Effect of APS flash bond coatings and curvature on TBC performance on rod specimens

M. J. Lance; B. P. Thiesing; J. A. Haynes; E. J. Gildersleeve; S. Sampath; B. A. Pint

doi:10.1016/j.surfcoat.2019.124940

Effect of APS flash bond coatings and curvature on TBC performance on rod specimens

M. J. Lance
, B. P. Thiesing
, J. A. Haynes
, E. J. Gildersleeve
, S. Sampath
, B. A. Pint

Materials Science and Engineering

Stony Brook University

Oak Ridge National Laboratory
Northern Arizona University
Stony Brook University

Research output: Contribution to journal › Article › peer-review

12 Scopus citations

Abstract

The addition of an air plasma sprayed (APS) “flash” bond coating layer on top of a high velocity oxy-fuel (HVOF) bond coating significantly extended the lifetime of APS yttria stabilized zirconia (YSZ) thermal barrier coatings (TBC) on rod specimens of superalloy 247 tested using 100-h cycles in air+10%H₂O at 1100 °C. The flash bond coatings of both NiCoCrAlY and NiCoCrAlYHfSi powder were compared to an HVOF-only and a vacuum plasma sprayed (VPS) NiCoCrAlYHfSi bond coating. The flash coatings appear to form a mixed oxide-metal zone, which likely inhibits crack formation and therefore extends lifetime compared to conventional bond coatings. The underlying dense HVOF layer appeared to act as a source of Al for this intermixed zone and prevented the oxide from penetrating deeper into the bond coating. Residual stress in the thermally-grown Al₂O₃ scale was measured using photo-luminescence piezospectroscopy (PLPS) as a function of time for each coating variation, including a comparison of concave and convex surfaces on a specially designed rod.

Original language	English
Article number	124940
Journal	Surface and Coatings Technology
Volume	378
DOIs	https://doi.org/10.1016/j.surfcoat.2019.124940
State	Published - Nov 25 2019

Keywords

APS flash bond coating
Alumina scale
Furnace cycle testing (FCT)
HVOF bond coating
Photo-stimulated luminescence piezospectroscopy (PLPS)
TBC
VPS bond coating

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10.1016/j.surfcoat.2019.124940

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title = "Effect of APS flash bond coatings and curvature on TBC performance on rod specimens",

abstract = "The addition of an air plasma sprayed (APS) “flash” bond coating layer on top of a high velocity oxy-fuel (HVOF) bond coating significantly extended the lifetime of APS yttria stabilized zirconia (YSZ) thermal barrier coatings (TBC) on rod specimens of superalloy 247 tested using 100-h cycles in air+10\%H2O at 1100 °C. The flash bond coatings of both NiCoCrAlY and NiCoCrAlYHfSi powder were compared to an HVOF-only and a vacuum plasma sprayed (VPS) NiCoCrAlYHfSi bond coating. The flash coatings appear to form a mixed oxide-metal zone, which likely inhibits crack formation and therefore extends lifetime compared to conventional bond coatings. The underlying dense HVOF layer appeared to act as a source of Al for this intermixed zone and prevented the oxide from penetrating deeper into the bond coating. Residual stress in the thermally-grown Al2O3 scale was measured using photo-luminescence piezospectroscopy (PLPS) as a function of time for each coating variation, including a comparison of concave and convex surfaces on a specially designed rod.",

keywords = "APS flash bond coating, Alumina scale, Furnace cycle testing (FCT), HVOF bond coating, Photo-stimulated luminescence piezospectroscopy (PLPS), TBC, VPS bond coating",

author = "Lance, \{M. J.\} and Thiesing, \{B. P.\} and Haynes, \{J. A.\} and Gildersleeve, \{E. J.\} and S. Sampath and Pint, \{B. A.\}",

note = "Publisher Copyright: {\textcopyright} 2019 Elsevier B.V.",

year = "2019",

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doi = "10.1016/j.surfcoat.2019.124940",

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T1 - Effect of APS flash bond coatings and curvature on TBC performance on rod specimens

AU - Lance, M. J.

AU - Thiesing, B. P.

AU - Haynes, J. A.

AU - Gildersleeve, E. J.

AU - Sampath, S.

AU - Pint, B. A.

PY - 2019/11/25

Y1 - 2019/11/25

N2 - The addition of an air plasma sprayed (APS) “flash” bond coating layer on top of a high velocity oxy-fuel (HVOF) bond coating significantly extended the lifetime of APS yttria stabilized zirconia (YSZ) thermal barrier coatings (TBC) on rod specimens of superalloy 247 tested using 100-h cycles in air+10%H2O at 1100 °C. The flash bond coatings of both NiCoCrAlY and NiCoCrAlYHfSi powder were compared to an HVOF-only and a vacuum plasma sprayed (VPS) NiCoCrAlYHfSi bond coating. The flash coatings appear to form a mixed oxide-metal zone, which likely inhibits crack formation and therefore extends lifetime compared to conventional bond coatings. The underlying dense HVOF layer appeared to act as a source of Al for this intermixed zone and prevented the oxide from penetrating deeper into the bond coating. Residual stress in the thermally-grown Al2O3 scale was measured using photo-luminescence piezospectroscopy (PLPS) as a function of time for each coating variation, including a comparison of concave and convex surfaces on a specially designed rod.

AB - The addition of an air plasma sprayed (APS) “flash” bond coating layer on top of a high velocity oxy-fuel (HVOF) bond coating significantly extended the lifetime of APS yttria stabilized zirconia (YSZ) thermal barrier coatings (TBC) on rod specimens of superalloy 247 tested using 100-h cycles in air+10%H2O at 1100 °C. The flash bond coatings of both NiCoCrAlY and NiCoCrAlYHfSi powder were compared to an HVOF-only and a vacuum plasma sprayed (VPS) NiCoCrAlYHfSi bond coating. The flash coatings appear to form a mixed oxide-metal zone, which likely inhibits crack formation and therefore extends lifetime compared to conventional bond coatings. The underlying dense HVOF layer appeared to act as a source of Al for this intermixed zone and prevented the oxide from penetrating deeper into the bond coating. Residual stress in the thermally-grown Al2O3 scale was measured using photo-luminescence piezospectroscopy (PLPS) as a function of time for each coating variation, including a comparison of concave and convex surfaces on a specially designed rod.

KW - APS flash bond coating

KW - Alumina scale

KW - Furnace cycle testing (FCT)

KW - HVOF bond coating

KW - Photo-stimulated luminescence piezospectroscopy (PLPS)

KW - TBC

KW - VPS bond coating

UR - https://www.scopus.com/pages/publications/85072164175

U2 - 10.1016/j.surfcoat.2019.124940

DO - 10.1016/j.surfcoat.2019.124940

M3 - Article

SN - 0257-8972

VL - 378

JO - Surface and Coatings Technology

JF - Surface and Coatings Technology

M1 - 124940

ER -

Effect of APS flash bond coatings and curvature on TBC performance on rod specimens

Abstract

Keywords

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