) N-1, (b) N-2, and (c) N-3 showing rumpling of the
coating at the initiation site, morphology of crack in the coating, and oxidation of
base material....................................................................................................................4-10
Figure 4-13 Optical micrographs of secondary cracks on GT29+ coated TMF specimens
(a) C-1, (b) C-2, and (c) C-3 showing internal oxidation of coating and the base
material near the cracks...................................................................................................4-11
Figure 4-14 (a) SEM image of a secondary crack in the GT29+ coating on TMF
Specimen C-1. (b) EDS spectrum obtained from the oxide scale on the crack
surface. The semi-qualitative composition of the scale is also shown. ............................4-12
Figure 4-15 (a) back scatter electron image of a secondary crack in the GT33+ coating
on TMF Specimen N-1. (b) EDS spectrum obtained of oxide scale in the secondary
crack.................................................................................................................................4-13
Figure 4-16 TMF strain-life relations developed based on experimental data of GT29+
coated GTD-111DS..........................................................................................................4-14
Figure 4-17 TMF strain-life relations developed based on GT33+ coated GTD-111DS. .........4-15
Figure 4-18 a) Photograph of the as-received Frame 7FA blade showing locations of
transverse sections removed at 10% and 55% blade heights. (b) Optical
photographs showing metallurgical mounts prepared from the transverse sections.
The numbers on the photographs denote locations where TMF cracks ere
observed. .........................................................................................................................4-17
Figure 4-19 (a) Photograph of the as-received 9FA blade section received from KEMA.
The numbers towards the trailing edge denote approximate locations where
pyrometer measurements were documented. (b) Photograph showing metallurgical
sample locations. The samples are identified by the pyrometer position numbers. .........4-18
Figure 4-20 Optical photograph showing the mounts prepared from the transverse
section. The numbers on the photograph denote locations where TMF cracks were
observed. .........................................................................................................................4-20
Figure 4-21 Optical micrographs showing morphology of TMF cracks on Frame 9FA
blade, (a) Location 9 (Pyrometer Position 9), (b) Location 8 (Pyrometer Position 9),
and (c) Location 1 (Pyrometer Position 3)........................................................................4-21
Figure 4-22 Optical micrographs showing morphology of TMF cracks on Frame 7FA
blade, (a) Leading edge (Location 1), (b) Suction side of the airfoil (Location 7),
(c) Suction side of the airfoil (Location 5).........................................................................4-22
Figure 4-23 Predicted TMF lives compared against field data for Frame 7FA and 9FA
blades coated with GT29+ coatings. The field data correspond to the suction side
(SS) and pressure side of Cooling Holes 4 and 6. ...........................................................4-23
st
Figure 4-24 Predicted TMF lives were compared against field data for Frame 7FA 1
stage blades coated with GT33+ coating. The field data corresponded to the suction
st
side (SS) of 1 stage blades at 20% and 50% blade height (BH). ...................................4-24
Figure 4-25 Look-up table containing information on metal temperatures for first-stage
combustion turbine blades. ..............................................................................................4-25
Figure 4-26 Look-up table for TMF strain ranges for 9FA, 7FA+, and 6B machines. ..............4-26
Figure 5-1 As received condition of first stage blade of Frame 7EA engine. The arrows
point to the section removed for metallographic evaluation. ..............................................5-1
xiv
Figure 5-2 Optical micrographs of coating on a service run Frame 7EA first stage blade
at the 55% airfoil height. (a) Leading edge. (b) Suction side near Cooling Hole 4.
(c) The pressure side of the airfoil near Cooling Hole 4. (d) Trailing edge.........................5-3
Figure 5-3 Microstructure of the coating at the leading edge of the Frame 7EA blade at
the 55% airfoil height..........................................................................................................5-4
Figure 5-4 Microstructure of the coating on the suction side of the airfoil near Cooling
Hole 4 (55% height). Note the width of the interdiffusion zone, which was larger
than the one observed at the leading edge (Figure 5-3). ...................................................5-4
Figure 5-5 Microstructure of the coating on the pressure side of the airfoil near Cooling
Hole 4.................................................................................................................................5-5
Figure 5-6 Optical micrograph showing the microstructure of the coating at the trailing
edge (55% airfoil height) ....................................................................................................5-5
Figure 5-7 Calculated coating life diagram compared against field data for GT29+
coating at the trailing edge of a 7EA blade after 328 startup/shutdown cycles that
averaged a cycle time of 68 hours per cycle......................................................................5-9
Figure 5-8 Predicted times-to-failure compared against field data of coating at four
locations of a 7EA blade after 328 startup/shutdown cycles that average a cycle
time of 68 hours per cycle. .................................................................................................5-9
Figure 5-9 Predicted Al and β-phase depletion compared against field data for the
trailing edge of a 7EA blade after service: (a) Al depletion, and (b) β-phase
depletion...........................................................................................................................5-10
suction side (Cooling Hole 4) of a 7EA blade after service: (a) Al depletion, and
(b) β-phase depletion. Note: The Al content is not available for this location..................5-11
pressure side (Cooling Hole 4) of a 7EA blade after service: (a) Al depletion, and
(b) β-phase depletion. ......................................................................................................5-12
leading edge of a 7EA blade after service: (a) Al depletion, and (b) β-phase
depletion...........................................................................................................................5-13
xv
LIST OF TABLES
Table 3-1 Chemical Composition of Bond Coating Powder (wt.%)............................................3-9

Table 3-2 Chemical Composition of Ceramic Coating Powder (wt.%).......................................3-9
Table 3-3 Isothermal Exposure Test Results at Various Temperatures ..................................3-14
Table 3-4 Thermal Cycling Exposure Test Results..................................................................3-15
Table 3-5 Influence of Time and Isothermal Exposure Temperature on Thermally Grown
Oxide Thickness...............................................................................................................3-18
Table 3-6 TBCLIFE model constants for the APS TBC. ..........................................................3-29
Table 4-1 Chemical Composition of NiCoCrAlY and CoCrAlY Powders (wt.%). .......................4-2
Table 4-2 TMF test data of coated GTD-111DS specimens along with coating thickness
and elastic modulus data. ..................................................................................................4-3
Table 4-3 TMF strain ranges obtained by transient aerothermal analyses for 9FA, 7FA+
and 6B machines. ............................................................................................................4-16
Table 4-4 Locations of TMF cracks on Frame 7FA Stage 1 blade. .........................................4-19
Table 4-5 Locations of TMF cracks on Frame 9FA Stage 1 Blade. .........................................4-20
Table 5-1 Variation of the β-phase and aluminum content in the different top aluminide
locations at the 55% airfoil height. .....................................................................................5-6
Table 5-2 Calculated metal temperature using variation of the interdiffusion zone width at
different locations at the 55% blade airfoil height...............................................................5-7
Table 5-3 Predicted values of coating life, life consumed, remaining life and coating
status at four locations of a 7EA blade after service. .........................................................5-8
Table 5-4 Comparison of predicted coating life, Al content, and volume percent of
β-phase for coating at four locations of a 7EA blade after service. ..................................5-14
xvii
1
INTRODUCTION
In order to achieve combined cycle thermal efficiencies approaching sixty percent, the major
turbine manufacturers are aggressively transitioning aircraft gas turbine design and materials
technologies to advanced combustion turbines for power generation. The advanced turbines are
fired at higher temperatures and utilize optimum cooling of hot section components. As a result,
these components experience higher operating temperatures. Because of the higher temperatures
encountered in these designs, the performance and durability of the coating system has now
become one of the prime life limiting factors for hot section components, including those in
Frame 7FA and Frame 9FA engines. Among these components, turbine blades are the most
critical and expensive parts, since the reliability and availability of a turbine often depends on
blade life, which in turn depends on the coating life. To extend and assess the service life of
these blades, it is essential to develop advanced coatings, methods to estimate operating metal
temperature, and more accurate coating life prediction methods.
Previous EPRI reports [1-3] have summarized the development of algorithms to predict the
oxidation life of advanced, duplex coatings such as GT29+ and GT33+. These algorithms have
been incorporated into an easy-to-use spreadsheet, entitled COATLIFE, that predicts the useful
coating oxidation life as a function of firing temperature, hours of operation, and number of
start-stop cycles of the turbine. A method was also developed for measuring the actual bucket
metal temperature of GTD-111DS or EA buckets from the size of the interdiffusion zone
between the coating and the substrate and the time of turbine operation. Mechanical and physical
properties of GTD-111DS bucket alloy were also obtained so that this data could be used to
conduct a complete aerothermal analysis of Frame 7FA+ and Frame 9FA buckets [4]. In
addition, work was initiated on developing a model for the thermomechanical fatigue (TMF) life
of GTD-111DS buckets coated with GT29+, GT33+, and GT33, and incorporating this model
into the COATLIFE spreadsheet.
Results during the past year that are in this report include completion of the TMF model,
incorporation of the model into COATLIFE for GT29+ and GT33+, and validation of the model
for GT29+ coated Frame 7FA and 9FA buckets based on field experience. Validation of
the COATLIFE oxidation model for a GT29+ coated Frame 7EA blade is also discussed.
As firing temperatures have increased even further, manufacturers have introduced thermal
barrier coatings on the buckets. This report also discusses test results and an initial life algorithm
for TBC-coated GTD-111DS bucket material.
1-1
2
SUMMARY OF PRIOR WORK ON THIS PROJECT
In a previous project conducted under EPRI sponsorship [5], a model called COATLIFE was
developed to predict the original or remaining oxidation life of protective coatings on hot section
turbine buckets. The model is based on the actual physical processes that are involved in coating
degradation, including formation, spallation and reformation of aluminum oxide on the surface
as well as interdiffusion between the coating and substrate. The model was initially applied to
aluminide, Pt-aluminide, and GT29 coatings, where the model constants were obtained by
performing accelerated cyclic oxidation tests in the laboratory. Model predictions were shown to
be consistent with the state of the coating on service-operated Frame 6 buckets (GTD-111)
coated with GT29.
In the current program [3, 6], COATLIFE was expanded to include the oxidation life GT29+
and GT33+ coatings on GTD-111DS buckets. Again, the model constants were obtained by
accelerated cyclic oxidation tests in the laboratory. Service-operated Frame 5, 6, 7FA and 9FA
buckets coated with GT29+ were obtained to further validate the COATLIFE predictions.
COATLIFE correctly predicted the failure of the coating at the leading edge of Frame 7FA
and 9FA buckets as well as the continued protectivity of the coating at various locations on the
Frame 5 and 6 buckets.
In order to increase the user friendliness of COATLIFE, a spreadsheet and accompanying user’s
manual were developed for computing original or remaining oxidation life of the various
coatings. The user simply enters the operating hours, number of start-stop cycles of the turbine,
and the bucket temperature, and the program computes the remaining life. The bucket
temperature is dependent on the firing temperature, and is available in a lookup table.
For buckets where the temperature is unknown and destructive sectioning is possible, another
development in the current project permits the actual bucket temperature to be determined.
Relationships have been developed between the size of the interdiffusion zone between the
coating and substrate and bucket operating temperature for various coatings on GTD-111,
IN-738, U-520, and CM-247 bucket alloys. Validation of this methodology was achieved by
predicting the local bucket temperature from metallographic examination of interdiffusion zone
sizes with actual pyrometer measurements that were made on an operating Frame 9FA bucket.
The two procedures agreed to within 25°F (14°C).
Since thermomechanical fatigue (TMF) as well as oxidation can limit the useful operating life of
a bucket, work was initiated last year on enhancing the COATLIFE spreadsheet by adding an
algorithm for computing TMF life. TMF testing was also started on GTD-111DS coated with
various coatings, including GT29+, GT33+, and GT33. These data are being used (see Section 4)
to define the TMF design life curves for the various coatings on GTD-111DS.
2-1
3
THERMAL BARRIER COATING LIFING
Thermal barrier coatings (TBCs) are widely used on the first stage turbine buckets and vanes
of F and G class machines. TBC coatings normally fail by spallation due to delamination of the
coating along the vicinity of the thermally grown oxide (TGO)/TBC interface. The objectives of
this task were to develop a stand-alone TBC coating life model, evaluate the durability of a
plasma-sprayed TBC coating under isothermal and thermal cycling exposures and determine the
kinetics of the TGO scale growth and the constants for the TBC life model.
Development of a Thermal Barrier Coating Life Model
A life prediction model for thermal barrier coating (TBC) was developed and programmed into a
stand-alone FORTRAN code. Figure 3-1 summarizes the essential features of this TBC model,
which has been developed to treat bond coat oxidation, sintering and spallation of the TBC, as
well as effects of coating thickness and substrate curvature on TBC spallation. The code,
called TBCLIFE, can be used to predict TBC life as a function of cycle time. The result can then
be used to construct a coating life diagram for TBC by plotting coating life versus cycle time in a
double logarithmic plot, Figure 3-2.
TBCLIFE
Data Input
Print Data Input
Calculate TBC/TGO
Interface Temperature
Calculate Mechanical Strain

Range, Fatigue Strength
Coefficient, and Curvature Effect
Calculate Oxide Growth
Calculate Sintering
Effect, and TBC Life
Write Output
End
Figure 3-1
Summary of the TBCLIFE code.
3-1
Thermal Barrier Coating Lifing
100
TBC Model
Number of Startups
Failure Boundary
10 Failed Coatings
Protective Coatings
T = 2102°F (1150°C)
1
1 10 100
Cycle Time, hrs

Figure 3-2
TBC life diagram computed via the TBCLIFE code.
Calculation of Interface Temperature
A temperature gradient exists between the TBC, bond coat, and the metal substrate. For
spallation of the TBC, the LCF behavior of the TBC and the oxidation kinetics of the thermally
grown oxide (TGO) at the TBC/bond coat interface are of the most importance [7-11]. In
the TBC model, the temperature at the TBC/bond coat interface is computed according to the
expression given by
dT
−k = Q flow Equation 3-1
dr
with
k = β 0 e β1 T
Equation 3-2
where k is thermal conductivity of the TBC, r is the radial distance, T is temperature, and Qflow is
the heat flux. The parameters, β0 and β1, in Eq. (3-2) are empirical constants. Eq. (3-1) can be
integrated to give the interface temperature, leading to
1  β  
Tint = ln −  1 Q flow h + e β1 Ts  Equation 3-3
β1   β 0  
3-2
where h is the TBC thickness, Ts is the surface temperature of the TBC, and Tint is the
temperature at the TBC/bond coat interface. The interface temperature, Eq. (3-3), is used in
the TBC model as the temperature where LCF and oxidation damage accumulate in a thermal
cycle.
Failure of a TBC is predicted on the basis of an isothermal stress-life equation to treat both
oxidation and thermomechanical stress cycling of the TBC [7]. The TBC life expression is given
by
  W c 
∆σ TBC N = σ
b
f
*
TBC (t ) 1 −  g*   Equation 3-4
  Wg  
 
where ∆σTBC is the stress range in the TBC, Nf is the number of start-ups (cycles-to-failure or
the TBC life), σ TBC
*
(t ) is the time-dependent fatigue strength of the TBC, Wg is the weight gain,
and Wg* is the critical weight gain for TBC spallation. In this approach, spallation of the TBC
from the bond coat is treated as an oxidation-induced cracking process that is assisted by thermal
cycling induced fatigue in the TBC/bond coat interface region. Spallation of the TBC is
envisioned to proceed by the initiation and propagation of cracks at the TBC/bond coat interface
or on planes adjacent to the interface. Both Wg and Wg* can be expressed in terms of the
thickness of the thermally grown oxide, TGO, leading to [9-11]
  δ c 
∆σ TBC N = σ b
f
*
TBC (t ) 1 −  *   Equation 3-5
  δ  
where δ and δ* are the thickness and the critical thickness of the TGO formed between the TBC
and the bond coat.
Mechanical Strain Range
The TBC is assumed to remain elastic during thermal cycling. As a result, the stress range in
the TBC is given by
∆σ TBC = ETBC (t )∆ε TBC Equation 3-6
with
1
∆ε TBC = (α 0, SS − α 0, TBC )(T2 − T1 ) +
2
(
(α1, SS − α1, TBC ) T22 − T12 ) Equation 3-7
and
α = α 0 + α1 T Equation 3-8
3-3
where α is the coefficient of thermal expansion; α0 and α1 are empirical constants; T2 and T1 are
the maximum and the minimum temperature at the TBC/bond coat interface, respectively. The
subscripts SS and TBC represent properties of the substrate and the TBC, respectively.
Oxidation Kinetics
The TGO is assumed to exhibit parabolic growth kinetics that can be described as [7-11]
δ = (k pt )1 2 Equation 3-9
where kp is the parabolic rate constant and t is time of oxidation at the maximum temperature of
the thermal cycle. Furthermore, the parabolic rate constant is described by an Arrhenius equation
given by
 Q 
k p = k po exp − ox  Equation 3-10
 RT 
where kpo is the parabolic oxidation coefficient, Qox is the activation energy for oxidation, R is
the universal gas constant, ant T is the absolute temperature.
Time-Dependent Fatigue Strength Coefficient and Young’s Modulus
The fatigue strength coefficient, σ TBC

*
(t ) , is assumed to degrade with time and decrease with the
radius of curvature according to the relation given by
−n
   
σ *
TBC (t ) = σ exp − a1  h  t 
*
0 Equation 3-11
  Ri  t0 
where σ 0* and a1 are empirical constants; h is TBC thickness; Ri is radius; t0 is a reference time,
and n is a time exponent. In addition, the Young modulus of the TBC is also assumed to vary
with the time at temperature according to a power-law, as given by
m
t
ETBC = E0   Equation 3-12
 t0 
where E0 is the Young’s modulus of the TBC at t = t0, and m is the time exponent for sintering.
Sintering of voids and microcracks in the TBC is represented by an increase in the Young’s
modulus with time.
3-4
TBC Life Equation
The TBC life, Nf, can be obtained by recasting Eq. (3-5) as

1b
σ * (t )   δ c  
N f =  TBC 1 −  *    Equation 3-13
 ∆σ TBC   δ   
which depends on the stress range, ∆σTBC, in the TBC and the TGO thickness at the TBC/bond
coat interface. It is usually more convenient to compute the cycle time, τc, for TBC failure at
specific number of startup cycles, Nf. Using ∆σTBC = εTBC ∆ETBC, Eq. (3-13) can be formulated to
give
c
 t*    ETBC ∆ε TBC  b 
τc =   1 −   N f  Equation 3-14
N   σ *
 f   TBC  
where t* is the time-to-failure by oxidation alone at Nf = 1 and σ TBC

*
is given by Eq. (3-11).
Parametric Calculations
A parametric study of the various key variables in the TBC model has been performed, using
air-plasma-sprayed (APS) TBC and MCrAlY bond coat as an example. The effect of the peak
temperature on TBC life is illustrated in Figure 3-3, which shows reduced TBC life with
increasing peak temperature at the TBC/bond coat interface. The TBC life decreases with
decreasing TBC fatigue strength coefficient, as shown in Figure 3-4. TBC sintering leads
to a decrease of the TBC life, Figure 3-5. The amount of degradation depends on the time
exponent, p = m + n, of the power law relating the TBC elastic modulus and the fatigue
strength to the time at the peak temperature of sintering. The TBC life is also predicted to
decrease with decreasing radius of curvature, as shown in Figure 3-6.
3-5
104
APS TBC
TBCLIFE Model
Number of Startups
103 Peak Temperature
1922°F (1050°C)
2012°F (1100°C)
2102°F (1150°C)
2192°F (1200°C)
102
101
100
100 101 102 103 104
Cycle Time, Hours

Figure 3-3
Effects of peak temperature on the calculated TBC life.
T = 2102°F (1150°C)
APS TBC
2 TBCLIFE Model
10
Number of Startups
TBC Strength, σo*

50 GPa
10 GPa
5 GPa
2 GPa
1 GPa
101
100
100 101 102
Cycle Time, Hours

Figure 3-4
Effect of TBC fatigue strength coefficient on the calculated TBC life.
3-6
Time Exponent APS TBC

102 TBCLIFE Model
Number of Startups
p=0
0.1
0.2
0.3
0.4
p = 0.45
101
p = 0.5
T = 2102°F (1150°C)
TBC Thickness = 7.87 mil (200 µm)
100
100 101 102
Cycle Time, Hours

Figure 3-5
Effect of sintering and time-dependent fatigue strength on the TBC life. Both sintering and
time-dependent degradation of fatigue strength are treated through a power law with a
time exponent p.
APS TBC
TBCLIFE Model
102
Number of Startups
Radius
1 in (25.4 mm)
0.5 in (12.5 mm)
0.25 in (6.35 mm)
0.125 in (3.18 mm)
0.0625 in (1.59 mm)
101
T = 2102°F (1150°C)
TBC Thickness = 7.87 mil (200 µm)
100
100 101 102
Cycle Time, Hours

Figure 3-6
Effect of substrate curvature on the calculated TBC life.
Isothermal and Thermal Cycling Tests of Coated First Stage Bucket

Material
Specimen Material and Design
Cylindrical specimens for isothermal and thermal cycling exposure tests were machined from the
shank sections of GTD-111DS buckets using an electro discharge machining (EDM) process.
The longitudinal axes of the specimens were oriented perpendicular to the DS grain growth
3-7
direction. The geometry of the specimens for isothermal and thermal cycling exposure tests is
illustrated in Figures 3-7 and 3-8, respectively. Isothermal testing was performed on about 2-inch
(50.8 mm) long cylindrical specimens with diameters of 0.36 inches (9.2 mm). To evaluate the
effect of radius of curvature on the durability or spallation behavior of the TBC, thermal cycling
exposure testing was performed on cylindrical specimens with two different diameters of 0.18
and 0.36 inch (4.6 and 9.2 mm). These specimens were about 1 inch (25.3 mm) long.
Figure 3-7
Isothermal exposure test specimen geometry and dimensions.
(a)
(b)
Figure 3-8
Thermal cycling exposure test specimens: (a) 0.18 inch (4.57 mm) diameter, (b) 0.36 inch
(91.4 mm) diameter.
3-8
Coatings and Test Conditions
Turbine Airfoils Coatings and Repairs applied both the bond (NiCoCrAlY) and ceramic (TBC)
coatings on the specimens. The bond coating was applied using a Low Pressure Plasma
Spray (LPPS) process. After application of the bond coating, the specimens were given a
diffusion heat treatment at 2050°F (1121°C) for two hours prior to application of the top ceramic
coating, yttria stabilized zirconia, by using an Air Plasma Spray (APS) process. The composition
of the powders for the bond and ceramic coatings are given in Tables 3-1 and 3-2, respectively.
The composition of the bond coating powder is comparable to the nominal chemistry of GT33.
Table 3-1
Chemical Composition of Bond Coating Powder (wt.%)
Al Co Cr Ni Y
8.0 Balance 20.5 31.3 0.5
Table 3-2
Chemical Composition of Ceramic Coating Powder (wt.%)
Al2O3 Fe2O3 SiO2 TiO2 Y2O3 HfO2 ZrO2
0.1 0.1 0.3 0.1 7.9 1.8 Balance
Isothermal exposure tests were conducted at five different temperatures ranging from 1850°F
(1010°C) to 2050°F (1121°C). The specimens had been exposed for up to 5000 hours. Thermal
cycling testing was performed at a peak temperature of 1950°F (1066°C).
As-Coated Microstructure of Bond and Top TBC Coatings
Figure 3-9 shows the microstructure of the coating in the as-coated condition. Examination of the
metallographic section of the as-coated specimen revealed a dense bond coat. In isolated areas, a
few small pores were observed in the bond coating. The microstructure of the NiCoCrAlY bond
coat consisted of fine β-phase (NiAl) particles in a matrix of γ (Ni solid solution). The thickness
of the bond coating was about 5 mils (127 µm). As expected, the bond coat exhibited irregular
surface topography, which is required for the adhesion of the air-plasma TBC coating. The LPPS
process produces an irregular rough surface and the surface roughness of the coating is related to
the powder particle size. Discontinuous, thin, thermally grown oxide scale was noted at the bond
coat/TBC interface. Examination of the interface of the bond coating/TBC revealed a few
microcracks at or near the interface in isolated areas. These cracks are parallel to the interface.
Some of these cracks looked like delamination cracks and were observed at the bond coat/TBC
interface in the proximity of the interface asperities as illustrated in Figure 3-10. Propagation of
these cracks during isothermal or cycling exposure could lead to TBC spallation. Thus, these
cracks may play a role in spallation of the TBC since the APS–TBC typically fails within the
porous TBC near the oxidized bond coat surface.
3-9
(a) (b) (c)

Figure 3-9
Structure of APS TBC in the as-coated condition.
(a) (b)
Figure 3-10
Optical micrographs of as-sprayed bond and TBC coatings. Arrows point to microcracks
(or delamination) parallel to and near or at the bond coat/TBC interface
The microstructure of the topcoat showed a layered structure resulting from splatting of the
powder particles during the deposition process. The structure exhibited pores/voids, and
microcracks, which is considered to be normal structure for an APS-processed Y2O3-ZrO2 [11].
The thickness of the topcoat was about 10 mils (254 µm). Energy dispersive spectroscopy (EDS)
analysis was performed at selected areas on the bond and top coatings and the results are
presented in Figure 3-11.
3-10
(a)
(b)
Figure 3-11
EDS results obtained (a) from the bond coating and (b) from the top TBC coating.
Isothermal Test Results
The TBC coated GTD–111 specimens were isothermally exposed at five temperatures, 1850°F
(1010°C), 1950°F (1066°C), 1975°F (1079°C), 2000°F (1093°C), and 2050°F (1121°C).
Multiple specimens were exposed at each temperature and one specimen at a time was removed
at predetermined intervals from each furnace for visual and metallographic examinations.
Cracks in the TBC coating were observed on specimens exposed to temperatures ranging
from 1950°F (1066°C) to 2050°F (1121°C). The inspection cycle at which a crack in the TBC
coating or spallation of TBC was observed is considered as initiation time for TBC spallation.
The inspection results showed that the time to initiate cracks in the TBC coating or TBC
spallation was inversely related to the exposure temperature. Visual examination of specimens
exposed at 1850°F (1010°C) showed that these specimens were free from cracking for up to
4800 hours. The specimens exposed for up to 4006 hours were metallurgically evaluated. Figure
3-12 shows the condition of a TBC coated specimen after 4006 hours exposure at 1850°F
(1010°C).
3-11
The extent of cracking among the specimens exposed at different temperatures is shown in
Figures 3-13 through 3-16. In the majority of the cases, the cracks initiated from the end faces of
the specimens. Time to initiate cracks in the TBC coating at various exposure temperatures is
given in Table 3-3.
(a)
(b)
Figure 3-12
Photographs of TBC-coated specimens after 4006 hours exposure at 1850°F (1010°C). Note
there were no visible cracks.
3-12
(a) (b)
(c) (d)
Figure 3-13
Photographs of TBC-coated specimen after 1500 hours exposure at 1950°F (1066°C).
Arrows point to TBC cracks.
(a) (b)
Figure 3-14
3-13
(a) (b)
Figure 3-15
(a) (b)
(c) (d)
Figure 3-16
Table 3-3
Isothermal Exposure Test Results at Various Temperatures
Exposure Temperature Time to initiate cracks

Comments
°F (C°) Hours
1850 1010 > 4800 No visible cracks
1950 1066 1500 Cracked
1975 1079 502 Cracked
2000 1093 225 Cracked
2050 1121 24 Cracked
3-14
Thermal Cycling Test Results
Automated thermal cycling testing was performed on coated specimens at a peak temperature
of 1950°F (1066°C). The specimens were inserted into the furnace for 55 minutes prior to
moving them to the forced air-cooling system. After cooling for five minutes, the specimens
were reinserted into the furnace. Eight specimens of each size were tested and the results are as
follows:
Table 3-4
Thermal Cycling Exposure Test Results
Number
Serial #/ Diameter Condition
of Remarks
Position Inches/(mm) of TBC
Cycles
Cracks originated predominantly from the hanging
1/1 0.18/(4.57) 395 Cracked holes and/or the end faces
A small crack away from the holes was present
2/2 0.18/(4.57) 395 Cracked
holes and/or the end faces
3/8 0.18/(4.57) 395 Cracked
4/7 0.18/(4.57) 395 Cracked
holes and/or the faces
5/10 0.18/(4.57) 395 Cracked
holes and/or end faces
No visible crack was seen. The specimen was
6/16 0.18/(4.57) 395 No cracks
removed for metallography
7/15 0.18/(4.57) 420 Cracked
8/9 0.18/(4.57) 420 Cracked
holes and/or end faces
1//4 0.36/(9.14) 395 Cracked
2/3 0.36/(9.14) 395 Cracked A small crack originated from the end face
3/5 0.36/(9.14) 395 Cracked Two small cracks originated from the holes
No visible crack was seen. The specimen was
4/14 0.36/(9.14) 395 No cracks
removed for metallography
5/6 0.36/(9.14) 420 Cracked Two cracks initiated from the holes
6/11 0.36/(9.14) 600 Cracked
7/12 0.36/(9.14) 600 Cracked
8/13 0.36/(9.14) 600 No cracks No visible crack was seen
3-15
Cracks in the TBC coating were observed on several specimens after 395 thermal cycles.
Examination of the specimens showed that cracks initiated predominantly from the holes and/or
from the end faces. In two specimens, small isolated cracks, away from the holes were observed.
Typical morphology of cracking and spallation of the TBC coating adjacent to the holes are
shown in Figures 3-17 through 3-20. The extent of cracking of the TBC was more predominant
for the smaller diameter specimens. Six of the eight smaller specimens exhibited cracking
after 395 thermal cycles, while three of the eight larger ones cracked after exposure to the same
number of thermal cycles.
(a) (b)
Figure 3-17
Photographs of a large TBC-coated specimen after 395 one-hour cycle exposures at a
peak temperature of 1950°F (1066°C).
(a) (b)
Figure 3-18
Photographs of a small TBC-coated specimen after 395 one-hour thermal cycle exposures
at a peak temperature of 1950°F (1066°C). Arrow points to a crack away from the hole.
(a) (b)
Figure 3-19
Photographs of a small TBC-coated specimen after 395 one-hour cycle exposures at a
peak temperature of 1950°F (1066°C). Arrow points to a crack that had not initiated from
the hole.
3-16
(a) (b)
Figure 3-20
Photographs of a large TBC-coated specimen after 395 cycles at a peak temperature
of 1950°F (1066°C).
Metallography
Following thermal exposure, the TBC coated specimens were vacuum infiltrated by epoxy and
then longitudinal and transverse sections were removed with a slow speed diamond saw prior to
mounting them in epoxy for metallographic evaluations. The mounts were metallographically
polished and examined under optical and scanning electron microscopes for oxide thickness,
bond coat/TBC interface delamination, and/or cracking, and for oxide chemical composition.
Chemical compositional measurements were made at selected locations on the thermally
grown oxide (TGO) scale between the bond coating and TBC by using EDS.
Examination of the metallurgical sections prepared from the exposed TBC-coated specimens
showed that the TGO scale thickness increased with exposure time at all temperatures. The
influence of time and temperature on the TGO thickness is shown in Table 3-5. The TGO scale
thickness for each specimen was measured at several locations and the average thickness values
are listed in the table. At higher exposure temperatures (>1950°F (1066C°)), evidence of
oxidation of the bond coat was observed, and the extent of oxidation increased with exposure
time and temperature. The TGO scale thickness was not measured for those specimens that
exhibited severe bond coat oxidation. Typical variation of TGO scale thickness with exposure
time at 1850°F (1010°C) and 1950°F (1066°C) is shown in Figures 3-21 and 3-22, respectively.
The TGO scale exhibited cracks and delamination of the bond coat oxide scale and TBC
interface in isolated areas. These cracks were present either in the TGO and/or in the
TBC-coating adjacent to the TGO/TBC interface. Figures 3-23 and 3-24 show variation of
interface cracking as a function of exposure time at 1850°F (1010°C), and 1950°F (1066°C),
respectively. Comparison of cracks in these photographs indicates that the length and the extent
of cracking increase with exposure time. At both temperatures, the cracks were seen in
specimens that were exposed for a relatively short time (500 and 1000 hours). Variation of the
interface crack length as a function of exposure time is presented in Figure 3-25. The extent of
cracking also increased with the exposure temperature. Severe interface cracking was observed
in the specimen that was exposed for 1000 hours at 1950°F (1066°C). Though visual examination of
this specimen revealed no external cracks in the TBC coating, the interfacial cracking extended
for approximately 25% of the circumference of the transverse section. In another uncracked
3-17
TBC-coated specimen after 1250 hours exposure at 1950°F (1066°C), the interfacial cracking
extended for almost 50% of the circumference of the cross section of the specimen. However,
interfacial cracking in these specimens did not produce any visible cracks in the TBC or cause
localized spallation, which suggests that a plasma sprayed TBC system is capable of enduring
significant localized interfacial cracking prior to spallation. These results also indicate that the
interface cracks initiate during early stages of exposure and propagate with exposure time prior
to either cracking and/or spallation of the TBC coating.
Table 3-5
Influence of Time and Isothermal Exposure Temperature on Thermally Grown Oxide
Thickness
Exposure Exposure Avg. TGO

Temperature Time thickness Remarks
°F °C Hours mils* µm
1850 1010 1000 0.29 7.39

2000 0.36 9.06
2736 0.36 9.15
3136 0.53 13.46
3500 0.52 13.16

4006 0.48 12.19
1950 1066 500 0.30 7.66
1000 0.36 9.12
1500 0.45 11.42 TBC- Cracked
1750 0.57 14.48 TBC- Cracked

2000 0.60 15.24 TBC- Cracked
1975 1079 106 0.26 6.68
304 0.35 8.78 Bond coat internally oxidized
375 NM** NM Bond coat severely oxidized

1975 1079 502 NM NM TBC – cracked and bond coat severely oxidized
2000 1093 225 0.46 11.78 TBC – cracked and bond coat internally oxidized
498 NM NM TBC - cracked and bond coat severely oxidized
2050 1121 24 NM NM TBC – cracked and bond coat severely oxidized
* 1 mil = 0.001 in.

** NM = Not Measured
3-18
(a) (b)
Figure 3-21
Optical micrographs of the TBC/bond coat interface after (a) 1000 hours and (b) 4006
hours exposure at 1850°F (1010°C) showing variation of TGO scale thickness. Note cracks
in the TBC and TGO and interface delamination.
(a) (b)
Figure 3-22
Optical micrographs of the TBC/bond coat interface after (a) 500 hours, (b) 1500 hours
exposure at 1950°F (1066°C). Note cracks in the TBC and TGO scale. Arrows point to
cracks.
3-19
(a) (b)
(c)
Figure 3-23
Optical micrographs of the TBC/bond coat interface of the specimens after (a) 1000 hours,
(b) 2000 hours, and (c) 3500 hours exposure at 1850°F (1010°C) showing variation of
cracking near the TBC/TGO interface.
3-20
(a) (b)
Figure 3-24
Optical micrographs of the TBC/bond coat interfaces of the specimens after (a) 500 hours,
and (b) 1000 hours exposure at 1950°F (1066°C) showing variation of cracking near the
interface.
Figure 3-25
Variation of crack length with exposure time.
Figure 3-26 contains photographs of the transverse sections of specimens after 106, 304 and 375
hours exposure at 1975°F (1079°C). Visual examination of these specimens showed no external
cracking in the TBC. Metallurgical examination of longitudinal and transverse sections of these
specimens showed evidence of severe internal oxidation of the bond coating after 304 and 375
hours exposure. In addition, the microstructure exhibited several voids at the bond
coating/substrate interface. Comparison of voids at the interface in these photographs showed
that the extent of the interface voids increased with exposure time, and the voids appear to
3-21
coalesce with time. The coalescence of the voids led to de-bonding or delamination of the bond
coat/substrate interface in localized areas as shown in Figure 3-26(b). The extent of void
formation at the bond coat/substrate interface also increased with the exposure temperature.
Typical delamination of the bond coating in the specimens exposed at higher temperatures
(2000°F (1093°C) and 2050°F (1121°C)) is presented in Figure 3-27. The effect of exposure
temperature on void formation at the bond coat/substrate interface is illustrated in Figure 3-28.
Microstructures of the specimens exposed for a long time at low temperatures 1850°F (1010°C)
and 1950°F (1066°C) also exhibited a few voids in isolated areas at the bond coating/substrate
interface as opposed to severe void formation, void coalescence, and de-bonding of the bond
coat/substrate interface observed in specimens after short term exposure at higher temperatures.
Transport of alloying elements and vacancies during the oxidation process produces these voids
at the interfaces. Formation of voids at the interfaces is a diffusion-controlled process, which
occurs at a rapid rate at higher temperatures. This failure mode is unlikely to occur at actual
bucket operating temperatures.
(a) (b)
(c)
Figure 3-26
Optical micrographs of the interface bond coat/substrate of specimens after (a) 106 hours,
(b) 304 hours, and (c) 375 hours exposure at 1975°F (1079°C) showing variation of voids at
the interface. Arrows point to delamination.
3-22
(a) (b)
Figure 3-27
Optical micrographs showing bond coat delamination in specimens after (a) 498 hours
exposure at 2000°F (1093°C), (b) 160 hours exposure at 2050°F (1121°C).
(a) (b)
(c) (d)
Figure 3-28
Optical micrographs showing voids at the bond coat/substrate interface of specimens
after (a) 4006 hours at 1850°F (1010°C), (b) 2000 hours at 1950°F ((1066°C), (c) 225 hours
at 2000°F (1093°C), (d) 24 hours at 2050°F (1121°C).
3-23
Characterization of TGO Scale
To characterize the TGO scale, the spalled TBC flakes were collected from the specimens
after 2500 hours exposure at 1950°F (1066°C) and after 160 hours at 2050°F (1121°C). A
photograph of a TBC flake is shown in Figure 3-29. EDS measurements were made on the inner
surface (TGO) of the flakes and the results are shown in Figures 3-30 and 3-31. The titanium
content in the TGO that formed at 2050°F (1121°C) was significantly larger compared to the one
that formed at the lower temperature (46% versus 3%). The presence of titanium disrupts
formation of an adherent alumina scale at the interface, which could adversely affect the
durability of the TBC by increasing the oxidation rate of the bond coat.
(a)
(b)
Figure 3-29
Photographs of a spalled TBC flake collected from a specimen after 160 hours exposure
at 2050°F (1121°C). EDS was performed at multiple locations on the inner surface (TGO).
3-24
Element Line Weight %

O Ka 13.86
Al Ka 2.25
Ti Ka 45.64
Cr Ka 6.66
Co Ka 9.23
Ni Ka 19.14
Y La 1.38
Ta Ma 1.32
W Ma .052
Total 100.00
Figure 3-30
Typical EDS spectrum obtained from a location on the inner surface of the flake collected
from a specimen after 160 hours exposure at 2050°F (1121°C).

O Ka 14.45
Al Ka 3.98
Ti Ka 2.95
Cr Ka 30.43
Co Ka 16.73
Ni Ka 26.91
Mo La 1.25
Ta Ma 1.46
W Ma 1.84
Total 100.00
Figure 3-31
EDS spectrum obtained from a location on the inner surface of a TBC flake spalled from a
specimen after 2500 hours exposure at 1950°F (1066°C).
Examination of longitudinal and transverse sections of the TBC specimens showed a dense
multiphase interfacial oxide scale between the TBC and bond coating. Typical morphology of
the TGO is shown in Figures 3-32 and 3-33. The TGO scale exhibited at least three different
phases, a continuous dark oxide scale over the bond coating, small particles (lighter in color) in
the dark oxide scale, and a small discontinuous white layer over the dark oxide scale. EDS
measurements were performed at multiple locations and typical results are presented in
Figures 3-32 and 3-33. These results showed that the dark oxide scale was predominantly
aluminum-rich oxide containing about 65% aluminum. This indicates that the continuous, dark
oxide scale is presumably alumina, Al2O3. The small particles in the dark aluminum-rich oxide
were oxides of aluminum and yttrium and the discontinuous scale over the dark aluminum-rich
oxide was an oxide of Ni, Co, Cr, and Al.
3-25
(a)

O Ka 14.15
Al Ka 20.57
Cr Ka 23.13
Co Ka 24.03
Ni Ka 16.79
Zr La 1.34
Total 100.01
(b)

O Ka 30.82
Al Ka 64.06
Y La 5.12
Total 100.00
(c)
Figure 3-32
(a) SEM back-scattered electron image of the bond coat/TBC interface of specimen after
4006 hours exposure at 1850°F (1010°C) showing morphology of interfacial oxide. The
numbers denote the locations for the EDS analysis; (b) EDS spectrum obtained from
Location 2, (c) EDS spectrum obtained from Location 3.
3-26
(a)

O Ka 14.71
Al Ka 17.76
Ti Ka 0.29
Cr Ka 26.21
Co Ka 27.32
Ni Ka 12.78
Zr La 0.94
Total 100.01
(b)

O Ka 30.81
Al Ka 67.64
Ti Ka 1.55
Total 100.00
(c)

O Ka 17.83
Al Ka 29.32
Ti Ka 1.67
Cr Ka 9.62
Co Ka 21.62
Ni Ka 17.16
Y La 2.78
Total 100.00
(d)
Figure 3-33
(a) SEM back-scattered electron image of the bond coat/TBC interface of specimen
after 1500 hours exposure at 1950°F (1066°C) showing morphology of interfacial oxide
scale. The numbers on the photograph denote the locations for the EDS analysis; (b) EDS
spectrum obtained from Location 1, (c) EDS spectrum obtained from Location 2, (d) EDS
spectrum obtained from Location 4.
3-27
The interfacial oxide scales formed at 1850°F (1010°C) were almost free from titanium, while
the scale formed at 1950°F (1066°C) contained about 2 wt.% titanium. Exposure at higher
temperatures (>1950°F (1066°C)) resulted in formation of a discontinuous aluminum-rich oxide
scale in isolated areas on the bond coating, which led to progression of oxidation into the bond
coating. Figure 3-34 shows an area where the aluminum rich-oxide scale was discontinuous and
oxidation had locally progressed into the bond coating on a specimen after 304 hours exposure
at 1975°F (1079°C). The mixed-oxide scale contained titanium as high as 5 wt.%. These results
also show that the titanium levels in the interfacial oxide scale was increasing with the exposure
temperature. The presence of higher amounts of titanium in the scale is considered to be
detrimental for the formation of a protective Al2O3 scale.
(a)

O Ka 14.18
Al Ka 27.10
Ti Ka 4.41
Cr Ka 4.88
Co Ka 19.55
Ni Ka 27.32
Y La 1.58
Ta Ma .98
Total 100.00
(b)
Figure 3-34
SEM back-scattered image of the bond coat/TBC interface of a specimen after 304 hours
exposure at 1975°F (1079°C) showing morphology of interfacial oxide scale. Note the
dark Al-rich, Al2O3 scale is not continuous. EDS analysis was performed on area shown by
an arrow.
3-28
Calibration of Model
Material constants in the TBC life model include physical, thermal, low-cycle fatigue, and
oxidation properties. A summary of the material constants for APS TBC is presented in
Table 3-6. The coefficients of thermal expansion, thermal conductivity, and Young's modulus
were obtained from the literature [8]. The constants in the oxidation kinetic and low-fatigue life
equations were determined from results of the static and cyclic oxidation tests performed in this
program, as well as those available in the literature [8].
Table 3-6
TBCLIFE model constants for the APS TBC.
σ 0* 10,000 MPa
a1 12.5
α0, SS 3.45 ×10-6 °K-1
α1, SS 1.59 × 10-8 °K-2
α0, TBC 9.48 × 10-6 °K-1
α1, TBC 6.77 × 10-10 °K-2
β0 0.634 W/m°K
β1 4.78 × 10-5 W/°K
b 0.35
c 1
h 2 × 10-4 m
Ri 4.572 × 10-3 m
Eo 5.8 × 104 MPa
P 0
Qflow 0
to 1 hr
δ*
20 µm
kpo 6.4108 × 1012 µm2/hr
Qox 3.417 × 105 J/mole °K
The parabolic rate constant in the oxidation kinetic equation was obtained by plotting the oxide
thickness data as a function of √t, where t is time of oxidation. Linear regression of the
experimental data, as shown in Figure 3-35, provided the value of the parabolic rate constant, kp,
at a given temperature, T. The kp parameter was then plotted as a function of the reciprocal
temperature, Figure 3-36, to obtain the activation energy, Qox, for TGO formation. Comparisons
of the calculated and measured oxide thickness are shown in Figure 3-37 and 3-38 for 1850°F
(1010°C) and 1950°F (1066°C), respectively.
3-29
30
APS TBC
1066°C
Oxide Thickness (δ), µm

25
20
15
δ = 0.317t1/2
10
0
0 20 40 60 80
1/2
(Time, t, Hr)
Figure 3-35
Plot of oxide thickness versus √t, where t is time of oxidation, for determining the
parabolic oxidation rate constant, kp, for a given temperature. (1066°C = 1950°F).
e2
APS TBC
e1 NiCoCrAlY/GTD-111DS
Isothermal Oxidation
TBC Model
e0 Experimental Data
kp, µm /hr
2
e-1
e-2
e-3
e-4
7.3 7.4 7.5 7.6 7.7 7.8 7.9
Recipocal Temperature x 104, K-1

Figure 3-36
Plot of kp as a function of the reciprocal temperature for determining the activation
energy, Qox, for TGO formation at the TBC/bond coat interface.
3-30
20
APS TBC
1010°C

Experimental Data
15 LSQ Regression
10
δ = 0.2052t1/2
5
0
0 1000 2000 3000 4000
Time (t), Hrs

Figure 3-37
A comparison of calculated and measured oxide thickness as a function of exposure time
at 1850°F (1010°C).
20
APS TBC
1066°C
15 Experimental Data
LSQ Regression
10
δ = 0.317t1/2
0
0 500 1000 1500 2000 2500
Time (t), Hrs

Figure 3-38
A comparison of calculated and measured oxide thickness as a function of exposure time
at 1950°F (1066°C).
The LCF constants were first determined based on experimental data for APS TBC generated in
the HOST program [8]. Subsequently, the value of the fatigue strength, σ 0* , and the critical oxide
thickness, δ*, at TBC spallation were revised so that the calculated TBC life matched the
cycles-to-failure observed in the cyclic oxidation tests performed in this program. The cyclic
oxidation tests were performed using one-hour thermal cycles until cracking occurred in
the TBC.
3-31
Figure 3-39 shows a comparison of the calculated and measured TBC lives for APS TBC for a
peak temperature of 1066°C. Excellent agreement was obtained because the model was fitted to
the experimental data. After the model constants were finalized using the experimental data
for 1950°F (1066°C), the TBC life model was used to predict the TBC lives for other
temperatures. The predictive capability of the TBC model is illustrated in Figures 3-40, 3-41,
and 3-42, which shows comparisons of the predicted and observed TBC lives for 1850°F
(1010°C), 1975°F (1079°C), and 2100°F (1150°C), respectively. There were limited
experimental data for 1850°F (1010°C) and 1975°F (1079°C) because cyclic oxidation testing
was in progress. The experimental results shown in Figure 3-42 are burner-rig and furnace data
at which the TBC spalled; these data are from the HOST program [8].
103
APS TBC
Number of Startup Cycles
GT33/GTD-111DS
1066°C Peak Temperature
Experimental Data
102 No Cracks
Cracked
TBC Model
Failed TBCs
10 1 Protective TBCs
100
100 101 102 103 104
Cycle Time, Hrs
Figure 3-39
Calculated TBC life diagram compared against experimental data for 1950°F (1066°C).
3-32
104
APS TBC

GT33/GTD-111DS
103 Experimental Data
No Cracks
Cracked
TBC Model
102
Failed TBCs
Protective TBCs
101
100
100 101 102 103 104
Cycle Time, Hrs
Figure 3-40
Computed TBC life curve compared against experimental data for 1850°F (1010°C).
103
APS TBC
GT33/GTD-111DS
Experimental Data
102 No Cracks
Cracked
TBC Model
Failed TBCs
101
Protective TBCs
100
100 101 102 103 104
Cycle Time, Hrs
Figure 3-41
Computed TBC life curve compared against experimental data for 1975°F (1079°C).
3-33
103
APS TBC

NASA/PWA HOST Data
Burner Rig Tests
Furnace Tests
102 TBC Model
101 Failed TBCs
Protective TBCs
Tmax = 1150°C
100
10-1 100 101 102 103 104
Cycle Time, Hrs
Figure 3-42
Calculated TBC life compared against burner-rig and furnace data from the HOST
program [8].
The coating life curves for TBCs are generally nonlinear in a log-log plot of number of startup
cycles versus cycle time, as shown in Figure 3-43. The amount of nonlinearity, however, is
sufficiently small so that a linear approximation, as shown in Figure 3-43, generally provides a
conservative estimation of the TBC life. The linear approximation was used to develop the
analytical relations for TBC lives at various temperatures. Figure 3-44 shows TBC lives
computed for five temperatures that range from 1650 to 2100°F (900° to 1150°C).
103
APS TBC
GT33/GTD-111DS
Experimental Data
102 No Cracks
Cracked
TBC Model
Linear approximation
101
Failed TBCs
Protective TBCs
100
100 101 102 103 104
Cycle Time, Hrs
Figure 3-43
Linear approximation of the coating life curve for APS TBC. (1066°C = 1950°F).
3-34
104
APS TBC
GT33/GTD-111DS

103
900°C Failed TBCs

102 950°C
1010°C
1066°C
1150°C
101
Protective TBCs
100
100 101 102 103 104 105
Cycle Time, Hrs
Figure 3-44
TBC life curves for APS TBC at various temperatures.
3-35
4
THERMOMECHANICAL FATIGUE (TMF) TESTING OF
FIRST STAGE BUCKET MATERIAL
Gas turbine blades experience complex thermal and mechanical loading history during a typical
cycle of operation, consisting of startup, steady state operation, and shutdown. Temperature
gradients and mechanical constraints during cycling result in cyclic thermomechanical stresses,
which can lead to thermomechanical fatigue (TMF) damage. The purpose of this task is to
generate TMF data for coated GTD-111DS material, calibrate and incorporate the TMF life
model into COATLIFE and validate the model using field data. The TMF data is required to
determine the constants for the TMF life model.
Materials and Coatings
Specimens for TMF testing were machined from the shank sections of Stage 1 GTD-111DS
blades removed from a Frame 5002 engine. The shank section operates at a much lower
temperature than the airfoil section of a blade and, as a result, the material at the shank is not
expected to degrade during service [13, 14]. The structure and properties of the material at the
shank section of a blade are a good approximation of the initial, as-heat treated condition. The
longitudinal axes of the specimens were oriented parallel to the columnar grain growth direction.
The geometry and dimensions of the specimens are shown in Figure 4-1.
Figure 4-1
TMF specimen geometry and dimensions. (All dimensions are in inches; 1 inch = 2.54 cm.)
4-1
Thermomechanical Fatigue (TMF) Testing of First Stage Bucket Material
Turbine Airfoils Coating and Repairs applied the coatings on these specimens. Fifteen specimens
were coated with NiCoCrAlY and seven were coated with CoCrAlY. The chemical composition
of the coating powders, obtained from material certification data, are shown in Table 4-1. The
composition of the NiCoCrAlY and CoCrAlY powders is comparable to the nominal
composition of GT33 and GT29 coatings, respectively. Following application of these coatings,
the specimens were given a diffusion (partial solution) treatment at 2050°F (1117°C) for two
hours. Then the specimens were peened to a surface finish of 125µ. The top aluminide coating
was then applied on twelve of fifteen NiCoCrAlY and all seven CoCrAlY coated specimens
using a pack cementation process. Following the application of the top aluminide coating, the
specimens were given a diffusion heat treatment at 1975°F (1080°C) for 4 hours. All twenty-two
specimens were then given an aging treatment at 1550°F (843°C) for 24 hours.
Table 4-1
Chemical Composition of NiCoCrAlY and CoCrAlY Powders (wt.%).
Coating Al Co Cr Ni Y
NiCoCrAlY 8.0 Balance 21.0 33.0 0.5
CoCrAlY 7.0 Balance 33.0  0.5
Review of Test Conditions and Prior Test Results
The test matrix for these specimens was developed considering the maximum metal temperature,
1850°F (1010°C), calculated for the Stage 1 turbine blades of Frame 7FA and 9FA engines [4].
The original test matrix for this task included testing of eight GT33+ and three GT29+ coated
specimens. All tests were conducted in out-of-phase cycling with a two-minute hold at the peak
temperature. Limited tests were also conducted on GT33+ coated specimens at a lower peak
temperature of 1650°F (899°C) to simulate the metal temperature conditions near the platform of
a turbine blade where TMF cracks have been seen. The original test matrix is given elsewhere
(Table 5-1 in Reference 3). It was subsequently decided to test three GT33 coated specimens to
determine the influence of the presence of an over aluminide layer on the TMF life. The results
of all specimens tested in this task are presented in the following section.
A specimen tested at the 0.8% strain range failed sooner than expected. To determine the cause
of a premature failure of this specimen, metallographic examinations were performed. The
examination of the fracture surface showed that the fracture occurred along a crystallographic
plane. The specimen was sheared off along this plane through the cross section of the specimen.
The thickness of the coating on the specimen was 6.8 mils (172.7 µm). The coating thickness
among all of the specimens varied in a narrow range of 6.8 and 7.7 mils (172.7 to 195.6 µm),
indicating that the premature failure of this specimen was not due to variation of coating
thickness. A review of the elastic modulus data further revealed that the specimen tested at the
highest strain range had the highest elastic modulus (24 × 106 psi) among the specimens tested.
The elastic modulus is a reflection of the angle between the specimen axis and the columnar
grain growth direction. As this angle increases, the elastic modulus increases, such that for a
given strain range higher tensile stresses are experienced, which lowers cyclic life. This indicates
4-2
that the specimen had a large angular deviation that was also reflected by the fracture mode, i.e.,
crystallographic shear off on a single plane. Based on the fracture mode and elastic modulus of
the specimen, this data point was considered to be invalid.
Test Results
TMF tests were performed at Mar Test, Inc., located in Cincinnati. GTD-111DS specimens
coated with three different coatings, GT33, GT33+ and GT29+, were tested under this task. The
TMF results along with coating thickness and the room temperature elastic modulus for each
specimen are presented in Table 4-2. All specimens except one failed in the gage section. In all
cases, the fracture initiated from the surface at multiple locations. Several small secondary cracks
were seen remote from the fracture surface on all the specimens.
Table 4-2
TMF test data of coated GTD-111DS specimens along with coating thickness and elastic
modulus data.
Modulus 106 psi

Specimen Coating/Thickness Total Strain Life, Temperature
# (in.) Range, % @ Room Temperature, Cycles Range*
75°F (24°C)
N-11 GT33/ND** 0.7 20.8 1499 600°-1850°F
N-12 GT33/ND 0.6 22.0 1971 600°-1850°F
N-13 GT33/ND 0.45 21.4 3009 600°-1850°F
N-1 GT33+/0.0070 0.6 22.0 681 600°-1850°F
N-3 GT33+/0.0073 0.6 23.7 757 600°-1850°F
N-2 GT33+/0.0076 0.5 22.9 2475 600°-1850°F
N-7 GT33+/0.008 0.45 21.7 2202 600°-1850°F
N-5 GT33+/0.0077 0.7 21.4 646 600°-1850°F
N-8 GT33+/0.0074 0.7 23.3 772 600°-1650°F
N-14 GT33+/ND 0.6 21.5 2992 600°-1650°F
N-10 GT33+/0.0074 0.45 21.7 3206 600°-1650°F
C-1*** GT29+/0.0072 0.6 22.8 1016 600°-1850°F
C-6 GT29+/.0056 0.6 20.8 1091 600°-1850°F
C-2 GT29+/0.0067 0.7 20.8 855 600°-1850°F
C-4 GT29+/0.0061 0.7 20.8 850 600°-1850°F
C-5 GT29+/0.0073 0.7 22.0 356 600°-1850°F
C-3 GT29+/0.0068 0.45 22.9 1383 600°-1850°F
C-8 GT29+/0.0067 0.45 20.9 1219 600°-1850°F
* Temperature Range 600°F-1850°F = 316°C-1010°C.

** ND = Not determined.
*** Failed outside the gage section.
4-3
The coating thickness among the specimens varied from 6 to 8 mils (152 to 203 µm), which is
within the variation typically observed on a turbine blade. No correlation of coating thickness
with TMF life was observed. Coating thickness on turbine blades typically varies from 5 to 10
mils (127 to 254 µm).
The influence of the test temperature range and the presence of a top aluminide layer on TMF
life of coated GTD-111 specimens are shown in Figures 4-2 and 4-3, respectively. For
comparison of the results, the data is curve-fitted using a least squares-fit analysis. However, for
TMF life estimation, a lower bound curve with a safety factor was used (see Figures 4-16 and 4-
17). A safety factor of two was used to account for the uncertainties associated with the thermal
and mechanical stress analyses, operating history, and material properties. The results show that
lowering the peak temperature from 1850°F (1010°C) to 1650°F (899°C) increased the TMF life
of GT33+ coated specimens by approximately a factor of two. This conclusion is based on
limited data generated at the lower peak temperature. As a result, it is necessary to perform
additional testing at the lower peak temperature to confirm this observation. The presence of a
top aluminide layer on the GT33 coated specimens also lowered TMF life by a factor of
approximately 2.5 at higher strain ranges. However, at the lowest strain range of 0.45%, the TMF
lives of specimens with and without top aluminide layer are comparable. It should be noted that
this conclusion is also based on limited testing on GT33 coated specimens. It is well known that
the presence of a top aluminide lowers the crack initiation life, and microcracks are generally
seen in the early stages of cycling in the top aluminide layer. The TMF life of the GT33+
and GT29+ coated specimens are compared in Figure 4-4.
1
0.9
0.8
0.7
0.6
0.5
Total Strain Range, %
0.4
0.3
0
0.2 Temperature Range 600-1850 F
0
Temperature Range 600-1650 F
0.1
100 200 400 600 1000 2000 5000
Cycles To Failure
Figure 4-2
Influence of temperature range on TMF life of GT33+ coated GTD-111DS material. (600°F-
1850°F = 316°C-1010°C; 600°F-1650°F = 316°C-899°C).
4-4
1
0.9
0.8
0.7
0.6
0.5

0.4
0.3
GT 33 with top aluminide layer

0.2 GT 33 (with out aluminide top layer)
0.1
100 200 400 600 1000 2000 5000
Cycles To Failure
Figure 4-3
Influence of aluminized layer on TMF life of GT33 coated GTD-111DS material.
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
Overaluminized NiCoCrAlY (GT 33+)
Overaluminized CoCrAlY (GT 29+)
0.1
100 200 400 600 1000 2000 3000 5000
Cycles To Failure
Figure 4-4
Comparison of TMF results of over aluminized NiCoCrAlY (GT33+) and CoCrAlY (GT29+)
coatings.
The elastic modulus of test specimens varied from approximately 20 × 106 to 24 × 106 psi. The
modulus depends on the extent of splaying of columnar grains in the DS material. Typically,
a 15° deviation is allowed in the airfoil section of a land-based turbine blade, and the angular
deviation is in general larger in the shank section of a blade. Since it is not possible to remove
the specimens from the airfoil section of a GTD-111DS blade, the specimens were extracted
from the shank section. The observed variation of the elastic modulus values was considered to
4-5
be common in the shank section of a large DS blade. The specimens that exhibited modulus
values 24 × 106 psi or higher were not tested because this value is directly related to the angular
deviation. It is well known that as the angle of deviation increases, the elastic modulus
increases. Low cycle fatigue (LCF) or TMF life decreases with increasing elastic modulus.
Gemma, Langer, and Leverant showed a significant decrease in TMF crack propagation life of
Mar-M200DS with increasing elastic modulus [16].
Fractographic and Metallographic Examinations
All fracture surfaces of the TMF specimens were examined under binocular microscope. The
fracture surfaces exhibited multiple origins and were covered with an oxide scale. Figure 4-5
contains photographs of fracture surfaces showing multiple origin sites. The oxide scale could
not be completely removed by using the standard cleaning processes. Following cleaning, the
fracture surfaces were examined in a scanning electron microscope (SEM) for fracture mode.
Figures 4-6 through 4-9 show typical fracture morphology of the GT29+ and GT33+ coated
specimens. The fracture mode was transgranular for all TMF specimens.
(a) (b)
(c)
Figure 4-5
Fractographs of fracture surfaces of TMF specimens showing multiple crack initiation
sites: (a) Specimen C-1, (b) Specimen N-2, and (c) Specimen N-3. Arrows point to the crack
initiation sites.
4-6
(a) (b)
Figure 4-6
SEM fractograph of fracture surface of Specimen C-2 near an initiation site. Note the
fracture mode is transgranular.
(a) (b)
Figure 4-7
SEM image of fracture surface of TMF Specimen C-3 showing transgranular fracture mode
near a crack initiation area.
4-7
(a) (b)
Figure 4-8
SEM fractographs of fracture surface of TMF Specimen N-2 showing transgranular mode
near a crack initiation area.
(a) (b)
Figure 4-9
SEM fractograph of TMF Specimen N-5 showing transgranular fracture mode near a crack
initiation area.
Several longitudinal sections were prepared through the fracture surfaces of the TMF specimens
for metallographic evaluations. Examination of these sections revealed secondary cracks below
the fracture surface as illustrated in Figures 4-10 and 4-11. Some of these cracks penetrated into
the base metal. Evidence of internal oxidation of base metal was observed in the vicinity of the
secondary cracks. The extent of secondary cracking was about the same in both GT29+
and GT33+ coated specimens. However, the morphology of secondary cracking in the coating
did vary with the type of coating. The cracks in the GT33+ coating were blunt and filled with a
continuous-oxide scale. No evidence of internal oxidation in the coating adjacent to these cracks
was observed. Figure 4-12 shows typical morphology of coating cracks on the gage sections of
4-8
the GT33+ coated specimens. A small, depressed area, due to rumpling of the coating, was
observed on the surface at the crack initiation sites, which is evidence of localized plastic
deformation. It is well known that ductile coatings such as NiCoCrAlY rumple when they are
subjected to thermal-mechanical strains. No evidence of plastic deformation was seen on the
surface of GT29+ coated specimens in the vicinity of secondary cracks, as shown in Figure 4-13.
Figure 4-10
Photograph of longitudinal section of coated TMF Specimen C-2. Showing secondary
cracks below the fracture surface.
4-9
Figure 4-11
Photograph of a longitudinal section of GT33+ coated TMF Specimen N-2 showing
secondary cracks below fracture surface.
(a) (b) (c)

Figure 4-12
Optical photographs of secondary cracks below the fracture surface of GT33+ coated
specimens (a) N-1, (b) N-2, and (c) N-3 showing rumpling of the coating at the initiation
site, morphology of crack in the coating, and oxidation of base material.
4-10
(a) (b)
(c)
Figure 4-13
Optical micrographs of secondary cracks on GT29+ coated TMF specimens (a) C-1,
(b) C-2, and (c) C-3 showing internal oxidation of coating and the base material near the
cracks.
Consistent with this observation, the secondary cracks on these specimens were not as blunt as
those observed on the GT33+ coated ones. Generally, the CoCrAlY (GT29) coating exhibits
lower toughness compared to the NiCoCrAlY coating. As a result, the cracks in the former
coating were sharper than those present in the latter coating.
Several internal oxide particles were seen in the CoCrAlY coating adjacent to the secondary
cracks as shown in Figure 4-13. The oxide scales present in the secondary cracks on the GT29+
and GT33+ coated specimens were analyzed using Energy Dispersive Spectroscopy (EDS) to
understand the internal oxidation behavior of these coatings. Figures 4-14 and 4-15 show
the EDS spectra obtained from the oxide scale in the secondary cracks of GT29+ and GT33+
coatings, respectively. The results showed that the oxide scale in the secondary cracks
of the GT29+ coated specimens was predominantly a chromium-rich oxide, containing
approximately 71% chromium and 6% cobalt with a small amount of aluminum.
The chromium-rich oxide is not as stable as aluminum-rich oxide and volatilizes at
approximately 1750°F (954°C). In contrast, the oxide scale in the cracks of the GT33+
coated specimens was predominantly an aluminum-rich oxide containing about 51%
4-11
aluminum, 7% chromium, and 8% cobalt. The scale is continuous. The higher aluminum
content in the GT33 coating is responsible for the formation of a continuous alumina-rich
oxide scale on the surfaces of secondary cracks in these specimens. The presence of an
aluminum-rich oxide scale on the crack surfaces is responsible for preventing the progression
of internal oxidation into the NiCoCrAlY coating through the surfaces of secondary cracks.
(a)
O Ka 20.01
Al Ka 0.45
Ti Ka 0.74
Cr Ka 71.43
Co Ka 5.75
Ni Ka 0.84
Ta Ma 0.37
W Ma 0.41
Total 100.00
(b)
Figure 4-14
(a) SEM image of a secondary crack in the GT29+ coating on TMF Specimen C-1. (b) EDS
spectrum obtained from the oxide scale on the crack surface. The semi-qualitative
composition of the scale is also shown.
4-12
(a)
O Ka 26.63
Al Ka 51.31
Ti Ka 0.87
Cr Ka 6.86
Co Ka 8.10
Ni Ka 6.22
Total 99.99
(b)
Figure 4-15
(a) back scatter electron image of a secondary crack in the GT33+ coating on TMF
Specimen N-1. (b) EDS spectrum obtained of oxide scale in the secondary crack.
4-13
Calibration of Model
The thermomechanical fatigue (TMF) model utilized in this program has the form given by
∆ε m = CN −f α Equation 4-1
where ∆εm is the mechanical strain range, Nf is the cycle-to-failure, C is the fatigue ductility
coefficient, and α is the fatigue life exponent. Material constants in the TMF model, which are C
and α, were evaluated by plotting the experimental data in a log-log plot of mechanical strain
range versus cycles-to-failure. Least-square regression analysis was then performed to obtain the
values of C and α for a particular coating/substrate combination. The value of C was then
reduced to give the minimum coating life in the data set. The adjustment in the C value was
necessary because of scatter in the TMF data. Finally, the C value was further reduced to that
corresponding to 1/2 of the minimum life. This was done so that the predicted TMF life would be
conservative. The TMF life equations and experimental data for GT29+/GTD-111DS are
presented in Figure 4-16, while those for GT33+/GTD-111DS are presented in Figure 4-17. Note
that, because of limited data, the 1650 and 1850°F (900 and 1010°C) data are lumped together in
Figurer 4-17.
TMF Life
Mechanical Strain Range, %
1 GT29+/GTD-111DS
180° OP Cycles
TMF Model 2X
LSQ Regression
∆εm = 4.869Nf-0.31
Minimum Line
-0.31
∆εm = 3.92Nf
1/2 Νf of Minimum
∆εm = 3.162Nf-0.31
GT29+/GTD-111DS
(600 - 1850°F, 1 cpm
2 min dwell)
0.1
10 100 1000 10000
Cycles-To-Failure
Figure 4-16
TMF strain-life relations developed based on experimental data of GT29+ coated
GTD-111DS.
4-14
TMF Life

1 GT33+/GTD-111DS
180° OP Cycles
2X
TMF Model
LSQ Regression
∆εm = 3.32Nf-0.249
GT33+/GTD-111DS
Minimum Line (600 - 1850°F, 1 cpm
∆εm = 2.95Nf-0.249 2 min dwell)
1/2 Νf of Minimum GT33+/GTD-111DS
(600 - 1650°F, 1 cpm
∆εm = 2.482Nf-0.249 2 min dwell)
0.1
10 100 1000 10000
Cycles-To-Failure
Figure 4-17
TMF strain-life relations developed based on GT33+ coated GTD-111DS.
To predict TMF failure, Eq., (4-1) is recast into the expression given by
1/α
 C 
Nf =   Equation 4-2
 ∆ε m 
in which the mechanical strain range needs to be determined from a transient aerothermal
analysis. Under EPRI sponsorship, transient aerothermal analyses were performed for 9FA
and 7FA+ machines by Turbine Technology International (TTI) and for 6B machines by
KEMA [4, 17, 18]. Results of these transient aerothermal analyses are summarized in Table 4-3.
Details of these analyses are available from previous reports [4, 17, 18]. In addition to results
reported by TTI and KEMA, interpolated and extrapolated results of the TMF strain ranges are
also given in Table 4-3 to cover the whole range of trip conditions involving partial and full
loads. The TMF life for a critical location in a blade can be predicted from Eq. (4-2) using the
mechanical strain range value shown in Table 4-3 for the operation condition of interest.
4-15
Table 4-3
TMF strain ranges obtained by transient aerothermal analyses for 9FA, 7FA+ and 6B
machines.
TMF Strain Ranges
Max. Metal Temp. Startup/ Startup/

Normal Startup/
part load part load
GEM/Model Coating Startup/ full load Location Reference
(30%) trip (80%) trip
Deg. F Deg. C shutdown trip cycle
cycle cycle
Leading Edge
0.37-
GT29+* 1700-1750 927-954 0.32% 0.46-0.54% 0.50-0.60% (Midspan TT1 [17]
0.40%
50% BH)
9FA
Not Not Not Pressure Side
GT29+ 1550-1600 843-871 0.60%
Available Available Available (20% BH)
Leading Edge
GT29+ 1723 939 0.40% 0.42% (a) 0.45% 0.46 (b) EPRI [4]
(50% BH)
Suction Side
GT29+ 1698 926 0.70% 0.70% 0.71% 0.71% (b)
(50% BH)
7FA+
Pressure Side
GT29+ 1623 884 0.65% 0.65% 0.66% 0.66%
(50% BH)
Trailing Edge
GT29+ 1600 871 0.70% 0.70% 0.71% 0.71%
(Bottom Slot)
GT29+ 1609 876 0.20% 0.37% (a) 0.46% (a) 0.53% Leading Edge EPRI [18]
GT29+ 1763 962 0.26% 0.27% (a) 0.29% (a) 0.30% Trailing Edge
GT29+ 1653 900 0.14% 0.17% (a) 0.21% (a) 0.23% Pressure Side
6B
GT29+ 1722 939 0.21% 0.29% (a) 0.43% (a) 0.48% Suction Side
st
Aluminide 1494 812 0.21% 0.34% (a) 0.55% (a) 0.64% 1 Cooling Hole
th
Aluminide 1489 809 0.37% 0.40% (a) 0.44% (a) 0.46% 5 Cooling Hole
Notes:
(a) Linear interpolation using TMF strain ranges for normal startup/shutdown and trip cycles
(b) Linear extrapolation using TMF strain ranges for normal startup/shutdown and 80% load trip cycles
* Also applicable for GT33 and GT33+ for all machines.
TMF Model Validation Frame 7FA/9FA Blades
For TMF model validation, a Frame 7FA blade was obtained. From this blade, two transverse
sections at the 55% and 10% height locations were removed by an electro discharge machining
(EDM) process. Several metallurgical mounts were prepared from these sections. Figure 4-18
illustrates the location of these transverse sections and the metallurgical mounts. These mounts,
along with the mounts prepared from the triangular 9FA blade section received from KEMA,
were examined for thermal fatigue cracking. The locations of the mounts that were prepared
from the Frame 9FA blade section are illustrated in Figure 4-19.
4-16
(a)
(b)
Figure 4-18
a) Photograph of the as-received Frame 7FA blade showing locations of transverse
sections removed at 10% and 55% blade heights. (b) Optical photographs showing
metallurgical mounts prepared from the transverse sections. The numbers on the
photographs denote locations where TMF cracks ere observed.
4-17
(a)
(b)
Figure 4-19
(a) Photograph of the as-received 9FA blade section received from KEMA. The numbers
towards the trailing edge denote approximate locations where pyrometer measurements
were documented. (b) Photograph showing metallurgical sample locations. The samples
are identified by the pyrometer position numbers.
Both Frame 7FA and 9FA blades were GTD-111 DS blades and had a GT29+ coating. The
coating thickness on these blades was about 9 mils. The Frame 7FA and 9FA blades had
operated for 21,000 and 17,188 hours and experienced 100 and 104 start-stop cycles,
respectively. The details of the Frame 9FA blade condition along with the coating and base
material microstructures were presented in References 3, 4, and 15.
Several TMF cracks were observed on both blades. The locations where TMF cracks were
observed on 7FA on the 7FA blade are marked on the photograph, (See Figure 4-18). The depth
of these cracks are given in Table 4-4 and varied from 2 to 14 mils (51 to 356 µm). At the 55%
blade height, the cracks on the leading edge and on the suction side of the airfoil near Cooling
Holes 4 and 6 had progressed into the base metal. The cracks at other locations, both the 55%
and 10% airfoil height locations, were limited to the coating.
4-18
Table 4-4
Locations of TMF cracks on Frame 7FA Stage 1 blade.
Blade Height Location as Marked on Figure 4-18 Crack Depth, mils* (µm)
55% 1 Leading Edge 13 ( 330)**
2 Near leading edge (towards pressure side) 4 (101)
5 Near cooling hole 4 (suction side) 14 (356)**
4 Near cooling hole 4 (pressure side) 4 (101)
7 Near cooling hole 6 (suction side) 14 (356)**
6 Near cooling hole 6 (Pressure side) 4 (101)
9 Near cooling hole 7 (suction side) 4 (101)
10% 3 Leading Edge (towards suction side) 7 (178)
2 Leading Edge (towards pressure side) 7 (178)
7 Cooling hole 6 (suction side) 9 (229)
6 Cooling hole (pressure side) 7 (178)
10 Trailing edge 2 (51)
* 1 mil = 0.001 inch

** Cracks propagated into the blade material
For TMF cracks, the transverse section removed from the Frame 9FA blade at the Pyrometer
Position 9 was examined from the leading edge to the trailing edge. This position corresponds to
approximately the 50% airfoil height of the blade. In addition, the sections removed from
Pyrometer Positions 7, 5, and 3 (for locations refer to Figure 4-19) were also examined under a
microscope. TMF cracks observed on the microsections at different pyrometer positions are
illustrated in Table 4-5. The locations where TMF cracks were seen are shown in Figure 4-20.
The depth of these cracks varied from 1 to 9 mils (25 to 229 µm).
4-19
Figure 4-20
Optical photograph showing the mounts prepared from the transverse section. The
numbers on the photograph denote locations where TMF cracks were observed.
Table 4-5
Locations of TMF cracks on Frame 9FA Stage 1 Blade.
Pyrometer Position Location (Marked on Figure 4-20) Crack Depth, mils* (µm)
9 1 Leading edge suction side 5 (127 µm)
9 2 Leading edge pressure side 5 (127 µm)
9 3 Airfoil suction side 6 (152 µm)
9 4 Airfoil pressure side 4 (102 µm)
9 6 Airfoil pressure side 5 (127µm)
9 Trailing edge 14 5 (127 µm)
7 2 Leading edge pressure side 5 (127 µm)
5 1 Leading edge suction side 6 (152 µm)
3 4 Airfoil Pressure side 1 (25 µm)
3 10 Airfoil Pressure side 5 (127 µm)
* 1 mil = 0.001 inch
4-20
The cracks on the Frame 9FA blade were limited to the coating and they did not propagate into
the substrate alloy. On the suction side of the airfoil blade at Pyrometer Position 3 (Location 5),
the crack progressed up to the interdiffusion zone.
The morphology of TMF cracks on both Frame 7FA and Frame 9FA blades was similar. Typical
morphology of cracks is shown in Figures 4-21 and 4-22. The cracks in the coating were filled
with oxide scale and a β-phase depleted zone was observed in the CoCrAlY coating in the
vicinity of TMF cracks. No evidence of internal oxidation attack in the coating adjacent to the
cracks was seen.
(a) (b) (c)

Figure 4-21
Optical micrographs showing morphology of TMF cracks on Frame 9FA blade, (a)
Location 9 (Pyrometer Position 9), (b) Location 8 (Pyrometer Position 9), and (c) Location 1
(Pyrometer Position 3).
4-21
(a) (b)
(c)
Figure 4-22
Optical micrographs showing morphology of TMF cracks on Frame 7FA blade, (a) Leading
edge (Location 1), (b) Suction side of the airfoil (Location 7), (c) Suction side of the airfoil
(Location 5).
Validation of the TMF model involved comparisons of predicted critical locations and calculated
TMF lives against field observations. These comparisons were made for both Frame 7FA and
Frame 9FA blades with GT29+ coatings using the results shown in Table 4-3, Figure 4-16 and
Eq. (4-2). The TMF life curve for GT29+/GTD-111DS is presented in Figure 4-23. The critical
locations for Frame 9FA blades are (1) leading edge at 50% blade height, and (2) pressure side
at 10% blade height. The TMF strain range for leading edge at 50% blade height is 0.32%. There
is no information on the TMF strain range at the pressure side and the suction side at 50% blade
height. Assuming a worst case scenario, the TMF strain ranges at PS and SS are taken to
be 0.32%, as at the leading edge. The predicted TMF life for this strain range is 1620 cycles
compared to a service history of 104 startups and 30 trips for the 9FA blade. The TMF model
predicted that the Frame 9FA blade was in good condition and was far from TMF failure, as
shown in Figure 4-23. Metallographic examination of the sectioned blade indicated the presence
of TMF cracks in the coating at the leading edge, suction side and pressure side, but none of the
TMF cracks extended into the base metal. Thus, no TMF failure was observed in the Frame 9FA
blade, as predicted by the TMF model.
4-22
GT29+/GTD-111DS TMF Model

(600 - 1850°F, 1 cpm
LSQ Regression
2 min dwell) -0.31
∆εm = 4.869Nf
7FA Field Data, 50%BH
13 - 14 mil Cracks Minimum Line
-0.31
Cracked into Base Metal ∆εm = 3.92Nf
9FA Field Data, 45%BH 1/2 Νf of Minimum

6 mil coating cracks
1
-0.31
∆εm = 3.162Nf
2X
PS, SS
TMF Life
Coated DS Ni-Alloys
180° OP Cycles
0.1
10 100 1000 10000
Cycles-To-Failure
Figure 4-23
Predicted TMF lives compared against field data for Frame 7FA and 9FA blades coated
with GT29+ coatings. The field data correspond to the suction side (SS) and pressure side
of Cooling Holes 4 and 6.
Transient aerothermal analysis is not available for Frame 7FA. To compare against Frame 7FA
field data, transient aerothermal analysis results for Frame 7FA+ were used. Since showerhead
cooling is used in Frame 7FA+ blades but not in Frame 7FA blades, field data for the leading
edge were excluded from comparison against model prediction. The TMF strain range at the
suction side is about 0.7%. For a strain range of 0.7%, the predicted TMF life is 130 cycles,
compared to the field data of 100 startups and an unknown number of trips. Assuming the
number of trips was equal to those found in the Frame 9FA blade, the total number of startups
would be about 130 cycles. Thus, the TMF model predicted that the Frame 7FA blade had either
failed by TMF or was close to TMF failure at the suction side as shown in Figure 4-23.
Metallographic examination of the sectioned blade indicated the presence of 350 µm TMF cracks
in the coating at the suction side of Cooling Holes 4 and 6 (Table 4-4). These TMF cracks
extended into the base metal. Thus, the Frame 7FA blade appeared to have failed by TMF at the
suction side of Cooling Holes 4 and 6 after ≈ 100 - 130 startup cycles. Both the number of
startup cycles and the failure location were predicted by the TMF model.
Validation of the TMF model for GT33+ coated blades involved using Eq. (4-2), the results
shown in Figure 4-17 and Table 4-3, and field data from Korean Power Company. TMF cracks
were found at several locations in GT33+ coated 1st stage 7FA buckets operated by Korean
Power Company (KEPCO) [4, 19]. In particular, TMF cracks were detected in the suction side
at 50% Blade Height (BH) after 250 starts and 4700 hours [4]. In addition, TMF cracks were
detected in the suction side at 20% BH after 272 starts and 6156 hours [19]. In both cases,
the TMF cracks initiated from the coating and extended into the base metal. According to the
transient aerothermal analysis by TTI, the TMF strain range is 0.70% at the suction side
4-23
and 50% BH (Table 4-3). TTI’s calculation also reported that the TMF strain range is 0.60%
for 20% BH in the pressure side, but the TMF strain range for 20% BH in the suction side was
not reported. Based on the TMF strain results for 9FA and 7FA+ shown in Table 4-3, the TMF
strain range for 20% BH in the suction side was estimated to be 0.65%. Using Eq. (4-2), the
predicted TMF lives were 217 and 161 for 20% BH and 50% BH, respectively. In comparison,
the TMF cracks were observed after 272 and 250 cycles for 20% and 50% BH, respectively.
Thus, the predicted TMF lives for GT33+ are in excellent agreement with field observations, as
shown in Figure 4-24.
Figure 4-24
Predicted TMF lives were compared against field data for Frame 7FA 1st stage blades
coated with GT33+ coating. The field data corresponded to the suction side (SS) of 1st
stage blades at 20% and 50% blade height (BH).
Guidelines on Metal Temperatures and TMF Strain Ranges
Guidelines on the metal temperatures and TMF strain range at critical locations of various
machines were updated and the results are shown in Figure 4-25 and Figure 4-26, respectively.
These two tables were incorporated into the COATLIFE-2 spreadsheet program [20].
The updated program, which is now referred to as COATLIFE-3, has a revised GUI with a
pull down menu that contains two additional buttons for “Metal Temperature” and “TMF
Strain.” A user can obtain information on the metal temperature for various gas turbine
machines by clicking the “Metal Temperature” button, which will bring down a look-up table
containing the metal temperatures for GT blades in a variety of machines, Figure 4-25. Similarly,
pushing the “TMF Strain” button will bring down a table, Figure 4-26, containing available TMF
strain ranges for a limited number of machines for various operational conditions. Information
contained in this table was compiled based on results of aero-thermal analyses [4, 17, 18]
performed by TTI and KEMA for EPRI.
4-24
Figure 4-25
Look-up table containing information on metal temperatures for first-stage combustion
turbine blades.
4-25
Figure 4-26
Look-up table for TMF strain ranges for 9FA, 7FA+, and 6B machines.
4-26
5
FURTHER VALIDATION OF COATLIFE OXIDATION
MODEL
The objectives of this task are to estimate blade metal temperatures using the previously
developed time-temperature correlation curves based on coating degradation [3], and use those
temperatures to further validate the COATLIFE oxidation life model by comparing the
calculated values of the remaining β-phase and aluminum content with the metallographic
results.
Background
A service run first stage blade of a Frame 7EA engine was procured. The turbine was reported to
have fired with natural gas and the firing temperature was reported to be 2020°F (1104°C). The
blade was a conventionally cast (equiaxed) GTD-111 and was coated with GT29+. The blade
had twelve radial cooling holes, which were coated with aluminide, and was operated for 22,459
hours with 328 start-stop cycles. The condition of the blade in the as-received condition is shown
in Figure 5-1.
Figure 5-1
As received condition of first stage blade of Frame 7EA engine. The arrows point to the
section removed for metallographic evaluation.
5-1
Further Validation of Coatlife Oxidation Model
Metallography and Temperature Estimation
A transverse section was removed from the leading edge to the trailing edge at approximately
the 55% blade height location using an electro discharge machining process. The transverse
section location is illustrated in Figure 5-1. The operating temperature is expected to be
maximum at this location. Several metallurgical mounts were prepared from this section and
were examined for coating degradation. The examinations showed that the coating was GT29+.
Thickness of the CoCrAlY and aluminide coatings varied from 6.2 to about 7 mils (157
to 178 µm) and 1.0 to 1.4 mils (25 to 30 µm), respectively. The coating was severely degraded at
the 55% airfoil height. The coating degradation was evidenced by transformation of the β-phase
into γ in the top aluminide coating, coarsening and depletion of the β-phase particles in the
CoCrAlY coating, and enlargement of the interdiffusion zone width below the CoCrAlY coating.
The extent of coating degradation varied from location to location.
Figure 5-2 shows the typical condition of the coating at several locations from the leading edge
to the trailing edge of the blade. At all locations, a small γ-phase layer was observed at the outer
surface of the top aluminide coating. Loss of aluminum from the top aluminide coating due to
spallation and re-formation of the protective oxide scale during service led to transformation of
the β-phase into the γ-phase. The γ-phase contained about 2.4 wt.% aluminum. The
transformation of the β-phase into γ-phase, and aluminum content in the γ-phase are consistent
with the results reported by Cheruvu and Leverant [21] for the service run Frame 6 buckets.
Comparison of the γ-phase layer width in the top aluminide coating showed that the
transformation was most severe at the trailing edge and at an area on the suction side of the
airfoil near Cooling Hole 4. Comparison of the microstructures showed that the amount
of β-phase in the CoCrAlY coating was less at the trailing edge and the suction side near Cooling
Hole 4 compared to the other two locations examined. At these locations the β-phase in the top
aluminide coating was broken down and discontinuous as shown in Figure 5-2, which appeared
to provide a path for outward diffusion of aluminum from the CoCrAlY coating. This led to the
transformation of the β-phase into the γ-phase in the CoCrAlY coating. These results indicate
that the CoCrAlY coating partly provided aluminum for the formation of the surface protective
oxide scale. The extent of the transformation was least at an area on the pressure side near
Cooling Hole 4.
Typical microstructures of both CoCrAlY and the top aluminide coatings, and the variation of
the interdiffusion zone width among the locations examined is shown in Figures 5-3 through 5-6
at a higher magnification. It can be seen that the interdiffusion zone width was largest at the
trailing edge followed by an area on the suction side near Cooling Hole 4. The interdiffusion
zone width at an area on the pressure side near Cooling Hole 4 was the smallest among the
locations examined. Variation of the interdiffusion zone width from location to location was
consistent with the variation of the γ-phase layer observed among these locations. These results
indicate that the metal temperature varied from location to location at the 55% blade height. The
trailing edge was exposed to the highest temperature, and the airfoil area on the pressure side
near Cooling Hole 4 had seen the lowest temperature during service.
5-2
(a)
(b)
(c) (d)
Figure 5-2
Optical micrographs of coating on a service run Frame 7EA first stage blade at the 55%
airfoil height. (a) Leading edge. (b) Suction side near Cooling Hole 4. (c) The pressure side
of the airfoil near Cooling Hole 4. (d) Trailing edge.
5-3
Figure 5-3
Microstructure of the coating at the leading edge of the Frame 7EA blade at the 55% airfoil
height.
Figure 5-4
Microstructure of the coating on the suction side of the airfoil near Cooling Hole 4 (55%
height). Note the width of the interdiffusion zone, which was larger than the one observed
at the leading edge (Figure 5-3).
5-4
Figure 5-5
Microstructure of the coating on the pressure side of the airfoil near Cooling Hole 4.
Figure 5-6
Optical micrograph showing the microstructure of the coating at the trailing edge (55%
airfoil height)
5-5
To determine the aluminum content, energy dispersive spectroscopic (EDS) analysis was
performed at several areas on the top aluminide coating. Volume fraction of the β-phase in the
top aluminide coating was determined using quantitative metallography techniques. Since
the β-phase in the top aluminide coating was discontinuous at the trailing edge and the suction
side of the airfoil, volume fraction of the β-phase in the overall coating was also determined at
these locations. Coating thickness, average aluminum content, and the volume fraction of
the β-phase in the top aluminide coating at different locations are presented in Table 5-1. In the
as-coated condition, the top aluminide coating typically contains about 25-28% aluminum [22].
The aluminum content in the top aluminide at all locations examined was significantly lower
than the original amount. The volume fraction of the β-phase in the top aluminide coating at the
trailing edge dropped to about 43% from the original amount of 100% in the as-coated condition.
The aluminum content and volume fraction of the β-phase were found to be lowest in the top
aluminide coating at the trailing edge. The volume fraction of the β-phase in the coating on the
suction side (SS) of the airfoil near Cooling Hole 4 was almost comparable to that of the trailing
edge. These results also show that that coating was severely degraded at the trailing edge and at
an area on the suction side, near Cooling Hole 4.
Table 5-1
Variation of the β-phase and aluminum content in the different top aluminide locations at
the 55% airfoil height.
Volume Fraction of
Coating Thickness
Average Al β-phase, %
Location Content,
(wt.%) Top Overall
CoCrAlY Aluminide
Aluminide Coating
Leading Edge Tip 7.0 mils (178 µm) 1.2 mils (30 µm) 16.5 70.9 ND
Cooling Hole 4, SS* 6.2 mils (157 µm) 1.4 mils (36 µm) ND* 46.8 29.6
Cooling Hole 4, PS* 6.8 mils (173 µm) 1.0 mil (25 µm) 14.6 66.3 ND
Trailing Edge Tip 7.0 mils (178 µm) 1.0 mil (25 µm) 10.7 43.4 31.7
*ND = Not determined; SS = Suction side of the airfoil; PS = pressure side of the airfoil
Temperature Estimation
The interdiffusion zone growth is due to the diffusion of elements from the coating into the
substrate and vice versa during service and, therefore, it is a diffusion-controlled process.
The change in the interdiffusion zone width is used to estimate the blade metal temperature
[3, 23, 24]. Time-temperature correlation curves were developed for various coatings under this
program. The temperatures estimated using these curves were previously compared with the
pyrometer-measured temperatures for Frame 6 and Frame 9 blades (last year’s report). The
estimated temperatures were in good agreement with the measured results.
5-6
To estimate local metal temperature, interdiffusion zone widths were measured. The average
interdiffusion zone widths at different locations are given in Table 5-2. Using the previously
developed time-temperature relationship (Equation 3-2 reported in Reference 3), local metal
temperatures were estimated at these locations. These results are also shown in Table 5-2. The
estimated metal temperature varied from 1661°F (905°C) to 1746°F (952°C). The results showed
that the trailing edge had been exposed to the highest metal temperature and the location on the
airfoil near Cooling Hole 4 on the pressure side experienced the lowest metal temperature. The
maximum temperature of 1746°F (952°C) at the trailing edge is considered to be normal for
Stage 1 Frame 6 and Frame 7 blades. The maximum metal temperature at the trailing edge of a
Frame 6 blade was reported to be 1742° (950°C) by Wood [25].
Table 5-2
Calculated metal temperature using variation of the interdiffusion zone width at different
locations at the 55% blade airfoil height.
Average Interdiffusion Zone Width Calculated Temperature

Location
Mils Microns °C °F
Leading Edge Tip 2.4 60.0 916 1681
Cooling Hole 4, SS* 3.3 82.9 944 1731
Cooling Hole 4, PS* 2.1 52.4 905 1661
Trailing Edge 3.6 91.3 952 1746
COATLIFE Validation
The validation of COATLIFE against the field data of 7EA blades was carried out in two parts.
First, the accuracy of COATLIFE-2 [20], the simplified spreadsheet program, in predicting the
remaining life of a 7EA blade under field conditions was verified. Second, the accuracy
of COATLIFE [26], the more complex FORTRAN program, in predicting the Al contents and
the volume percents of the β-phase remaining in the coating of a 7EA blade after service was
evaluated. Two levels of validation were required because coating life results generated
by COATLIFE [26] were parameterized and used to develop the spreadsheet lifing tools utilized
in COATLIFE-2 [20].
The remaining coating life of the 7EA blade after service was predicted using COATLIFE-2
[20]. Input data required for the coating life prediction were the maximum blade metal
temperature, the number of startup/shutdown cycles, and the cycle time. The maximum metal
temperatures that were determined by the temperature estimation method described in the
previous section were used in the life prediction calculations. As summarized in Table 5-2, the
maximum metal temperatures in the 7EA blades ranged from 1661°F (905°C) at the pressure
side of Cooling Hole 4 to 1746°F (952°C) at the trailing edge. The maximum metal temperatures
were 1681°F (916°C) at the leading edge and 1731°F (944°C) at the suction side of Cooling Hole
4, respectively. There were 328 startup/shutdown cycles that averaged about 68 hours per cycle.
The coating lives at these four locations of the 7EA blade were predicted and the results are
5-7
presented in Table 5-3 in terms of cycles-to-failure and times-to-failure, together with the
percentages of life consumed, the remaining life, and the coating status. As shown in Table 5-3,
the lowest coating life was predicted for the trailing edge, which experienced the highest
temperature (≈ 1750°F ((954°C)) among the four locations. About 99.6% of the coating life at
the trailing edge was consumed. The predicted remaining life was only 0.4% or ≈ 88 hours.
Figure 5-7 shows a comparison of the calculated coating life diagram against the field data of
the 7EA blade for the trailing edge location. The data point lies just below the coating life
boundary, indicating that the coating is almost completely consumed. Coating degradations at the
suction side, pressure side, and leading edge were less severe. The predicted remaining lives
are 4700, 27,000 and 39,000 hours at the suction side, pressure side, and leading edge,
respectively. A summary of the coating conditions at the four locations of the 7EA blade is
shown in Figure 5-8.
Table 5-3
Predicted values of coating life, life consumed, remaining life and coating status at four
locations of a 7EA blade after service.
Cycle Number Coating Life Life Remaining Life

Temp., Coating
Location Time, of Consumed,
°F Status
hr. Startups Cycles Time, hr. % Cycles Time, hr.
Leading
1681 68 328 725 49,300 45.2 397.2 27,000 Safe
Edge
Cooling
1731 68 328 397 27,000 82.6 69.2 4,700 Safe
Hole 4, SS
Cooling
1661 68 328 913 62,081 35.9 585.0 39,800 Safe
Hole 4, PS
Trailing
1746 68 328 329 22,400 99.6 1.3 88.4 Safe
Edge
5-8
105
GT29+ Coating
GTD -111 Substrate
104 COATLIFE
No. of Startup Cycles

954°C (1750°F)
7EA Trailing Edge
COATLIFE
103
Failure Boundary
102
Failed Coatings
Protective Coatings
101
100
100 101 102 103 104 105
Cycle Time, Hrs
Figure 5-7
Calculated coating life diagram compared against field data for GT29+ coating at the
trailing edge of a 7EA blade after 328 startup/shutdown cycles that averaged a cycle time
of 68 hours per cycle.
106
COATLIFE
Failure Boundary
7EA Field Data
Time-To-Failure, hrs
Failed Coatings Trailing Edge

Leading Edge
Cooling Hoe 4, PS
Cooling Hole 4, SS
105
Protective Coatings
GT29+ Coating
GTD -111 Substrate
104
800 900 1000
Metal Temperature, °C
Figure 5-8
Predicted times-to-failure compared against field data of coating at four locations of a 7EA
blade after 328 startup/shutdown cycles that average a cycle time of 68 hours per cycle.
5-9
The COATLIFE code [26] was used to predict the depletion of Al content and β-phase in
the 7EA blade as functions of the number of startup/shutdown cycles and the local metal
temperature at the location of interest. The calculated Al content and the volume percent of
the β-phase for the trailing edge are compared against experimental data in Figures 5-9(a)
and (b), respectively.
40
Aluminum Depletion
954°C, 55%BH
30 68 Hr Cycle Time
COATLIFE
Al Content, %
Prediction
7EA Field Data
Trailing Edge
20
10
Nf = 398 Cycles
0
0 100 200 300 400 500
Number of Start-Up Cycles

(a)
100
Aluminum Depletion
Vol Percent β Phase, %
80 954°C, 55%BH
68 Hr Cycle Time
COATLIFE
Prediction
60 7EA Field Data
Trailing Edge
40
Nf = 398 Cycles
20
0
0 100 200 300 400 500

(b)
Figure 5-9
Predicted Al and β-phase depletion compared against field data for the trailing edge of
a 7EA blade after service: (a) Al depletion, and (b) β-phase depletion.
5-10
Similar comparisons for the suction side (Cooling Hole 4), pressure side (Cooling Hole4),
and the leading edge tip are presented in Figures 5-10, 5-11, and 5-12, respectively.
40
Aluminum Depletion
944°C, 55%BH
30 68 Hr Cycle Time
COATLIFE
Al Content, %
Prediction
7EA Field Data
Cooling Hole 4
20 Suction Side
10
Nf = 468 Cycles
0
0 100 200 300 400 500 600

(a)
120
Aluminum Depletion
100
Vol. Percent β Phase, %
944°C, 55%BH
68 Hr Cycle Time
COATLIFE
80 Prediction
7EA Field Data
Cooling Hole 4
60 Suction Side
40
Nf = 468 Cycles
20
0
0 100 200 300 400 500 600

(b)
Figure 5-10
Predicted Al and β-phase depletion compared against field data for the suction side
(Cooling Hole 4) of a 7EA blade after service: (a) Al depletion, and (b) β-phase depletion.
Note: The Al content is not available for this location.
5-11
40
Aluminum Depletion
904°C, 55%BH
68 Hr Cycle Time
30 COATLIFE
Prediction
Al Content, %
7EA Field Data
Cooling Hole 4
Pressure Side
20
10
Nf = 930 Cycles
0
0 200 400 600 800 1000

(a)
120
Aluminum Depletion
100
904°C, 55%BH
68 Hr Cycle Time
COATLIFE
80 Prediction
7EA Field Data
Cooling Hole 4
60 Pressure Side
40
Nf = 930 Cycles
20
0
0 200 400 600 800 1000

(b)
Figure 5-11
Predicted Al and β-phase depletion compared against field data for the pressure side
(Cooling Hole 4) of a 7EA blade after service: (a) Al depletion, and (b) β-phase depletion.
5-12
40
Aluminum Depletion
916°C, 55%BH
30 68 Hr Cycle Time
COATLIFE
Al Content, %
Prediction
7EA Field Data
Leading Edge
20
10
Nf = 753 Cycles
0
0 200 400 600 800 1000

(a)
120
Aluminum Depletion
100
916°C, 55%BH
68 Hr Cycle Time
COATLIFE
80 Prediction
7EA Field Data
Leading Edge
60
40
Nf = 753 Cycles
20
0
0 200 400 600 800 1000

(b)
Figure 5-12
Predicted Al and β-phase depletion compared against field data for the leading edge of
a 7EA blade after service: (a) Al depletion, and (b) β-phase depletion.
In addition, the calculated and observed Al contents and volume percents of the β-phase are
compared in Table 5-4. The comparison indicates that the predicted Al contents and volume
percents of β-phase are in good agreement with experimental data for the trailing edge, suction
side, and pressure side. The predicted volume fraction of β-phase and % Al were too low at the
leading edge. The under-predictions have been attributed to the high temperature gradients at the
5-13
leading edge, which makes precise determination of the diffusion zone width, local temperature,
Al content, and volume percent of β-phase difficult. However, the predicted life is conservative.
Table 5-4 also shows that the coating life predictions made by COATLIFE and the results of the
simplified spreadsheet program, COATLIFE-2, are in good agreement. Thus, the accuracy of
COATLIFE-2 was validated for the 7EA blade.
Table 5-4
Comparison of predicted coating life, Al content, and volume percent of β-phase for
coating at four locations of a 7EA blade after service.
Cycle Coating Life Cycles AL Content, at.%

Temp., Vol. % β, %
Location Time,
°F COATLIFE MEASURED
hr. COATLIFE-2 COATLIFE COATLIFE MEASURED
Leading
1681 68 329 398 21.5 29.9 52.5 70.9
Edge
Cooling
1731 68 397 468 15.2 ND* 28.6 29.6
Hole, SS
Cooling
1461 68 913 930 23.5 26.8 60.0 66.3
Hole, PS
Trailing
1746 68 725 753 12.2 11.4 16.9 31.7
Edge
5-14
6
GUIDELINES FOR TURBINE OPERATORS
Bucket Coating Oxidation Life
The most desirable method to determine the remaining oxidation life (prior to refurbishment) of
an in-service coating is by non-destructive means. This might be accomplished on-site when the
upper casing has been removed or on buckets that have been removed for more detailed
examination. EPRI has projects underway to develop NDE methods to measure coating
conditions, including the extensively used duplex coatings such as GT29+ and GT33+. It is
anticipated that ultimately the appropriate NDE data will be fed into COATLIFE to compute the
remaining coating life.
Until the NDE method is developed and validated, other approaches can be used. The most direct
is to enter the average number of hours of operation per cycle, the number of start-stop cycles,
and the maximum bucket temperature (from a look-up table in the user’s manual) into the
COATLIFE spreadsheet and the remaining life will be automatically computed. Several
examples of how to use the spreadsheet are detailed in the user’s manual that accompanies the
COATLIFE software [27].
Because the maximum blade temperature can be dependent on a particular user’s operational
practice, a second approach to compute the remaining life involves destructive sectioning of a
bucket. Based on the size of the interdiffusion zone between the coating and substrate, the
location of the hot spots can be determined as well as the bucket temperature at that location.
Calibration curves between interdiffusion zone size and temperature have been developed for
several coating/substrate combinations in this project [3]. Once the temperature is obtained, the
use of the spreadsheet is identical to that described above
It is important to remove the buckets from service prior to the computed remaining life in order
to avoid oxidation of the superalloy substrate. Oxidation of the substrate can preclude the ability
to refurbish the bucket by stripping the coating, re-heat treating, and re-coating.
Bucket Thermomechanical Fatigue (TMF) Life
The startup/shutdown cycles of the turbine may result in the development of TMF cracks in the
protective coating. The formation of these cracks is exacerbated by trips from full load operation.
Depending upon the future operation of the turbine, these cracks may remain entirely confined to
the coating or may propagate into the superalloy substrate. Propagation of the cracks into the
substrate generally renders the bucket unsuitable for refurbishment.
6-1
Guidelines for Turbine Operators
The TMF life of several coating/substrate combinations can also be computed from the
COATLIFE spreadsheet. A look-up table provides the strain ranges for fired shutdowns and for
trips. Entering this information into the spreadsheet provides the operator the total number of
cycles that can be run prior to refurbishment. See the COATLIFE user’s manual.
The design curves for TMF life in COATLIFE are conservative. The curves were drawn at a
position that is a factor of two lower than the minimum data obtained in laboratory testing, and
the lab testing, itself, is generally conservative. This provides some flexibility to the operator in
terms of the time at which the buckets must be refurbished.
Whether oxidation life of the coating or TMF cracking is life limiting will be a direct result of
exercising the COATLIFE spreadsheet for both failure modes. Clearly, peaking operators have to
be more vigilant regarding the possibility of TMF failures
6-2
7
PROJECT SUMMARY
The previously developed COATLIFE model was extended to a user-friendly spreadsheet

format. The spreadsheet is capable of computing the original or remaining oxidation life and the
TMF life of several coatings, including GT29+ and GT33+, on GTD-111DS buckets. The user
simply enters the average operating hours per start and the number of start/stop cycles (including
trips) and obtains bucket temperature and strain range input data from pull-down tables. The
output provides information on percent of the life consumed and the remaining life in terms of
number of starts. The code also handles variable turbine operating conditions. A comprehensive
user’s manual accompanies the software.
In instances where the local bucket temperature is unknown, a method was developed to estimate
the temperature. The width of the interdiffusion zone between the coating and base metal was
used to develop time-temperature relationships for estimating the local blade temperature for
several coating/blade alloy combinations. Some of these relationships were used to predict actual
blade temperatures for Frame 6B and Frame 9FA turbines operated by KEMA. Good
correlations between pyrometer-measure and predicted temperatures, as well as temperature
profiles, demonstrated by the validity of using interdiffusion zone widths to establish actual,
local blade operating temperatures. Further validation was obtained by detailed analysis of a
service-operated Frame 7EA bucket where the temperatures estimated by measuring the width
of the interdiffusion zone were used to correctly predict the remaining aluminum content in
the GT29+ coating.
The TMF design curves for GT29+ and GT33+ coatings on GTD-111DS were developed based
on TMF testing in this project. The design curves were validated by examination of cracked 7FA
and 9FA buckets coated with GT29+ and a cracked 7FA bucket coated with GT33+. Limited
testing on GT33, i.e., without the aluminide overlayer, indicated improved TMF resistance
compared to GT33+. This is important for operators of peaking units.
Development of life prediction algorithms for air-plasma-sprayed (APS) thermal barrier

coating (TB’s) was initiated. Model development was completed. Initial isothermal and cyclic
laboratory tests were run on GTD-111DS coated with a NiCoCrAlY bond coat (similar to GT33)
and an APS TBC. Cracking and spallation data from these tests, in conjunction with additional
data to be obtained in a follow-on project, will be used to calibrate the life model algorithms for
eventual incorporation into the COATLIFE spreadsheet.
7-1
8
REFERENCES
1. Cheruvu, N.S., Chan, K.S., and Leverant, G.R.: “Blade Life Management System for GE
Frame 7FA/9FA Gas Turbine: 1998 Interim Report, EPRI, Palo Alto, CA, Report No. TR-
111548, 1998.
2. Cheruvu, N.S. Chan, K.S., and Leverant, G.R.: “Blade Life Management: Coating Systems”
EPRI, Palo Alto, CA, Report No. TR-113899, 1999.
3. Cheruvu, N.S., Chan, K.S., and Leverant, G.R.: “Combustion Turbine Hot Section Life
Management: High Temperature Coating Systems,” EPRI, Palo Alto, CA, Report No.
1000432, 2000.
4. Dewey, R., and Huslhof, H.: “Combustion Turbine F-Class Life Management: General
Electric FA First Stage Blade Analysis,” EPRI Solutions, Palo Alto, CA, Report
No. 1000318, 2000.
5. Chan, K.S., Cheruvu, N.S., and Leverant, G.R.: “Development of COATLIFE  A Life
Prediction Code for Hot Section Combustion Turbine Coatings,” EPRI, Palo Alto, CA,
Report No. TR-109731, 1997.
6. Chan, K.S., Cheruvu, N.S., and Leverant, G.R.: “Degradation and Life Prediction of Gas-
Turbine Duplex Coatings,” Materials Science Forum, Vol. 369-372, pp. 623-630, 2001.
7. Miller, R.A.: “Progress Towards Life Modeling of Thermal Barrier Coatings for Aircraft
Gas Turbine Engines,” ASME Paper 87-ICE-18, 1987.
8. DeMasi, J.T, Sheffler, K.D., and Ortiz, M.: “Thermal Barrier Coating Life Prediction Model
DevelopmentPhase I Final Report,” NASA CR-182230, 1989.
9. Meier, S.M., Nissley, D.M., Sheffler, K.D., and Cruse, T.A.: “Thermal Barrier Coating Life
Prediction Model Development,” ASME Paper 91-GT-40, 1991.
10. Cruse, T.A., Stewart, S.E., and Ortiz, M.: “Thermal Barrier Coating Life Prediction Model
Development,” J. Engineering for Gas Turbines and Power, Vol. 110, pp. 610-616, 1988.
11. Chan, K.S., Lee, Y.-D., Leverant, G.R., Fitzgerald, T.J., and Goedjen, J.G.: “Prediction of
Damage and Failure in Thermal Barrier Coatings,” Damage and Failure of Interfaces, edited
by H-P. Rossmanith, Balkema, Brookfield, VT, pp. 249-256, 1997.
8-1
References
12. Haynes, J.A., Ferber, M.K., Porter, W.D., and Rigney, E.D.: “Characterization of Alumina
Scales Formed During Isothermal and Cyclic Oxidation of Plasma-Sprayed TBC Systems at
1150°C,” Oxidation of Metals, Vol. 52, pp. 31-76, 1999.
13. Cheruvu, N.S., Swaminathan, V.P., and Kinney, C.D.: “Recovery of Microstructure and
Mechanical Properties of Service Run GTD-111DS Buckets,” Presented at the ASME
International Gas Turbine & Aeroengine Congress & Exhibition, Indianapolis, IN, Paper No.
99-GT-425, June 7-10, 1999.
14. Swaminathan, V.P. Cheruvu, N.S. Klein, J.M., and Robinson, W.M.: “Microstructure and
Property Assessment of Conventionally Cast and Directionally Solidified Buckets
Refurbished After Long-Term Service,” Presented at the ASME International Gas Turbine &
Aeroengine Congress & Exhibition, Stockholm, Sweden, Paper 98-GT-510, June 2-5, 1998.
15. Dewey, R. and Hulshof, H.: “Blade Management System for Advance F Class Gas
Turbines,” EPRI, Palo Alto, CA, Report No. TR-114312, 1999.
16. Gemma, A.E., Langer, B.S., and Leverant, G.R.: ASTM STP 612, pp. 199-213, 1976.
17. Wan, E: Turbine Technology International, Inc., private communication, June 2000.
18. Grant, T.S., Dannemann, K., Chan, K.S., and Leverant, G.R.: “Blade Life Management
System for GE Frame 6B Gas Turbines,” EPRI, Palo Alto, CA and KEMA Nederland B.B.,
Report TR-109196-V2, 1998.
19. Krzywosz, K.: EPRI, private communication, October 31, 2001.
20. Chan, K.S., Cheruvu, N.S., and Leverant, G.R.: Proceedings of the ASME International Gas
Turbine & Aeroengine Congress & Exhibition, Indianapolis, IN, Paper No. 99-
GT-381, 1999.
21. Cheruvu, N.S., and Leverant, G.R.: “Influence of Metal Temperature on Base Material and
Coating Degradation of GTD-111 Buckets,” ASME International Gas Turbine and Aero
Engine Congress and Exhibition, Stockholm, Sweden, Paper 98-GT-5111, June 1998.
22. Cheruvu, N.S. Chan, K.S., and Leverant, G.R.: “In-Service Degradation and Life Prediction
of Coatings for Advanced Land-Based Gas Turbine Buckets,” Proceedings of Creep 7, Japan
Society of Mechanical Engineers, Tsukuba, Paper SA-04-1(085), pp. 185-189, June 3-8,
2001.
23. Cheruvu, N.S., Carr, T.J., Dworak, J., and Coyle, J.: “In-Service Degradation of Corrosion
Resistant Coatings,” ASME International Gas Turbine & Aeroengine & Exhibition,
Birmingham, UK, Paper 96-GT-429, June 1996.
24. Srinivasan, V., Cheruvu, N.S., Carr, T.J., and O’Brien, C.M.: “Degradation of MCrAlY
Coatings and Substrate Superalloy During Long-Term Thermal Exposure,” Materials and
Manufacturing Processes, Vol. 10, pp. 955-969, 1995.
8-2
References
25. Wood, M.I., Raynor, D., and Cotgrove, R.M.: “Thermomechanical Fatigue of Coated
Superalloys for Gas Turbine Blading,” ERA Technology, Surrey, UK, ERA Report 96-1088,
1999.
26. Chan, K.S.: COATLIFE Version 2.0 User’s Manual, EPRI, Palo Alto, CA, Report
No. 1001145, 2001.
27. Chan, K.S.: COATLIFE Version 3.0 User’s Manual, EPRI, Palo Alto, CA, 2002 (in press).
8-3
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Blade Life Management: Coating Systems

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Final Report, February 2002

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2 SUMMARY OF PRIOR WORK ON THIS PROJECT .............................................................2-1

3 THERMAL BARRIER COATING LIFING...............................................................................3-1

4 THERMOMECHANICAL FATIGUE (TMF) TESTING OF FIRST STAGE BUCKET

TMF Model Validation Frame 7FA/9FA Blades...................................................................4-16

5 FURTHER VALIDATION OF COATLIFE OXIDATION MODEL ............................................5-1

6 GUIDELINES FOR TURBINE OPERATORS.........................................................................6-1

7 PROJECT SUMMARY ...........................................................................................................7-1

Figure 3-1 Summary of the TBCLIFE code................................................................................3-1

Table 3-1 Chemical Composition of Bond Coating Powder (wt.%)............................................3-9

Development of a Thermal Barrier Coating Life Model

Print Data Input

Calculate Mechanical Strain

Calculate Oxide Growth

Thermal Barrier Coating Lifing

Cycle Time, hrs

Calculation of Interface Temperature

Thermal Barrier Coating Lifing

Mechanical Strain Range

Thermal Barrier Coating Lifing

Time-Dependent Fatigue Strength Coefficient and Young’s Modulus

The fatigue strength coefficient, σ TBC

Thermal Barrier Coating Lifing

TBC Life Equation

The TBC life, Nf, can be obtained by recasting Eq. (3-5) as

where t* is the time-to-failure by oxidation alone at Nf = 1 and σ TBC

Thermal Barrier Coating Lifing

Cycle Time, Hours

TBC Strength, σo*

Cycle Time, Hours

Thermal Barrier Coating Lifing

Time Exponent APS TBC

Cycle Time, Hours

Cycle Time, Hours

Isothermal and Thermal Cycling Tests of Coated First Stage Bucket

Specimen Material and Design

Thermal Barrier Coating Lifing

Thermal Barrier Coating Lifing

Coatings and Test Conditions

8.0 Balance 20.5 31.3 0.5

Al2O3 Fe2O3 SiO2 TiO2 Y2O3 HfO2 ZrO2

0.1 0.1 0.3 0.1 7.9 1.8 Balance

As-Coated Microstructure of Bond and Top TBC Coatings

Thermal Barrier Coating Lifing

(a) (b) (c)

Thermal Barrier Coating Lifing

Isothermal Test Results

Thermal Barrier Coating Lifing

Thermal Barrier Coating Lifing

Thermal Barrier Coating Lifing

Exposure Temperature Time to initiate cracks

Thermal Barrier Coating Lifing

Thermal Cycling Test Results