Development of Highly Durable Thermal Barrier Coating by Suppression of Thermally Grown Oxide

摘要

Durability of thermal barrie coating (TBC) systems is important because of recent rising of turbine inlet temperature (TIT) for improved efficiency of industrial gas turbine engines. However, high-temperature environment accelerates the degradation of the TBC as well as causes spoiling of the top coat. Spalling of the top coat may be attributed to several factors, bat evidently the growth of thermally grown oxide (TGO) should be considered as an important factor. One method for reducing the growth rate of TGO is to provide a dense alpha-Al2O3 layer at the boundary of the bond coat and top coat. This alpha-Al2O3 later will suppress the diffusion of oxygen to the bond coat and consumption of aluminum of the bond coat is suppressed. In this study, we focused on thermal pre-oxidation of the bond coat as a means for forming an alpha-Al2O3 barrier layer that would be effective at reducing the growth rate of TGO, and we studied the suitable pre-oxidation conditions. In the primary stage, we analyzed the oxidation behavior of the bond coat surface daring pre-oxidation heat treatment by means of in situ synchrotron X-ray diffraction (XRD) analysis. As a result, we learned that during oxidation in ambient air environment, in the initial stage of oxidation metastable alumina is produced in addition to alpha-Al2O3 but if the thermal treatment is conducted under sonic specific low oxygen partial pressure condition, unlike in the ambient air environment, only is formed with suppressing formation of metastable alumina. We also conducted transmission electron microscope (TEM) and XRD analysis of oxide scale formed after pre-oxidation heat treatment of the bond coat. As a result, we learned that if pre-oxidation is performed under specific oxygen partial pressure conditions, a monolithic alpha-Al2O3 layer is formed on the bond coat. We performed a durability evaluation test of TBC with the monolithic alpha-Al2O3 layer formed by tire-oxidation of the bond coat. An isothermal oxidation test confirmed that the growth of TGO in the TBC that had undergone pre-oxidation was suppressed more thoroughly than that in the TBC that had not undergone pre-oxidation. Cyclic thermal shock-test by hydrogen burner rig was also carried out. TBC with the monolithic alpha-Al2O3 layer has resistance to 2000 cycle thermal shock at a load equivalent to that of actual,peas turbine.