Novel thermal barrier coatings (TBCs) that are resistant to high temperature attack by calcium oxide-magnesium oxide-silicon oxide-aluminum oxide (CMAS) glassy deposits.

摘要

Higher performance and durability requirements of gas-turbine engines will require a new generation of thermal barrier coatings (TBCs). This is particularly true of engines operated at higher temperatures, where TBCs are subjected to attack by CaO-MgO-Al2O3-SiO 2 (CMAS) glassy deposits. In this work, a new approach for mitigating CMAS attack on TBCs is introduced, where up to 20 mol% Al2O 3 and 5 mol% TiO2 in the form of a solid solution is incorporated into Y2O3-stabilized ZrO2 (YSZ) TBCs. The fabrication of such TBCs with engineered chemistries is made possible by the solution-precursor plasma spray (SPPS) process, which is uniquely suited for depositing coatings of metastable ceramics with extended solid-solubilities. In the current work, the TBC serves as a reservoir of Al and Ti solutes, which are incorporated into the molten CMAS glass that is in contact with the TBC. An accumulation of Al concentration in the CMAS glass as it penetrates the TBC shifts the glass composition from the difficult-to-crystallize psuedowollastonite field to the easy-to-crystallize anorthite field. The incorporation of Ti in the glass promotes crystallization of the CMAS glass by serving as a nucleating agent. This combined effect results in the near-complete crystallization of the leading edge of the CMAS front into anorthite, essentially arresting the front. Both of these phenomena will help crystallize the CMAS glass, making it immobile and ineffective in penetrating the TBC. It is shown that incorporation of both Al and Ti in the CMAS glass is essential for this approach to be effective. Additionally, incorporation of Al and Ti as solutes is expected to alleviate thermal-expansion and thermal-conductivity issues associated with crystalline second phases used before. Moreover, the metastable nature of the Al and Ti solutes will make them more readily available for incorporation in the molten CMAS glass. CMAS interactions with SPPS TBCs of various metastable compositions are compared with reference air plasma spray (APS) TBC.;In this dissertation, results from characterization and testing of these new TBCs are presented, together with a discussion of mechanisms responsible for CMAS-attack mitigation. The penetration of CMAS causes a loss of strain tolerance of the coating. Delamination maps are used to demonstrate the combined effects of CMAS penetration, temperature gradient and cooling inhomogeneity on the coating. Evans and Hutchinson's model has been used to produce delamination maps and predict the durability of novel TBCs.