report of thermal barrier coating of gas turbine blades
TRANSCRIPT
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A
SEMINAR REPORT
ON
THERMAL BARRIER COATING OF
GAS TURBINE BLADES
SUBMITTED BY
Ashutosh kumar tiwari
Roll o!"#$#%$#%&
IIIr' B!T()h M!E
SUBMITTED TO
Mr!*i+(k ,asari
Mr! -!S B(hl
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INDE.
Cot(ts ,a/(! No!
0! INTRODUCTION 0
%! HISTORIACL BAC1GROUND 2
2! DIFFERENT LAYERS &
&! CREATION OF TBC $
3! FAILURE OF TBC 4
5! MATHEMATICAL BAC1GROUND 00
$! ,RO,OSED RESEARCH 02
6! CONCLUSION 0$
4! REFERENCES 06
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Providing o%idation protection to the sustrate' the meta!!ic ond coat !a"er
provides an ade4uate!" prepared surface to #hich the ceramic !a"er adheres$ The
ceramic !a"er composition is se!ected ased on therma! conductivit"' high3temperature
stai!it"' and therma! e%pansion compatii!it" #ith the sustrate$ Due to its !o# therma!
conductivit" and good thermo c"c!ic durai!it" #hen stai!i9ed against phase
transformation' 9irconia has ecome the ceramic of choice$ The current i!a"er design
and composition of TB& have evo!ved from a mu!titude of designs and a numer of
compositions tested over a period of severa! decades$
Fi/ 0! Mi)ro/ra7hs o8 La%9r%O$a' YS9 )oati/
Som( o8 7ro'u)ts i)or7orati/ TBC:"
Turine !ades
&utting too! inserts
Aero engine parts
1as turine parts such as comustion !iners' shroud' no99!es or !ades
I& engine parts
Roc2et no99!es and va!ve odies
Damper pin for turine uc2et
Th(rmal
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/:0
%! HISTORICAL BAC1GROUND
Pratt ;
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2! DIFFERENT LAYERS
In an effort to protect the turine !ades from e%treme!" high temperature gasesF the
therma! arrier coating /TB&0 s"stem has een imp!emented$ The TB& s"stem
primari!" consists of fo!!o#ing !a"ers.
(0 &eramic top3coat'
:0 Therma!!" gro#n o%ide /T1O0',0 Bond coat' and
C(rami) to7")oat. 3 The ceramic top3coat is the !a"er that provides therma! insu!ation
for the !ade$ It has a ver" !o# therma! conductivit" and has een designed using point
defects to #ithstand therma! c"c!es$ This !a"er is t"pica!!" made of :O, #hich is
stai!i9ed #ith rO:or in short S$ The therma! conductivit" for this !a"er at a
temperature of a thousand degrees &e!sius is :$,
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/)0
Fi/ur( 2! A s)h(mati) illustratio o8 a mo'(r th(rmal ;arri(r )oati/ s a th(rmall< /row o=i'( ?TGO@ a' a alumium
ri)h ;o' )oat! Th( t(m7(ratur( /ra'i(t 'uri/ (/i( o7(ratio is o+(rlai'!
Temperature
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&! CRAEATION OF TBC
The ond coat is primari!" deposited " He!ectrop!ating in con-unction #ith diffusion3
a!umini9ing or chemica!3vapour deposition$ Recent!"' the high ve!ocit" o%"3fue!
techno!og" /5COG0 is a!so increasing!" used for this tas2$
Fi/!&" a@A,S> Lamiar
stru)tur(
;@EB",*D )olumar stru)tur(
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The &eramic top3coat on other hand is current!" eing deposited in t#o different #a"s.
(0 Air p!asma3 spra"ed /APS0 deposition and
:0 E!ectron3eam ph"sica!3vapour deposition /EB3PCD0$
A picture of the different
microstructures created " each method are sho#n in Gigure +$
Air 7lasma" s7ra
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El()tro";(am 7h
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#as decreased' crac2ing of the ond coat in EB3PCD coated s"stems #as suppressed'
the !ife of the coated s"stem increased significant!" and de!amination of the top3coat
#as oserved$ A suse4uent GE ana!"sis sho#ed that' " su-ecting the s"stem to the
higher mechanica! strain' significant tensi!e stresses deve!op in the T1O and the ond
coat that are thought to e responsi!e for the oserved crac2 initiation and
propagation$ The GE mode! a!so predicts that crac2ing initiates at specific geometric
features of the rough interface of a PS coated s"stem' #hich #as confirmed "
meta!!ographic e%amination of fai!ed samp!es$ The decrease of the app!ied mechanica!
strain and hence of the deve!oped stresses !ed to the suppression of fai!ure " ond coat
crac2ing and activate de!amination$ These resu!ts out!ine the importance of designing
TMG tests and se!ecting the appropriate mechanica! !oading in order to acce!erate
testing and sti!! trigger the same fai!ure mechanisms as oserved in3service$
/?0
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O=i'atio"I'u)(' Failur( o8 Th(rmal Barri(r Coati/s:"
On pro!onged high3temperature e%posure in air' therma! arrier coatings /TB&s0 on
ond3coated super a!!o"s fai! " spa!!ing$ It is a ne# discovered TB& fai!ure mode' in
#hich fai!ure is associated #ith moisture3enhanced su3critica! crac23gro#th a!ong the
ond3coat therma!!" gro#n o%ide interface$ B" ma2ing concurrent pie9ospectroscop"
measurements' the interfacia! fracture energ" #as determined to e K (* =m/e%p :0 3 a
considera!" sma!!er va!ue than that of sapphiremeta! interfaces prepared in the
!aorator" ut consistent #ith measurements of the effects of segregation onmeta!ceramic interfaces$ Ne# insights into the mechanism under!"ing fai!ure of the
therma!!" gro#n o%ide have come from direct optica! microscop"$ These indicate that
fai!ure is associated #ith surface roughness of the ond3coat and specifica!!" that the
therma!!"3gro#n o%ide separates from the ond3coat on coo!ing at the concave /LcrestsL0
surface features$ These !oca!!" separated regions gro# #ith o%idation time and are seen
to !in23up$ These events are e!ieved to e the precursor events that gro# to provide the
critica!3si9ed f!a#s from #hich uc2!ing and spa!!ing of therma! arrier coatings occur$
/(*0
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5! MATHEMATICAL BAC1GROUND
Because of the comp!e%it" of this mode!' the ma-orit" of the resu!ts are done
through e%perimentation$ In order to get a ph"sica! fee! for #hat is happening' #e have
made severa! assumptions in our ana!"sis.
(0 Tgas J T( J (>7, degrees e!vin #hich is 2ept constant$
:0 T+ J Tair J :?> degrees e!vin #hich is 2ept constant$
,0 Assume that a sma!! portion of the air foi! that I represent as a rectang!e is a
good mode! of the entire air foi!$
+0 Properties of state sta" constant throughout the mode! ecause oundar"
conditions sta" constant$
)0 No heat f!u% through the top and ottom of our mode! /insu!ated0$
60 T1O !a"er has no effect on temperature distriution
This information comined #ith ta!e ( #as inputted into &OMSO and so!ved$ The
resu!ts are sho#n in figure 6$
Ta;l( 0: Mat(rial 7ro7(rti(s 8or a tur;i( ;la'(
Ni Sustrate Ni&o&rA! SR
Densit" /2gm,0 >>>* 7,:* 6*,7
Therma!
conductive/( 6)6
/((0
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Fi/ur( $: %"D Dia/ram o8 th( ;la'(
Fi/ur( 6: Comsol mo'(l o8 th( t(m7(ratur( 'istri;utio i a tur;i( ;la'(
As one can see in Gigure 6' the temperature distriution drops dramatica!!" through the
ceramic top coat ecause of its ver" !o# therma! conductivit"$ Gurthermore' these
resu!ts sho# that the temperature distriution through the supper a!!o" is #e!! e!o# the
me!ting point of the meta! #hich is #hat #as e%pected$
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$! ,RO,OSED RESEARCH
The on!" #a" to improve efficienc" in a gas turine engine is to increase the
temperatures #ithin the s"stem$ Because of this more research needs to e done in
improving re!ia!" and therma! conductive!" of the therma! arrier coat$ Gocus needs to
e p!aced on the current fau!ts of TB& s"stem and ho# the" can e reso!ved$ Some
pro!ems are #ith o%idation of the materia!' and !ac2 of mode!!ing to predict the !ife
span of the therma! arrier coating$ In addition' ne# research in different #a"s of
coo!ing the !ade needs to e done$ A reasona!e area to focus on #ou!d e #ater
coo!ing and nitrogen coo!ing$
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Mo'(lli/:3 Mode!!ing constitutes a second main research area$ The principa! goa! in
the mode!!ing of the p!asma spra"ing process is the improvement of our understanding
aout the re!ation et#een the process parameters and the structure and effectiveness of
the coating s"stems$ Mode!!ing "ie!ds asic information' #hich can !ead to the
optimi9ation of the process$ A simi!ar function corresponds to the mode!!ing of therma!
arrier coating !ife$ The achieved deve!opment of a !ifetime mode! ased on the
microstructure gives important indications for an optimi9ed !a"er s"stem$
Th(rmal )
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temperatures in an o%idi9ing atmosphere$ An ear!" e%amp!e of such a s"stem is a!umina
fiers in an a!umina matri%$ To rea!i9e the u!timate !oad carr"ing capai!ities at high
temperatures' sing!e cr"sta! o%ide fiers ma" e used' giving the possii!it" to operate
under temperatures of (+**&$ 5igher operating temperatures for gas turine engines
are continuous!" sought in order to increase their efficienc"$ 5o#ever' as operating
temperatures increase' the high temperature durai!it" of the components of the engine
must corresponding!" increase$ Significant advances in high temperature capai!ities
have een achieved through formu!ation of iron' nic2e! and coa!t3ase super a!!o"s$
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6! CONCLUSION
1as turines engine constitute a #ide and good option for po#er generation
used for oth' industria! and aeronautica! app!ications$ This techno!og" is re4uesting for
etter and more re!ia!e materia!s to use most!" in those areas in #hich temperatures
are e%treme!" highF !i2e' fist ro# of turines !ade and comustion chamer$ B!ades
materia!s for turine area in gas turines have advanced rapid!" in the !ast : decades$
These !ades are constructed using specia! a!!o"s and are covered " specia! coats$
Modifications are intended to increase the a!!o#ed temperature up to ()**O& #ithout
coo!ing$ To increase efficienc"$
&eramic coating is app!ied to the surface of the turine !ade using severa!
methods$ The most important ones are. E!ectron Beam Ph"sica! Capor Deposition /EB3
PCD0 and Arc P!asma Spra"a!e /APS0 po#der method$ Besides the techno!og" aimed
to produce etter coats' materia!s science is current!" #or2ing e%tensi!e in &eramic
Matri% &omposites' formed asica!!" " si!icon caride fiers and specia! farics in
order to increase the temperature gap in !ocations specia!!" sensi!e for gas turine
operation$
The !ast and' at the same time' !argest area dea!s #ith the deve!opment of ne#
therma! arrier coatings$ In this #ide activit"' o%idic materia!s are principa!!" eing
studied as candidates for therma! arrier coatings and' #here app!ica!e' deve!oped to
ne# TB&3s"stems$ The e%perience and 2no#3ho# in the other research areas
/processing' characteri9ation' mode!!ing0 are eing intense!" used for the further
deve!opment of ne# s"stems$
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0#! REFERENCES
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(0 &!ar2e' D$ R$ and evi' &$ 1$ /:**,0$ HMateria!s Design for the Ne%t 1eneration
Therma! Barrier &oatings$ Annua! Revie#s of Materia!s Research. Co!$ ,,' pp$ ,>,3
+(7$
:0 Nitin P$ Padture' Maurice 1e!!' Eric 5$ =ordan$ LTherma! Barrier &oatings for 1as3
Turine Engine App!ications$L Science (: Apri! :**:. Co!$ :?6$ no$ ))66' pp$ :>* 3
:>+
,0 ODonoghue isa$ L,3+(7$ August :**,
>0 $A$ hor' $
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