Search Results (251)

The degradation process of HVOF-MCrAlY + APS-nanostructured YSZ (APS-nYSZ) thermal barrier coatings, produced using gas turbine OEM-approved MCrAlY powders, is investigated by studying the TGO growth and crack propagation behaviors in a thermal cycling environment. The TGO growth yields a parabolic mechanism on the surfaces of all HVOF-MCrAlYs, and the growth rate increases with the aluminum content in the “classical” MCrAlYs. The APS-nYSZ layer comprises micro-structured YSZ (mYSZ) and nanostructured YSZ (nYSZ) zones. Both mYSZ/mYSZ and mYSZ/nYSZ interfaces appear to be crack nucleation sites, resulting in crack propagation and consequent crack coalescence within the APS-nYSZ layer in the APS-nYSZ/HVOF-MCrAlY vicinity. Crack propagation in the TBCs can be characterized as a steady-state crack propagation stage, where crack length has a nearly linear relationship with TGO thickness, and an accelerating crack propagation stage, which is apparently a result of the coalescence of neighboring cracks. All TBCs fail in the same way as APS-/HVOF-MCrAlY + APS-conventional YSZ analogs, but the difference in thermal cycling lives is not substantial, although the HVOF-low Al-NiCrAlY encounters chemical failure in the early stage of thermal cycling. Full article

This study investigates the impact of thermal barrier coatings (TBCs) on the individual contributions of cooling components in impingement-jet combined cooling under low Reynolds number conditions. Using decoupled methods, numerical simulations were conducted for cylindrical, fan-shaped, and conical hole geometries. The results show that without TBCs, the conical hole provides the best cooling performance, while the fan-shaped hole performs the worst. After applying TBCs, the cooling effectiveness of the cylindrical and conical holes remains largely unchanged, but the fan-shaped hole shows significant improvement, with performance comparable to the conical hole. The cylindrical hole keeps a uniform shape, leading to increased velocity and preventing stable film formation. In contrast, the expanding flow passages of the fan-shaped and conical holes promote a gradual decrease in flow velocity, supporting stable film formation and effective thermal protection. Impingement cooling accounts for more than 75% of the overall cooling effectiveness for across hole types. For cylindrical and conical holes, the TBCs primarily enhance in-hole cooling, while for the fan-shaped hole, it increases in-hole cooling effectiveness and shifts film cooling effectiveness from negative to positive, significantly improving its overall contribution. Full article

Under service conditions, randomly distributed cracks in the top coat (TC) layer of thermal barrier coatings (TBCs) lead to local stress concentrations, which serve as the primary drivers of crack propagation and coating delamination. This study systematically analyzes the influence of crack defects on the thermal stress distribution in TBCs, based on their microstructural characteristics, using a multi-physics-coupled finite element model. Numerical analysis of crack characteristics reveals that crack length significantly influences the stress distribution in the coatings, with the maximum tensile stress at the crack tip increasing from 104.02 to 238.51 MPa as the crack half-length extends from 400 to 1000 μm. Shorter cracks induce lower tensile stresses, thereby retarding crack propagation and delaying coating delamination. Crack depth also influences the stress distribution, with the maximum tensile stress decreasing from 205.88 to 101.65 MPa as the crack is buried deeper, from 50 to 200 μm, indicating a more stable stress state less prone to propagation in deeper cracks. For inclined cracks, increasing the inclination angle induces a shift in stress from tensile to compressive, with larger inclination angles exhibiting greater stability. Accordingly, this study proposes a laser scribing strategy to mitigate crack-tip stress concentration, which is validated through comparison with two-dimensional crack models. Laser scribing shortens crack length by interrupting crack continuity, relieves localized thermal expansion strain, effectively suppresses crack growth, and significantly enhances the crack resistance and thermal shock stability of the coating. Full article

Residual particles embedded at the bond coat/substrate (BC/SUB) interface after grit blasting can affect the failure behavior of thermal barrier coatings (TBCs) under thermal cycling. This study employed a 2D finite element model combining the cohesive zone method (CZM) and extended finite element method (XFEM) to analyze the effect of interfacial grit particles. Specifically, the CZM was used to simulate crack propagation at the BC/thermally grown oxide (TGO) interface, while XFEM was applied to model the arbitrary crack propagation within the BC layer. Three models were analyzed: no grit inclusion, 20 μm grit particles, and 50 μm grit particles at the BC/SUB interface. This systematic variation allowed isolating the influence of particle size on the location of crack propagation onset, stress distribution, and crack growth behavior. The results showed that grit particles at the SUB/BC interface had negligible influence on the crack propagation location and rate at the BC/TGO interface, due to their spatial separation. However, their presence significantly altered the radial tensile stress distribution within the BC layer. Larger grit particles induced more intense stress concentrations and promoted earlier and more extensive vertical crack propagation within the BC. However, due to plastic deformation and stress redistribution in the BC, the crack propagation was progressively suppressed in the later stages of thermal cycling. Overall, grit particles primarily promoted vertical crack propagation within the BC layer. Optimizing grit blasting to control grit particle size is crucial for improving the durability of TBCs. Full article

The stability of thermal barrier coating (TBC) materials during service is a prerequisite for the normal operation of aircraft engines. The high-temperature corrosion of CaO–MgO–Al₂O₃–SiO₂ (CMAS) is an important factor that affects the stability of TBCs on turbine blades and causes premature engine failure. For traditional 6-8 YSZ, at temperatures of more than 1200 °C, the thermal insulation performance is significantly reduced, which makes it necessary to find new, alternative materials. La₂Zr₂O₇ has good thermal physical properties; the addition of Ce⁴⁺ improves its mechanical properties, while adding Gd₂O₃ affects its corrosion resistance. Herein, high-temperature corrosion studies of (La_1−xGd_x)₂(Zr_0.7Ce_0.3)₂O₇ (L-GZC) (x = 0, 0.3, 0.5, 0.7) ceramic TBC were conducted using CMAS glass at 1250 °C. The results indicate that CMAS rapidly dissolves L-GZC and separates the (La, Gd)₈Ca₂(SiO₄)₆O₂ apatite phase, ZrO₂, and other crystalline phases. These products form a crystalline layer at the contact boundary, which can inhibit further CMAS reactions. Among the coatings examined, the L-GZC ceramic (x = 0.7) exhibits better corrosion resistance, and the penetration depth is <200 μm after high-temperature corrosion at 1250 °C for 5, 10, and 20 h. The failure mechanism and potential risk of CMAS were also analyzed and discussed. The L-GZC ceramic material has good thermal corrosion resistance and is expected to replace the traditional YSZ to better meet the high-temperature working requirements of gas turbines and aircraft engines. Full article

Subjective selection of simulation interface shapes may introduce errors in the strength and fatigue analysis of thermal barrier coatings (TBCs). However, the applicability of different interface shapes for the TBCs simulation has rarely been investigated. Based on the TBCs thermal fatigue experiment, a finite element model is established and combined with the Fruit Fly Optimization Algorithm (FOA), a TBCs life prediction model is established. Then, five typical interface shapes, sawtooth, sinusoidal, semicircular, elliptical, and trapezoidal, are identified based on fine-scale photographs of the real interface morphology of the TBCs. Finally, the interface shape with the highest simulation applicability is identified through interface stress state analysis and life prediction error analysis, and verified through experiment. The results show that the stress maximum location of the sawtooth and trapezoidal interface shapes is inconsistent with the experimental onset of damage in TBCs, which proves that the applicability of the two shapes in the simulation of TBCs is not high. When applying equivalent strain for life prediction, the life prediction errors for the semicircular interface shape, elliptical interface shape, and sinusoidal interface shape are 72.84%, 61.74%, and 58.72%, respectively. The lowest life prediction error is obtained by using data from the sinusoidal interface shape. Therefore, the sinusoidal interface shape is the most applicable simplified shape for TBC simulation. Applying sinusoidal interface shape for additional TBCs life prediction with only 13.52% error, which verifies the accuracy of the methodology and conclusions of this study. These conclusions can inform accurate strength and fatigue simulation analysis of TBCs. Full article

The main purpose of this work is to suppress the rate of thermal and oxidative corrosion of copper substrates using double-ceramic-layer thermal barrier coatings (TBCs). Herein, the orthogonal spray experiment was employed to optimize the spraying parameters for TBCs consisting of Cu/NiCoCrAlY/8YSZ/(Y_0.5Gd_0.5)TaO₄. The thermal cycling and average mass loss rate of TBCs prepared by atmospheric plasma spraying (APS) with optimum spraying parameters correspond to 20 cycles and 0.56‰, respectively. The thermal conductivity (0.39 W·m⁻¹·K⁻¹ at 900 °C) of (Y_0.5Gd_0.5)TaO₄ is 71.68% and 52.7% lower than that of (Y_0.5Gd_0.5)TaO₄ bulk and 8YSZ, respectively. Meanwhile, the bond strength increased from 8.86 MPa to 14.03 MPa as the heat treatment time increased from 0 h to 24 h, benefiting from the heat treatment to release the residual stresses inside the coating. Additionally, the hardness increased from 5.88 ± 0.56 GPa to 7.9 ± 0.64 GPa as the heat treatment temperature increased from room temperature to 1000 °C, resulting from the healing of pores and increased densification. Lastly, crack growth driven by thermal stress mismatch accumulated during thermal cycling is the main cause of coating failure. The above results demonstrated that 8YSZ/(Y_0.5Gd_0.5)TaO₄ can increase the service span of copper substrate. Full article

The effects of microstructure, density, and porosity of a FeCoNiCrAl high-entropy alloy (HEA) coating, fabricated using an internal diameter high-velocity air fuel (ID-HVAF) torch (model: i7 ID), on the isothermal oxidation behavior were investigated. This study pioneers the use of the ID-HVAF i7 ID system for HEA bond coat manufacturing, achieving a highly dense microstructure because of its low-operating spray temperature technique. To elucidate these effects, the microstructure and chemistry of the coating, the growth of the thermally grown oxides (TGOs), the phase transformation of alumina, and the oxidation rate were investigated at different temperatures. After 50 h at 1000 °C, 1100 °C, and 1150 °C, a dense, uniform, and thin alumina TGO layer (1.8 μm) was observed. The results demonstrate that the oxidation resistance of the HEA coating is enhanced because of the dense microstructure achieved via HVAF-i7, characterized by low porosity and uniform phase distribution, which contribute to improved barrier properties against oxygen diffusion. The growth of the TGO layer is controlled, resulting in a dense and continuous TGO layer. However, with increasing temperature and time, the alumina TGO layer becomes spalled, which is attributed to the absence of reactive elements. Overall, this study reveals that the FeCoNiCrAl HEA exhibits significant potential for enhancing oxidation resistance at high temperatures. Full article

Thermal shock testing has long been employed to assess thermal barrier coatings (TBCs), with crack formation and propagation on TBC surfaces serving as important indicators of fracture toughness. In this study, the influence of preexisting cracks within TBC coatings was investigated. These cracks can help alleviate stress concentrations at the interface and within the thermally grown oxide (TGO) layers of the TBC model. In other words, surface crack propagation may eventually intersect the interface, leading to delamination and spallation. This research focused on modifying the volume fraction of functionally graded materials (FGMs) and optimizing preexisting surface cracks in TBCs to extend their lifespan before delamination occurs. The accuracy of the J-integral and displacement correlation technique (DCT) methods was evaluated for use in thermal shock testing simulations. The results showed that both the stress intensity factor (SIF) and interface tensile stress of preexisting cracks were significantly reduced when the volume fraction was set at N = 3. Furthermore, the SIF values demonstrated strong agreement with calculations using the J-integral and DCT methods. The SIF for preexisting cracks dropped to below 62.42% of the fracture toughness when the crack length was approximately 50% of the TBC coating thickness in FGM structures, with a crack density of 10 cracks per inch (CPI). Full article

Aircraft gas turbine blades operate in aggressive, generally oxidizing, atmospheres. A solution to mitigate the degradation and improve the performance of such components is the deposition of thermal barrier coatings systems (TBCs). High-velocity air fuel (HVAF) is a very efficient process for coating deposition in TBC systems, particularly for bond coats in aerospace applications. However, its low-temperature variant has received little attention in the literature and could be a promising alternative to limit oxidation during spraying when compared to conventional methods. This study has the main objective of analyzing how the geometry of the low-temperature HVAF gun influences the microstructure and the in-flight oxidation of MCrAlX coatings. To that end, a low-temperature HVAF torch is used to deposit MCrAlX coatings on a steel substrate with different nozzle lengths. In-flight particle diagnosis is used to measure the MCrAlX particle velocity, and to correlate to the nozzle geometry and to analyze its influence on the final coating. The microstructure of the coatings is assessed by scanning electron microscopy (SEM) and the material oxidation is analyzed and measured on a field emission scanning transmission electron microscope (FE-STEM) equipped with focused ion beam (FIB) and by Energy Dispersive Spectroscopy (EDS). Full article

Thermal barrier coatings (TBCs) can be applied on the inner surface of the combustion chamber of internal combustion engines to reduce fuel consumption and pollution and also improve the fatigue life of their components. The purpose of the present work was to evaluate the corrosion resistance in an environment equivalent to the one generated by combustion gases for three types of TBCs—P1 from Cr₃C2-25(Ni20Cr), P2 from MgZrO₃-35NiCr and P3 from ZrO₂-5CaO—with all of them having a base coat from Al₂O₃-30(Ni20Al) powder. The coatings were deposited via atmospheric plasma spray (APS) on the intake/exhaust valves of a gasoline internal combustion engine, both before and after their use in operation (Dacia 1400 model, gasoline fuel, Dacia Company, Mioveni, Romania). The samples were studied from the electrochemical corrosion resistance point of view, and their morphology and structure were analyzed using SEM, EDS and XRD methods. After analyzing the results of the samples before and after testing them in operation, it was observed that the presence of the coatings improved the corrosion resistance of the material used for the production of the valves. Full article

Microstructure evolution and cracking behavior of a four-layer thermal barrier coating (TBC) with double YSZ layers during thermal cycle tests were studied in the current work. The temperature range of the thermal cycle test ranged from room temperature to 1100 °C under atmospheric conditions. The TBC consisted of tetragonal t′ and t phases as well as monoclinic yttrium oxide. After 500 thermal cycles, the m-ZrO₂ phase was formed through the phase transformation from t′-ZrO₂ to m-ZrO₂ and c-ZrO₂. A large number of bulk thermally grown oxides (TGO), including chromium, spinel, and yttrium aluminates, were formed around pores in the transition layer (TL). Furthermore, the thickness of the TGO layer increased with a relatively low increase rate during the test (where k_p was about 0.17 μm²/h). This may be attributed to the formation of bulk TGO around pores within the TL, which could consume some of the oxygen. The results show that large horizontal cracks are likely to form at the TSL/TIL and TIL/TL interfaces, while vertical cracks tend to occur near the surface of the TSL, and the propagation rate is relatively low. The propagation of horizontal cracks is the primary cause of failure in this four-layer structure. After the thermal cycle test, the porosity of TSL decreased significantly, from 7.17% to 0.76%. The results in this study may help optimize the design and preparation of TBCs with double YSZ layers. Full article

In this study, SmFeN/YSZ thermal barrier coating (TBC) composites with SmFeN mass fractions of 25 wt.%, 30 wt.%, and 50 wt.% were synthesized using plasma spraying technology. Testing methods, including scanning electron microscopy (SEM), X-ray diffraction (XRD), and the coaxial method, were comprehensively employed to systematically and thoroughly investigate the influence of SmFeN content on the microstructure, electromagnetic wave absorption performance, and the underlying mechanism of the composites. The research results show that during the plasma spraying process, a significant phase transformation occurred in the SmFeN/YSZ mixed powder, where the original Sm₂Fe₁₂N_2.9 phase transformed into Fe₄N and Sm₃Fe₅O₁₂ phases. However, this phase transformation did not have an adverse effect on the electromagnetic wave absorption performance of the coating. On the contrary, further research revealed that the newly formed Fe₄N phase plays a decisive role in the electromagnetic wave absorption performance of the coating. When the SmFeN mass fraction was 30%, the proportion of Fe₄N in the coating reached its peak. At this time, the impedance matching characteristics of the coating were significantly optimized, and the dipole orientation polarization rate was significantly increased. This enhanced the dielectric relaxation loss capacity of the coating and broadened the electromagnetic wave absorption frequency band. Specifically, the coating exhibited a minimum reflection loss (RL_min) of −52.371 dB and an effective absorption bandwidth (EAB) as high as 2.1588 GHz, covering a frequency range from 11.0739 GHz to 13.2327 GHz. This result indicates that there is great application potential in preparing electromagnetic wave absorption coatings using SmFeN/YSZ mixed powder. Full article

Yttria-Stabilized Zirconia (YSZ) is an important material in thermal barrier coatings (TBCs), which are widely applied in aviation engines and ground gas turbines. Therefore, the quality inspection of the YSZ layer is of great significance for the safety of engines and gas turbines. In this work, the YSZ powder is mixed with Polytetrafluoroethylene (also known as teflon) in different mass ratios and pressed into tablets with different thicknesses. A terahertz time-domain spectroscopy system is used to obtain their time-domain spectra, and their frequency spectra are then obtained by fast Fourier transform. Based on theory formulas, we obtained the frequency-dependent curves of the absorption coefficient, refractive index, and absorbance of the YSZ tablets. The results show that the YSZ tablets have characteristic absorption peaks in the terahertz band, and these peaks are affected by the mass ratio of YSZ to teflon and the thickness of the tablets. Finally, we conducted a terahertz Raman spectroscopy test of the YSZ tablets for the first time. The results show that in the range from 0 to 1600 cm⁻¹, there are about ten strong Raman peaks. More importantly, these peaks are approximately independent of the mass ratio and the thickness of tablets. This study is of great significance for the nondestructive testing of TBC quality using terahertz spectroscopy technology. Full article

This study investigates the enhancement of thermal durability in multilayer yttria-stabilized zirconia (YSZ) thermal barrier coatings (TBC) with porosity-controlled structures. Conventional single-layer YSZ and multilayer TBCs with dense and porous layers were fabricated by air plasma spraying and the TBC specimens were subjected to furnace cyclic testing. The single-layer TBC suffered from catastrophic delamination under cyclic thermal loading, driven by the mismatch in thermal expansion, while the multilayer TBCs exhibited a significant increase in thermal durability, by up to 50%. The relevant delamination mechanism was suggested with microstructural analysis, showing that the multilayer structure effectively relieved residual stresses by forming horizontal cracks, thereby mitigating crack propagation. This study emphasizes that the multilayer design in TBC with controlled porosity significantly enhances thermal durability, improving the operational lifespan of gas turbine hot components. Full article