advanced thermal barrier and environmental barrier coating ...advanced thermal barrier and...

55
1 Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental Effects and Coatings Branch Materials and Structures Division NASA Glenn Research Center Cleveland, Ohio 44135, USA Information Exchange Meeting, Army Research Laboratory Aberdeen Proving Ground, Maryland April 6, 2017 https://ntrs.nasa.gov/search.jsp?R=20170005680 2020-02-22T12:37:44+00:00Z

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Page 1: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

1

Advanced Thermal Barrier and Environmental Barrier Coating

Development at NASA GRC

Dongming Zhu And Craig Robinson

Environmental Effects and Coatings BranchMaterials and Structures Division

NASA Glenn Research Center

Cleveland, Ohio 44135, USA

Information Exchange Meeting, Army Research Laboratory

Aberdeen Proving Ground, Maryland

April 6, 2017

https://ntrs.nasa.gov/search.jsp?R=20170005680 2020-02-22T12:37:44+00:00Z

Page 2: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

2

Durable Thermal and Environmental Barrier Coating Systems for

Ceramic Matrix Composites (CMCs): Enabling Technology for Next Generation Low Emission, High Efficiency and

Light-Weight Propulsion

— NASA Environmental barrier coatings (EBCs) development objectives

• Help achieve future engine temperature and performance goals

• Ensure system durability – towards prime reliant coatings

• Establish database, design tools and coating lifing methodologies

• Improve technology readiness

Fixed Wing Subsonic

Aircraft

Supersonics

Aircraft

Hybrid Electric Propulsion Aircraft

Page 3: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

3

NASA Advanced Turbine Thermal and Environmental

Barrier Coating Development Goals

* Recession: <5 mg/cm2 per 1000 hr (40-60 atm., Mach 1~2)

** Component strength and toughness requirements

2400°F (1316°C) Gen I and Gen II SiC/SiC

CMCs

3000°F+ (1650°C+)

Gen I

Temperature

Capability (T/EBC) surface

Gen II – Current commercialGen III

Gen. IV

Increase in T

across T/EBC

Single Crystal Superalloy

Year

Ceramic Matrix Composite

Gen I

Temperature

Capability (T/EBC) surface

Gen II – Current commercialGen III

Gen. IV

Increase in T

across T/EBC

Single Crystal Superalloy

Year

Ceramic Matrix Composite

2700°F (1482C)

2000°F (1093°C)

Step increase in the material’s temperature capability

3000°F SiC/SiC CMC

airfoil and combustor

technologies

2700°F SiC/SiC thin

turbine EBC systems for

CMC airfoils

2850ºF

combustor

TBC

2500ºF

Turbine TBC 2700°F (1482°C) Gen III SiC/SiC CMCs

• Develop innovative coating technologies and life prediction approaches

• 2500°F Turbine TBCs with high toughness, and improved impact erosion resistance

• 2700°F (1482°C) EBC bond coat technology for supporting next generation turbine engines

• 2700-3000°F (1482-1650°C) turbine and CMC combustor coatings

– Meet 1000 h for subsonic aircraft and 9,000 h for supersonics/high speed aircraft hot-time life requirements

– Improve impact/erosion and CMAS resistance

Page 4: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

4

NASA Turbine Thermal and Environmental Barrier

Coatings for CMC-EBC Systems

• Emphasize temperature capability, performance and durability for next generation turbine engine systems

• Increase Technology Readiness Levels (TRLs) for component system demonstrations

2900°F

(T41)

Gas TBC Bond

coat

Metal

blade3200°F

(T41)

Gas TBC Bond

coat

Metal

blade3200°F

(T41)

Baseline metal

temperature

300°F

increase

Gas EBC Bond

coat

CMC

airfoil

Tsurface

Tsurface

Current metal turbine

airfoil system

State of the art metal turbine

airfoil system 2500°F TBCs

2700-3000°F CMC

turbine airfoil systems

200-500°F

increase

Tsurface

2500°F TBCs2700-3000°F

EBCs

Thin turbine

coating

development

2200°F TBCs2400°F CMCs

2700°F CMCs

Page 5: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

5

NASA Environmental Barrier Coating (EBC) - Ceramic

Matrix Composite (CMC) Development Needs– Advanced Component Development Programs (particularly under the

Environmentally Responsible Aviation Program): Advanced environmental barrier coatings for SiC/SiC CMC combustor and turbine vane components, technology demonstrations in engine tests

– N+2 (2020-2025) generation with 2400°F CMCs/2700°F EBCs (cooled)

– NASA Aeronautics Program (FAP-SUP*, SRW/Aero Sciences/TTT** Projects): Next generation high pressure turbine airfoil environmental barrier coatings with advanced CMCs

– N+3 (2020-2025) generation with advanced 2700°F CMCs/2700-3000°F EBCs (uncooled/cooled)

– Turbine TBC development under NASA Partner Collaborative ProgramsInstability

ControlFuel

Staging

CMC

Liners

Multipoint

Injection

Low emission combustor High Pressure Turbine CMC vane and blade

* SUP: NASA Supersonics Project; SRW: NASA Subsonic Rotary Wing Project; TTT**: NASA Transformational Tools and Technologies Project.

Page 6: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

6

Outline

─ Environmental barrier coating system development: NASA’s

perspectives, challenges and limitations• Thermomechanical, environment and thermochemical stability issues

• Prime-reliant EBCs for CMCs, a turbine engine design requirement

─ Advanced thermal and environmental barrier coating systems (EBCs)

for CMC airfoils and combustors• NASA turbine and combustor EBC coating systems

• Performance and modeling

• Advanced EBC development: processing, testing and durability

─ Advanced CMC-EBC performance demonstrations• Fatigue – Combustion and CMAS environment durability

• Component demonstrations

─ Summary

Page 7: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

7

NASA Turbine Environmental Barrier Coating

Development: Major Emphases and Milestones

FY 11 FY 12 FY 13 FY 14 FY 15 FY 16-17

2.5D CVI CMC rig

demo

3D CVI/MI

Architecture

Airfoil

CMC Development

Supporting

Advanced EBC-CMC

Development

Develop advanced

architecture hollow

CMC blade

subelements

Advanced EBCs Demo EBC for

CMC

subelement

Develop creep

resistant

turbine EBC

with advanced

2700°F bond

coats

Impingement &

Film cooled

recession

Turbine EBC on

CMC blade

subcomponents

Initial

environment and

fatigue

interactions

Develop Life

Models for EBC

on CMC blade

Rig Demo

Optimized

2700°F EBC-

3D CMC

blades

Durable CMC

w/EBC

developed -

2700°F turbine

coating for

2400°F CMC

(15 ksi 1000 h

durability)

EBC/CMC

Component

Development

Program – NASA

ERA Program

2700°F turbine

EBC on 2400-

2500°F CMC

turbine vanes

Rig Demo

(TRL 4-5)

2700°F

Combustor EBC

on 2400°F CMC

Combustor –Rig

Demo 250 hr

(TRL 4-5)

CMAS EBC 300h

durability Demo

2700°F EBC-

Advanced

architecture

hollow CMC

blade

subelements

Turbine TBC

Erosion/CMAS (in

collaboration with

DOE and Air Force,

Army, Navy)

2X Erosion

resistant turbine

TBC

Advanced CMAS

Resistant TBC (with

ARFL Venture and

IR&D programs)

Luminance

sensing TBC

Advanced CMAS

Resistant Turbine

Coating Rig and Engine

Demos (with Army and

NAVAIR)NASA-NETL Turbine TBC developments

for Next-Gen high steam resistance

NASA and NASA-ARFL for Embedded

Sensor for TBC-EBC/CMCs

2700°F

EBC on 3D

CMC vane

(TTT

Augmentati

on Project)

NASA Turbine Coatings Supporting Tinker

Air Force Base Turbine Engine Programs

Page 8: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

8

Thermal and Environmental Barrier Coating Development:

Challenges and Limitations

─ Thermal barrier coatings and, in particular, environmental barrier coatings

are limited in their temperature capability, water vapor stability and long-

term durability

- Prime-reliant coatings are critical for future engines

─ Advanced EBCs also require higher strength and toughness• In particular, resistance to combined high-heat-flux, engine high pressure,

combustion environment, creep-fatigue, loading interactions

─ Turbine airfoil coating low thermal conductivity critical (half k thermal and

environmental barrier)

─ Thermal and environmental barrier coating need improved impact,

erosion and calcium-magnesium-alumino-silicate (CMAS) resistance

Page 9: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

9

Development of Advanced Defect Cluster Low

Conductivity Thermal Barrier Coatings

— Multi-component oxide defect clustering approach (Zhu et al, US Patents No.

6,812,176, No.7,001,859, and No. 7,186,466)

— Defect clusters associated with dopant segregation

— The nanometer sized clusters for reduced thermal conductivity, improved

stability, toughness, CMAS resistance and mechanical properties

EELS elemental maps of EB-PVD ZrO2-(Y,

Gd,Yb)2O3

Plasma-sprayed ZrO2-(Y,

Nd,Yb)2O3

EB-PVD ZrO2-(Y,

Nd,Yb)2O3

e.g.: ZrO2-Y2O3-Nd2O3(Gd2O3,Sm2O3)-Yb2O3(Sc2O3) systems

Primary stabilizer

Oxide cluster dopants with distinctive ionic sizes

Page 10: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

10

Advanced Multi-Component Erosion Resistant

Turbine Blade Thermal Barrier Coating Development

─ Rare earth (RE) and transition metal oxide defect clustering approach (US

Patents No. 6,812,176, No.7,001,859, and 7,186,466; US Patent 7,700,508

NASA-Army ) specifically by additions of RE2O3 , TiO2 and Ta2O5

─ Significantly improved toughness, cyclic durability and erosion resistance while

maintaining low thermal conductivity

─ Improved thermal stability due to reduced diffusion at high temperature

ZrO2-Y2O3- RE1 {e.g.,Gd2O3,Sm2O3}-RE2 {e.g.,Yb2O3,Sc2O3} – TT{TiO2+Ta2O5} systems

Primary stabilizer

Oxide cluster dopants with distinctive ionic sizesToughening dopants

Page 11: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

11

Thermal Conductivity of Multi-Component Thermal

Barrier Coatings – Recent Developments with The Air

Force Programs─ Rare earth (RE) and transition metal oxide defect clustering approach (US

Patents No. 6,812,176, No.7,001,859, and 7,186,466; US Patents 7,700,508 -

TBC and 7,740,960 - EBC; NASA-Army ) specifically by additions of RE2O3 ,

TiO2 and Ta2O5

t’ phase region Cubic phase region

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

2 4 6 8 10 12 14

8YSZ k0 (2500F)

8YSZ k20 (2500F)

8YSZ k0 (2600F)

8YSZ k20 (2600F)

Refractron k0 (~2500F)

Refractron k20 (~2500F)

Refractron k0 (~2700F)

Refractron k20 (~2700F)

Praxair k0 (2500F)

Praxair k20 (2500F)

NASA k0 (2500F)

NASA k20 (2500F)

Th

erm

al c

ond

uct

ivit

y,

W/m

-K

Total dopant concentration, mol%

Plasma-sprayed

coatings

Advanced

ZrO2-

based

coatings

k0k20k0k20k0k20k0k20

t’ phase region Cubic phase region

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

2 4 6 8 10 12 14

8YSZ k0 (2500F)

8YSZ k20 (2500F)

8YSZ k0 (2600F)

8YSZ k20 (2600F)

Refractron k0 (~2500F)

Refractron k20 (~2500F)

Refractron k0 (~2700F)

Refractron k20 (~2700F)

Praxair k0 (2500F)

Praxair k20 (2500F)

NASA k0 (2500F)

NASA k20 (2500F)

Th

erm

al c

ond

uct

ivit

y,

W/m

-K

Total dopant concentration, mol%

Plasma-sprayed

coatings

Advanced

ZrO2-

based

coatings

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

2 4 6 8 10 12 14

8YSZ k0 (2500F)

8YSZ k20 (2500F)

8YSZ k0 (2600F)

8YSZ k20 (2600F)

Refractron k0 (~2500F)

Refractron k20 (~2500F)

Refractron k0 (~2700F)

Refractron k20 (~2700F)

Praxair k0 (2500F)

Praxair k20 (2500F)

NASA k0 (2500F)

NASA k20 (2500F)

Th

erm

al c

ond

uct

ivit

y,

W/m

-K

Total dopant concentration, mol%

Plasma-sprayed

coatings

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

2 4 6 8 10 12 14

8YSZ k0 (2500F)

8YSZ k20 (2500F)

8YSZ k0 (2600F)

8YSZ k20 (2600F)

Refractron k0 (~2500F)

Refractron k20 (~2500F)

Refractron k0 (~2700F)

Refractron k20 (~2700F)

Praxair k0 (2500F)

Praxair k20 (2500F)

NASA k0 (2500F)

NASA k20 (2500F)

Th

erm

al c

ond

uct

ivit

y,

W/m

-K

Total dopant concentration, mol%

Plasma-sprayed

coatings

Advanced

ZrO2-

based

coatings

k0k20k0k20k0k20k0k20

Metco 204 8YSZ (Porous) k0

Metco 204 8YSZ (Porous) k20

ZrO 312 Low k k0

ZrO 312 Low k k20

ZComP Low k k0

ZComP Low k k20

Page 12: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

12

Thermal Conductivity of NASA EB-PVD Low Thermal

Conductivity Thermal Barrier Coatings

0.0

0.5

1.0

1.5

2.0

7Y

SZ

t' E

B-P

VD

t' E

B-P

VD

Cu

bic

EB

-PV

D

Cu

bic

EB

-PV

D

Cu

bic

/0.5

mil

7Y

SZ

Cub

ic/0

.5m

il 7

YS

Z

Cu

bic

/1m

il 7

YS

Z

k20+

k0

Th

erm

al c

on

du

ctiv

ity

, W

/m-K

EB-PVD Coatings

─ Turbine TBC development focusing on toughness and CMAS resistance

─ The systems are applicable to advanced environmental barrier coatings for

ceramic matrix composites

Page 13: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

13

0.8

0.9

1.0

1.1

1.2

1.3

0.3 0.4 0.5 0.6 0.7 0.8 0.9

NASA GE 960 Conductivity data-1

k0 -Total 10 mol%k20-Total 10 mol%k0 -Total 12 mol%k20-Total-12 mol%

Th

erm

al c

on

du

ctiv

ity

, W

/m-K

Cluster dopants/Total dopants, mol/mol

244

433

622

822

633 444

Dopant in mol%, m1, m2, m3

Thermal Conductivity Optimization of A Series of NASA EB-PVD

Processed Low Conductivity Thermal Barrier Coatings- A ZrO2-m1 Y2O3-m2 Gd2O3-m3 Yb2O3 System Composition Optimization

- Low thermal conductivity and low rare earth design criteria, including the commercial coating

alloy 206A

Praxair ZrO 256

Sulzer Metco 206A

Page 14: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

14

Thermal Conductivity of ZrO2-(Y,Gd,Yb)2O3 and ZrO2-

(Y,Gd,Yb)2O3 + TT( TiO2-Ta2O5) Systems – Compared

with Low k + Gd2Zr2O7 Composite Systems

0

0.2

0.4

0.6

0.8

1

ZrY

GdY

b t'

ZrY

GdY

b t'

ZrY

GdY

b t'

ZrY

GdY

b t'

ZrY

GdY

b t'

ZrY

GdY

b t'

Cub

ic T

T

ZrY

GdY

b C

ubic

+TT

ZrY

GdY

b C

ubic

+TT

tZrY

GdY

b TT

t'

ZrY

GdY

b t'"

and

Cub

ic m

ultil

ayer

ZrY

GdY

b t'"

and

Cub

ic m

ultil

ayer

ZrY

GdY

b t'

ZrY

GdY

b t'

YSZ

+TT

YSZ

+TT

ZrY

GdY

b t'+

TT

ZrY

GdY

b t'+

TT

ZrY

GdY

b t'+

TT

ZrY

GdY

b t'+

TT

ZrY

GdY

b t'+

TT

ZrY

GdY

b t'+

TT

ZrY

GdY

b C

ubic

Thermal conductivity of EB-PVD erosion TBCs

Nor

mal

ized

con

duct

ivity

baseline2500ºF

- The six-component low conductivity coating systems, for toughness and CMAS resistance,

have lower TRLs

Page 15: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

15

Thermal Conductivity of ZrO2-(Y,Gd,Yb)2O3 and ZrO2-

(Y,Gd,Yb)2O3 + TT( TiO2-Ta2O5) Systems – Compared with

Low k + Gd2Zr2O7 Composite Systems - Continued

0.0 0.5 1.0 1.5 2.0 2.5

7YSZ

Low k t’-ZrO2-2mol%Y2O3-1mol%Gd2O3-1mol%Yb2O3

7YSZ/Gd2Zr2O7

7YSZ/40 layer Gd2Zr2O7

Low k t’-ZrO2-2mol%Y2O3-1mol%Gd2O3-1mol%Yb2O3

Low k t'/low k t'-Gd2Zr2O7 alternating-nanovariant

Low k t'/low k t'-Gd2Zr2O7 alternating nanovariant

Low k t'/low k t'-Gd2Zr2O7 alternating multilayer

Low k t'/low k t'-Gd2Zr2O7 alternating multilayer

Low k t'/low k t'-Gd2Zr2O7 alternating thicklayer

Low k c-ZrO2-7mol%Y2O3-1.5mol%Gd2O3-1.5mol%Yb2O3

Low k c-ZrO2-7mol%Y2O3-1.5mol%Gd2O3-1.5mol%Yb2O3

Thermal conductivity, W/m-K

Coat

ing T

ypes

- The EB-PVD processing of low k t’, low k cubic phased and Gadolinium Zirconate coatings

Page 16: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

16

Initial Furnace Cyclic Behavior of Advanced Multi-

Component Rare Earth Oxide Cluster Coatings

— The dopant concentration and coating architecture have been optimized and

developed to significantly improve the cyclic durability

— Some composition showed exceptional durability even at higher dopant

concentrations

— Lower rare earth concentration was found to be preferred for better durability

(a) Plasma-sprayed coatings (b) EB-PVD coatings

0

100

200

300

400

500

0 5 10 15 20 25 30

YSZ-Nd-Yb

YSZ-Gd-Yb

YSZ-Sm-Yb

Baseline 4.55YSZ

YSZ

Cy

cle

s to

fail

ure

Total dopant concentration, m ol%

YSZ

0

100

200

300

400

500

600

0 5 10 15 20 25 30 35

YSZ-Nd-Yb

YSZ-Gd-Yb

YSZ-Sm-Yb

YSZ

Cy

cle

s to

fail

ure

Total dopant concentration, m ol%

YSZ

Tested at 1165°C, 45

min hot time cyclesTested at 1165°C, 45

min hot time cycles

Page 17: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

17

Furnace Cyclic Behavior of Advanced

Multicomponent Thermal Barrier Coatings with an

Interface t’ Coating layer― t’ low k TBCs had good cyclic durability

― The cubic-phase low conductivity TBC durability generally improved by an 7YSZ

or low k t’-phase interlayer

0

200

400

600

800

1000

4 5 6 7 8 9 10 11 12

Cubic phase low k TBC

Tetrogonal t' phase low k TBCs

8YSZ

Cyc

les

to f

ailu

re

Total dopant concentration, mol%

2075°F (1135°C)

Low-k t’-phase

regionLow-k cubic

phase region

With the

interlayer

1135°C

Without

interlayer

0

200

400

600

800

1000

4 5 6 7 8 9 10 11 12

Cubic phase low k TBC

Tetrogonal t' phase low k TBCs

8YSZ

Cyc

les

to f

ailu

re

Total dopant concentration, mol%

2075°F (1135°C)

Low-k t’-phase

regionLow-k cubic

phase region

With the

interlayer

1135°C

0

200

400

600

800

1000

4 5 6 7 8 9 10 11 12

Cubic phase low k TBC

Tetrogonal t' phase low k TBCs

8YSZ

Cyc

les

to f

ailu

re

Total dopant concentration, mol%

2075°F (1135°C)

Low-k t’-phase

regionLow-k cubic

phase region

With the

interlayer

0

200

400

600

800

1000

4 5 6 7 8 9 10 11 12

Cubic phase low k TBC

Tetrogonal t' phase low k TBCs

8YSZ

Cyc

les

to f

ailu

re

Total dopant concentration, mol%

2075°F (1135°C)

Low-k t’-phase

regionLow-k cubic

phase region

With the

interlayer

1135°C

Without

interlayer

EB-PVD low k coatings

Page 18: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

18

Furnace Cyclic Behavior of ZrO2-(Y,Gd,Yb)2O3 and

with Co-doped with TiO2 and Ta2O5

0

100

200

300

400

500

ZrY

GdY

b t'

ZrY

GdY

b t'

ZrY

GdY

b t'

ZrY

GdY

b t'

ZrY

GdY

b t'

ZrY

GdY

b t'

ZrY

GdY

b t'

ZrY

GdY

b t'

ZrY

GdY

b t'

ZrY

GdY

b C

ubic

+TT

ZrY

GdY

b C

ubic

+TT

ZrY

GdY

b C

ubic

+TT

ZrY

GdY

b t'+

Hig

h T

T

ZrY

GdY

b t'+

Hig

h T

T

ZrY

GdY

b t'+

Hig

h T

T

ZrY

GdY

b t'

and

Cub

ic m

ulti

laye

r

ZrY

GdY

b t'

and

Cub

ic m

ulti

laye

r

ZrY

GdY

b t'

and

Cub

ic m

ulti

laye

r

YS

Z B

asel

ine

YS

Z B

asel

ine

Furnace cyclic life of EB-PVD erosion coatings

Fur

nace

cyc

lic

life

at 2

125F

2125°F

baseline

0

100

200

300

400

500

0 .0

0 .5

1 .0

1 .5

2 .0

2 .5

3 .0

C ub ic low k 4 33 FC T life

C ub ic 433+ 10T iO2 low k FC T l ife

C ub ic low k 433 low k therm al conductiv ity

C ub ic 4 33+ 10T iO2 low k th erm al condu ctiv ity

FC

T c

yc

les t

o f

ail

ure

, h

r

Th

erm

al

co

nd

uc

tiv

ity

, W

/m-K

Cu

bic

4-c

om

po

ne

nt

Cu

bic

5-c

om

po

ne

nt

(Re

2O

3+

TiO

2)

Cu

bic

4-c

om

po

ne

nt

Cu

bic

5-c

om

po

ne

nt

(Re

2O

3+

TiO

2)

— Low to moderate concertation TiO2 and Ta2O3 dopants significantly improve

cyclic life and thus the coating toughness

Page 19: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

19

Furnace Cyclic Behavior of ZrO2-(Y,Gd,Yb)2O3 and

with Co-dopant TiO2-TaO5 Thermal Barrier Coatings

1150oC Cyclic Oxidation of Low k

T RE-doped PVD TBC,

Pt-Al Bond Coat on Rene'N5

1-hr cycles

0 100 200 300 400 500

sp

ecific

we

igh

t ch

an

ge

, m

g/c

m2

-1.0

-0.5

0.0

0.5

1.0

1.5

bare N5+50Y

no TBC, bond coat on N5

4Y baseline

11-7 (2.5Y 0.75Gd 0.75Yb)

12-7 (1Y 1.5Gd 1.5Yb)

13-7 ( 2Y 1.5Gd 1.5Yb)

15-7 (4Y 3Gd 3Yb 5Ti 5Ta)

16-3 (1.6Y 1.2Gd 1.2Yb 5Ti 5Ta)

17-1 (4Y,3Gd,3Yb) // (1.6Y,1.2Gd,1.2Yb)

With J. Smialek

- Six component system- Six component system

Page 20: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

20

Advanced Ballistic Impact Resistant NASA Four-Component

Low Thermal Conductivity Turbine Coatings

─ 10X improvements in Impact Resistance; experience learnt for also being used

for developing advanced EBC systems

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.0 0.5 1.0 1.5 2.0 2.5

7YSZ and t' lowk baseline TBCsZr-RE-Ti-Ta t' oxide systemsImpact resistant series

Spal

led a

rea,

cm

2

Energy, J

ATES 104

ATES 105

ATES 103

150 200 500250 350 400 450300

Projectile velocity, m/s

Tested at 2100°F

(four-component systems)

Page 21: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

21

Advanced Ballistic Impact Resistant NASA Four-Component

Low Thermal Conductivity Turbine Coatings - Continued

─ 10X improvement in Impact Resistance; experience learnt for also being used for

developing advanced EBC systems

Four-component and six-component coating systems showed excellent impact (10X

improvement) and erosion resistance (up to 2X) compared to 7YSZ baseline

Page 22: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

2222

Erosion and Impact Aspects: Early Mach 0.3 Ballistic

Impact Tests of HfO2-Si Bond Coat EBC Systems

─ Advanced EBCs on par with best TBCs

─ More advanced EBC compositions in developments

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

0.0 0.5 1.0 1.5 2.0 2.5

7YSZ and low k TBCs

ZrRETT

ATES series

ND2

ND3

ND6

ND7

SUP-ERA7.4 EBC

t'-ZrO2/NASA EBC

Cubic low k ZrO2 k-NASA EBC

Spal

led

are

a, c

m2

Energy, J

150 200 500250 350 400 450300

Projectile velocity, m/s

NASA SUP-ERA 7.4 EBC

ND6 NASA EBC

t'/ NASA EBCND7 NASA EBC

Spalled

ND2

ND3

ND6

SUP-ERA 7.4

ND3

ND6

ND7

SUP7.1A

SUP-ERA 7.4

Page 23: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

23

High Heat Flux CO2 Laser Rig and Testing for Thermal and

Environmental Barrier Coatings Development with CMAS

ZrO2-1.0Y2O3-1.5Gd2O3-

1.5Yb2O3

ZrO2-1.6Y2O3-1.2Gd2O3-

1.2Yb2O37YSZ

EB-PVD Low k ZrO2-4mol%Y2O3-

3mol%Gd2O3-3mol%Yb2O3

/PtAl/Rene N5 (Howmet Processing-

Run 3844, ID 15H1)

– Direct Laser heat flux infiltrated thermal barrier coatings (Air Force/PTI CMAS)

– Direct Laser heat flux infiltrated thermal barrier coatings (Conventional CMAS)

– Low conductivity thermal barrier coatings may have improved “non-wetting”

performance compared to baseline 7YSZ

Page 24: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

24

CMAS Related Erosion Failure (CMAS+Erosion)• CMAS Tested Specimen in Burner Rig

Regular Erosion

01 to 07

08 to 13

Page 25: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

25

High Heat Flux CO2 Laser Rig and Testing for Thermal and

Environmental Barrier Coatings Development with CMAS– Heat flux cyclic failure of a thick Gd2Zr2O7 system tested at 1300°C, due to low

toughness and the formation of a reaction layer

Typical cyclic failure due to the reaction layer within a few cycles in a Gd2Zr2O7 system.

0.0

0.5

1.0

1.5

2.0

2.5

3.0

0

400

800

1200

1600

0 0.5 1 1.5 2 2.5 3

kceraTsurface

Tinterface

Tback

Ther

mal

conduct

vit

y, W

/m-K

Tem

per

ature

, °C

Time, hours

After 5 cycles

Page 26: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

26

High Heat Flux CO2 Laser Rig and Testing for Thermal and

Environmental Barrier Coatings Development with CMAS• Low k ZrO2-2.25mol%Y2O3-9mol%Gd2O3-2.25mol%Yb2O3 tested at 1300°C

• Limited CMAS spreading or penetration, suggesting the coating have resistance to CMAS

• Top and reacted layers had some spallation after 170h cyclic tests

• Preliminary effects of heat flux on baseline coatings determined, further studies planned

• Establish the life database and will compare with those of advanced systems

0.0

0.5

1.0

1.5

2.0

2.5

3.0

0

200

400

600

800

1000

1200

1400

0 40 80 120 160

kcera/kcera0

Tsurface

Tinterface

Tback

qthru

Norm

aliz

ed t

her

mal

conduct

ivit

y k

/k0

Tem

per

ature

, °C

; hea

t fl

ux, W

/cm

2

Time, hours

NASA Low k Metco AE10389

coating specimen, after 170

hr tested in laser rig

Page 27: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

27

CMAS Reaction Studies for Advanced TEBCs: Advanced Low k and HfO2 showed

Potential Benefits

- CMAS reactions studied for selected coating candidate materials

- Preliminary results showed 7YSHf, ZrO2-9.6Y2O3-2.2Gd2O3-2.1Yb2O3, and

30YSZ had the highest CMAS resistance

0 20 40 60 80 100 120

0 20 40 60 80 100 120

30YSZ

12YSZ

ZrO2-9.0Y2O3-4.5Gd2O3-4.5Yb2O3

ZrO2-9.6Y2O3-2.2Gd2O3-2.1Yb2O3

7DyHf

Coating surface recession rate, microns/hr

Percentage coating volume consumed, %

Coating surface recession rate, microns/hr

Percentage coating volume consumed, %

Coating Types

>100 m/hr

>100 m/hr

100%

100%

16 m/hr

52.2 m/hr

21%

67%

1 - 12YSZ 2 - 30YSZ 3 - 7DySH

4 - ZrO2-9.0Y2O3-4.5Gd2O3-4.5Yb2O3 5 - ZrO2-9.6Y2O3-2.2Gd2O3-2.1Yb2O3 6 - ZrO2-3.0Y2O3-1.5Sm2O3-1.5Yb2O3

SEM cross – sectional electron images ceramic

coating reacted with CMAS at 1300 C for 5 hCMAS resistance of selected coating systems

With Gustavo Costa et al

Page 28: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

28

• Fundamental studies of environmental barrier coating materials and coating

systems, stability including recession in rig environments, temperature limits and

failure mechanisms

• Focus on high performance and improving technology readiness levels (TRL),

including high stability HfO2 and ZrO2 -RE2O3-SiO2/RE2Si2-xO7-2x environmental

barrier systems, including processing optimizations for improved composition

control and process robustness

• Advanced NASA HfO2-Si and Rare Earth-Silicon based EBC bond coat systems

• More advanced, multicomponent composition and composite EBC systems to improve

the temperature capability, strength and toughness

• Develop HfO2-Si based + X (dopants) bond coat systems for 2700°F (1482°C) long-

term applications

• Develop prime-reliant 2700°F+ (1482°C) Rare Earth (RE)-Si + X (dopants) bond coat

systems for advanced integrated EBC-CMC systems, improving bond coat temperature

capability and durability

Advanced Environmental Barrier Coatings Developments

Page 29: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

29

Developing 3000°F (1650°C) EBCs

- High stability multicomponent HfO2 Top Coat (Hf-RE-SiO2 systems, tetragonal t’ ZrO2 toughened rare

earth silicate EBC; Ta, Ti additions)

- Graded and Layer graded interlayers

- Advanced HfO2-Rare Earth-Alumino-Silicate EBC

- Ceramic HfO2-Si composite bond coat capable up to 2700°F

Multicomponent Rare Earth (RE)

doped HfO2

(HfO2-11Y2O3-2.5Gd2O3-2.5Yb2O3)

HfO2-Rare Earth-Alumino-Silicate EBC(e.g., Metco 10157)

HfO2-Si or RE modified mullite bond coat

(e.g., Metco 10219 in APS systems)

Strain tolerant interlayer

– Hybrid 3000°F EBC system

10 m

Advanced ZrO2

Advanced ZrO2 - ytterbium

silicate composite coating

Also available alloys such as Metco AE 10155 and AE 9892

in APS systems

Page 30: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

30

SiC/SiC and Environmental Barrier Coating Recession in Turbine

Environments

- Recession of Si-based Ceramics

(a) convective; (b) convective with film-cooling

- Advanced rig testing and modeling (coupled with 3-D CFD analysis) to

understand the recession behavior in a High Pressure Burner Rig simulated

Turbine Enviornment

SiO2 + 2H2O(g) = Si(OH)4(g)

Recession rate = const. V1/2 P(H2O)2/(Ptotal)

1/2

Combustion gas

SiO2 + 2H2O(g) = Si(OH)4(g)

Combustion gas

Cooling gas

(a) (b)

Page 31: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

31

b

NASA High Pressure High Velocity and High Heat Flux SiC/SiC

and EBC Recession Studies Under Film Cooling Conditions

High temperature recession kinetics for film-cooled

and non-film cooled Gen II SiC/SiC CMCs

0.0 0.2 0.4 0.6 0.8 1.0 1.2

Recession rate, mg/cm2-hr

Film cooled recession at 2400°F

Film cooled recession at 2100°F

Non-film cooling recession at 2100°F

Non-film cooling recession at 2400F

(model extrapolated to 300m/s gas velocity)

300 m/s, 16 atm

Examples of environmental barrier coating recession

in laboratory simulated turbine engine conditions

― Determined recession under complex, and realistic High Pressure Burner Rig and

Laser Rig simulated turbine steam conditions

Specimen recession and durability testing

under air cooled, heat flux conditions:

-1” and 2” discs, 600 psi cooling chamber

Steam heat flux test rig

Page 32: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

32

Degradation Mechanisms for Si Bond Coat – Interface Reactions

— Significant interfacial pores and eutectic phases formation due to the water vapor

attack and Si diffusion at 1300°C

— Heat flux condition further limit the use tempertatures

MulliteBSAS

Si

SEM images Interface reactions at 1300°C; total 200 hot hoursBaO-Al2O3-SiO2 ternary phase diagram

Si bond coat

Interface Si bond coat melting of

selected coating systems, under laser

heat flux tests, 1” dia button specimen

Page 33: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

33

The Yb2SiO5/Yb2Si2O7 EBC Delamination Crack Propagation

Tests under Heat Flux Thermal Gradient Test Conditions

─ Penney-shaped crack initially size 1.5 mm in diameter, tested in air at 1350°C

─ Crack propagated from 1.5 mm to 7.5 mm 60, 1 hr cyclic testing

─ SiO2 loss (volatility) accelerated crack propagation

After 60 hr, 1 hr cyclic

testing

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

0

200

400

600

800

1000

1200

1400

1600

0 10 20 30 40 50 60 70

kcera

TsurfaceTinterfaceTbackqthru

Th

erm

al c

on

du

ctiv

ity,

W/m

-K

Tem

per

atu

re,

°CTime, hours

Tinterface=1250°CTsurface=1350°C

Tback=1100°C

Page 34: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

34

Ytterbium Mono-/Di-Silicate EBC Tested in Laser High Heat

Flux Steam Rig

─ Observed mudflat cracking after 1400°C test

─ Loss of Silica and increased porosity observed after the testing

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

0

200

400

600

800

1000

1200

1400

1600

0 10 20 30 40 50 60

kcera

TsurfaceTinterfaceTbackqthru

Th

erm

al c

on

du

ctiv

ity,

W/m

-K

Tem

per

atu

re,

°CTime, hours

Tinterface=1230°CTsurface=1400°C

Tback=1015°C

Page 35: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

35

Fatigue Testing using a Laser High-Heat-Flux Approach for

Environmental Barrier Coated Prepreg SiC/SiC CMCs

- Environmental Barrier Coatings Yb2SiO5/Yb2Si2O7/Si on MI Prepreg SiC/SiC CMC substrates

- One specimen tested in air, air testing at 1316°C

- One specimen tested in steam, steam testing at TEBC 1316°C, TCMC at ~1200°C

- Lower CMC failure strain observed in steam test environments

failure

failure

failure

failure

Fatigue strains (amplitudes) – Time Plot Thermal conductivity – Time Plot

Page 36: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

36

Fatigue Testing using a Laser High-Heat-Flux Approach for EBC

Coated Prepreg SiC/SiC CMCs - Continued

In steam; EBC cracking and volatility

OYb

Si

In Air; EBC cracking

- Crack and recession failure in the laser rig air and steam environment tests tests

Page 37: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

3737

Advanced High Temperature and 2700°F+ Bond Coat and

EBC Development NASA Advanced EBC Development:

• Advanced compositions ensuring environmental and mechanical stability

• Bond coat systems for prime reliant EBCs; capable of self-healing• Corresponding oxygen containing EBCs with high toughness and CMAS resistance• Composition further being developed for Ultra-High Temperature Ceramics and Coatings

High strength, high

stability reinforced

composites: HfO2-Si

and a series of Oxide-

Si systems

HfO2-Si based and

minor alloyed systems

for improved strength

and stability, e.g., rare

earth dopants

Advanced 2700°F

bond coat systems:

RE-Si based systems

Advanced 2700°F bond

coat systems: RE-Si based

Systems, grain boundary

engineering designs and/or

composite systems

HfO2-Si systems Advanced 2700°F+ Rare Earth - Si Bond Coat systems

Rare Earth – Si + Hf coating systems

Hf – Rare Earth – Si coating systems

Temperature capability increase

Page 38: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

38

NASA EBC Bond Coats for Airfoil and Combustor EBCs– Patent Application 13/923,450 PCT/US13/46946, 2012

– Advanced systems developed and processed to improve Technology Readiness Levels (TRL)

– Composition ranges studied mostly from 50 – 80 atomic% silicon• PVD-CVD processing, for composition downselects - also helping potentially develop a low cost CVD

or laser CVD approach• Compositions initially downselected for selected EB-PVD and APS coating composition processing• Viable EB-PVD and APS systems downselected and tested; development new PVD-CVD approaches

YSi YbGdYSi GdYSi

ZrSi+Y YbGdYSi GdYSi

ZrSi+Y YbGdYSi GdYSi

ZrSi+Ta YbGdYSi GdYSi

ZrSi+Ta YbGdSi GdYSi-X

HfSi + Si YbGdSi GdYSi-X

HfSi + YSi YbGdSi

HfSi+Ysi+Si YbGdSi

YbSi YbGdSi

HfSi + YbSi

YbSi

GdYbSi(Hf)

YYbGdSi(Hf) YbYSi

YbHfSi

YbHfSi

YbHfSi

YbHfSi

YbHfSi

YbSi

HfO2-Si;

REHfSi

GdYSi

GdYbSi

GdYb-LuSi

NdYSi

HfO2-Si

YSi+RESilicate

YSi+Hf-RESilicate

Hf-RESilicate

Used in ERA components as part of bond coat system

Hf-RE-Al-Silicate

Used also in ERA componentsUsed in ERA components as part of bond coat system

PVD-CVD EB-PVD APS*

REHfSi

FurnaceLaser/C

VD/PVD

Process and

composition

transitions

APS*: or plasma spray related

processing methods

Page 39: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

National Aeronautics and Space Administration

www.nasa.gov

NASA EBC Processing Developments for SiC/SiC Ceramic

Matrix Composites

− Develop processing capabilities, experience and demonstrate feasibilities in

various techniques: air plasma spray, Electron Beam - Physical Vapor

Deposition (EB-PVD), Plasma Sprayed-Physical Vapor Deposition (PS-PVD)

• Efforts in developing turbine EBC coatings with Directed Vapor Technologies

using Directed Vapor EB-PVD: Turbine Airfoils

• NASA APS, and Triplex Pro APS (with Sulzer/Oerlikon Metco) - for Combustor

applications

• Cathodic arc and Magnetron PVD processes: bond coat developments

• NASA PS-PVD

• Some planned EBCs DVM/DVC coatings (with Praxair): aiming at combustor

EBC

− Other processing techniques such as Polymer Derived Coating composite

coatings (Ceramtec), and laser processing for improved stability

Page 40: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

40

— Focused on advanced composition and processing developments using state-

of-the-art techniques

— Improved processing envelopes using high power and higher velocity, graded

systems processing for advanced TEBCs and thermal protection systems

Air Plasma Spray Processing of Environmental Barrier

Coatings for Combustor Liner Components

Sulzer Triplex Pro system having high

efficiency and high velocity processing

Advanced Multilayer

EBCs

HfO2-Si bond coat

NASA EBC processed by Triplex pro

EBC coated SiC/SiC CMC Inner and

Outer Liner componentsInner and outer liner articles

Page 41: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

41

Development and Processing of Directed Vapor Electron

Beam - Physical Vapor Deposition (EB-PVD) ─ NASA programs in supporting processing developments and improvements with Directed

Vapor Technologies International, Inc.• Multicomponent thermal and environmental barrier coating vapor processing

developments• High toughness turbine coatings• Affordable manufacture of environmental barrier coatings for turbine components

Directed Vapor Processing systems

NASA HfO2-Si bond

coat on SiC/SiC

NASA Hybrid

EBC on SiC/SiCAdvanced multi-component and multilayer turbine EBC systems

HfO2-Si bond coatEBC

Alternating layered High toughness EBC

Processed EBC system

Page 42: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

42

Plasma Sprayed-Physical Vapor Deposition (PS-PVD)

Processing of Environmental Barrier Coatings

─ NASA PS-PVD and PS-TF coating processing using Sulzer (Oerlikon) newly developed technology

• High flexibility coating processing – PVD - splat coating processing at lo pressure (at ~1 torr)

• High velocity vapor, non line-of-sight coating processing potentially suitable for complex-shape components

• Significant progress made in processing the advanced EBC and bond coats

Nozzle section view Mid section view End section (sample side) view

100 kW power, 1 torr operation pressure HfO2-Si bond coat

NASA PS-PVD Coater System Processed coating systems

Page 43: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

4343

HfO2-Si Bond Coats Processing using EB-PVD compared

with Early Hot-Press Coatings - Continued

─ Capble of processing silicide dominant HfO2-Si bond coats in EB-PVD coating and

magnetron PVD

─ Graded coatings being designed and used

─ Processing nano-structured coatings

HfO2-Si At% Wt% Units

O 26.08 6.70 wt.%

Si 49.10 22.15 wt.%

Hf 24.82 71.15 wt.%

Total 100.00 100.00 wt.%

0

200

400

600

800

1000

10 20 30 40 50 60 70 80

HfO2-25wt%Si-1350°C

HfO2-50wt%Si-1350°C

HfO2-75wt%Si-1400°C

EB-PVD HfO2-Si 48-6

HfO2

SiHfSiO4

HfSi2, Hf5Si4, HfSi etc

SiO2 (t)

0

1 104

2 104

3 104

4 104

5 104

6 104

7 104

Re

lative I

nte

nsity

Re

lative I

nte

nsity

Diffraction angle, 2

HfO2-Si (EB-PVD 48-6) Bond Coat

Page 44: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

44

Environmental Barrier Coatings and SiC/SiC DIC Testing –

High Temperature (12C-470-08-11 and 12C-470-08-12)

• The uncoated and EBC HfO2-Si coated CVI-MI specimen pre-tested in high

pressure burner rig

• Uncoated specimen exposed showed severe degradation of composite properties

• Oxidation and embrittlement of the MI-CVI CMC in HPBR lead to the lowers

strength of uncoated specimen

coated

uncoated

Extensometer DIC

uncoated

coated

Specimen

Surface

Temp.

(°C)

Back

Temp.

(°C)

coated 1230 1070

uncoated 1200 1010

SpecimenE (GPa)

Extensometer DIC

σUTS

(MPa)

εfail

(%)

coated 241 266 238 0.371

uncoated 146 221 166 0.134

With Matt Appleby et al, Surface and Coatings Technology, 2015

12C-470-08-11

12C-470-08-12

Page 45: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

45

Environmental Barrier Coatings and SiC/SiC DIC Testing –

High Temperature (12C-470-08-11 and 12C-470-08-12)

With Matt Appleby et al, Surface and Coatings Technology, 2015

• DIC studies of coated and uncoated CMC specimens

• Energy distribution of AE events compared in specimen gage section with

corresponding DIC strain mapping at failure stress

Failure

PlaneCOATED

Nominal thermomechanical

strain: 0.96%

UNCOATED

Nominal thermomechanical

strain: 0.71%

Failed below area

of DIC interest

12C-470-08-11

12C-470-08-12

Page 46: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

46

coated

uncoated

Extensometer DIC

uncoated

coated

Environmental Barrier Coatings and SiC/SiC DIC Testing –

High Temperature (12C-470-08-11 and 12C-470-08-12)

• The uncoated and EBC HfO2-Si coated CVI-MI specimen pre-tested in high

pressure burner rig

• Uncoated specimen exposed showed severe degradation of composite properties

• Oxidation and embrittlement of the MI-CVI CMC in HPBR lead to the lowers

strength of uncoated specimen Si

C

Page 47: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

47

Advanced EBC-CMC Fatigue Test with CMAS: Successfully

Tested 300 h Durability in High Heat Flux Fatigue Test

Conditions - Continued- Advanced Hf-NdYb silicate-NdYbSi bond coat EBC coatings on 3D architecture

CVI-PIP SiC-SiC CMC (EB-PVD processing)

Surface view CMAS

35mg/cm2)Back view CMAS

35mg/cm2)

EBC/CMC-CMAS Laser heat Flux Fatigue Tests

Page 48: Advanced Thermal Barrier and Environmental Barrier Coating ...Advanced Thermal Barrier and Environmental Barrier Coating Development at NASA GRC Dongming Zhu And Craig Robinson Environmental

48

Thermal Gradient Tensile Creep Rupture Testing of Advanced

Turbine Environmental Barrier Coating SiC/SiC CMCs

- A thin EB-PVD turbine airfoil EBC system with advanced HfO2-(Yb,Gd,Y)

silicate and (Yb,Gd)Si bond coat tested 300hr at TEBC-surface 1537°C, Tbond coat

1480°C, Tback CMC surface 1250°C with CMAS

- Fatigue stress amplitude 69 MPa, at frequency f=3Hz, stress ratio R=0.05

Strain amplitude

1537°C, 10ksi, 300 h fatigue (3 Hz, R=0.05) on 14C579-

011001_#8 CVI-SMI SiC/SiC (with CMAS)

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Laser Rig Testing and Development of NASA Advanced Multicomponent

Yb-Gd-Y Silicate EBC/HfO2-Si System on 3D Architecture SiC/SiC CMC

under 2700°F+ SPLCF Conditions• The EBC specimens tested under the laser heat flux test rig under 10 ksi (500 hr) and 15

ksi (140 hr completed) SPLCF conditions, respectively;

• One EBC specimen tested in isothermal furnace test at 2700°F, 300 hr completed for

comparisons

RB2014-54-4, EBC 512h/CMC 492h RB2014-54-6, EBC 140h

RB2014-54-8, Isothermal furnace 300hr

Laser MTS 810 Test rig

Tsurface 2912-3090°F

Tinterface ~2700°F

TCMC back 2400-2450°F

EBC

Bond Coat

SiC/SiC CMC

Example EBC cross-section

Laser rig test creep strains

Laser NDE and in-plane

thermal conductivity

measurements

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Valerie Wiesner

Fundamental EBC Studies, and High Stability and CMAS Resistant

Advanced EBC Developments: High Melting Point Coating, and

Multi-Component Compositions

Area AArea B

– Demonstrated Calcium-Magnesium-Alumino-

Silicate (CMAS) resistance for NASA RESi

system at 1500°C, 100 hr

– Silica-rich phase precipitation

– Still some rare earth elements leaching into the

melts (low concentration ~9 mol%)

Surface side of

the CMAS melts

EDS E

Ahlborg & Zhu

CMAS melts

200 hr, 1500°C

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Laser Rig Thermomechanical Creep - Fatigue Tests of

Advanced 2700°F+ RESi Bond Coats and EBC Systems

- APS, PVD and EB-PVD processed 2700°F bond coats and EBCs on SiC/SiC CMC: focus on creep,

fatigue high heat flux testing at temperatures of 1316-1482°C+ (2400-2700°F+) – Selected Examples

Air Plasma Sprayed YSi+Hf-RESilicate

EBC Bond Coat series on CVI-MI SiC/SiC

1400°C,at 10 ksi, 400 hr

Creep and Fatigue Tests with CMAS

Fatigue Tested

PVD GdYSi coated on Hyper Them CVI-MI

SiC/SiC

1316°C, 10ksi, 1000 h fatigue (3 Hz, R=0.05)

PVD GdYbYSi coated on Prepreg SiC/SiC

1316°C, 15ksi, 1169 h fatigue (3 Hz, R=0.05)

NASA 2700°F(1482°C)+ EBC System 188

on SA Tyrannohex SiC Composite, 1482°C

15 ksi, 500hr

Creep rate

7.1x10 -6 1/s

EB-PVD Rare Earth Silicate EBC/YbGdYSi

bond coat on CVI-(MI)

TEBC surface 2850-3000°F (1600-1650°C)

Tcmc back at ~2600°F (1426°C)

Laser rig testing

EB-PVD (Hf,Yb,Gd,Yb)2Si2-xO7-x EBC/GdYbSi

bond coat on CVI-MI SiC/SiC (with CMAS)

1537°C, 10ksi, 300 h fatigue (3 Hz, R=0.05)

D. Zhu, “Advanced Environmental Barrier Coatings for SiC/SiC

Ceramic Matrix Composite Turbine Components”, Engine

Ceramics – Current Status and Future Prospects, pp 187-202, 2016

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The Advanced EBCs on SiC/SiC CMC Turbine Airfoils Successfully Tested for Rig

Durability in NASA High Pressure Burner Rig

NASA advanced EBC coated turbine vane subcomponents tested in rig simulated engine environments (up

to 240 m/s gas velocity, 10 atm), reaching TRL of 5

Swirl jet

flows

EBC Coated Rig Inner

and outer liner testing

2500°F, 10-16 atm,

completed 250 h

Vane leading edge

seen from viewport

in High Pressure

Burner Rig Testing

16 atm, 200 m/s,

up to 2650°F

EBC Coated CVI SiC/SiC vane after 31

hour testing at 2500°F+ coating

temperature

EBC Coated Prepreg SiC/SiC vane after

21 hour testing at 2500°F

EBC Coated Prepreg

SiC/SiC vane tested

75 hour testing at

2650°F

Uncoated vane

tested 15 hr

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Advanced environmental barrier coatings – Prepreg CMC systems demonstrated long-term EBC-CMC system creep

rupture capability at stress level up to 20 ksi at TEBC 2700°F, TCMC interface ~2500°F

The HfO2-Si based bond coat showed excellent durability in the long term creep tests

Thermal Gradient Fatigue-Creep Testing of Advanced Turbine Environmental Barrier

Coating SiC/SiC CMCs

Hybrid EBCs on Gen II CMC after 1000

h low cycle creep fatigue testing

Advanced EBC coated CMC subelement testing and

modeling

EBC-2.5D CMC

Sub-element

demo in HPBR

EBC-CMC vane

laser rig testing

Displacements, mm

0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35

Lo

ad

, N

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

TEST

DAMAGE model

Von MisesStress Plot

No reduction

MI SiC/SiC CMC

FEM modeling of EBC-CMC creep

and thermal gradient and stress rupture

interactions

FEM modeling of EBC-CMC vane

trailing edge rig test failure

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Summary─ Advanced thermal barrier coatings are based on rare earth co-doped, defect

clustered oxide systems, aiming at low thermal conductivity, and high thermal

stability, and impact/erosion CMAS resistance

─ Durable EBCs are critical to emerging SiC/SiC CMC component technologies,

requiring prime-reliant designs

─ The NASA EBC development built on a solid foundation from past experience,

evolved with the current state of the art compositions of higher temperature

capabilities and stabilities• Multicomponent EBC Zr, Hf, oxide/silicates with higher stabilities

• Improved strength and toughness

• HfO2-Si and RE-Si bond coats for realizing 1482°C+ (2700°F+) temperature capabilities

for helping prime-reliant EBC-designs

• New EBC compositions improved combustion steam and CMAS resistance, and protecting

CMCs

─ EBC processing and testing capabilities significantly improved

─ Advanced testing and modeling being emphasized

─ Focused on next generation turbine airfoil EBC developments, demonstrated

component EBC technologies in simulated engine environments

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Acknowledgements

• The work was supported by NASA Aeronautics Programs, currently under the

Transformational Tools and Technologies (TTT) Project, and NASA Environmentally

Responsible Aviation (ERA) Project

NASA EBC-CMC Team, In particular, Jim DiCarlo, Jim Smialek, Dennis Fox, Bryan Harder, Robert A.

Miller, Janet Hurst, Martha Jaskowiak, Ram Bhatt, Mike Halbig, Valerie Wiesner, Nate Jacobson,

Narottam Bansal, Francisco Sola-Lopez, and Serene Farmer (NASA GRC)

Collaborators include:

Sulzer Metco (US) - Mitch Dorfman; Chis Dambra

Directed Vapor Technologies, International – Derek Hass and Balvinder Gogia

Praxair Surface Technologies – John Anderson and Li Li (currently with Rolls Royce)

Southwest Research Institute – Ronghua Wei (PVD coating processing)

in supporting the coating processing

Engine OEM Companies including GE Aviation, Rolls Royce (Kang Lee, now with NASA GRC),

Honeywell, Pratt & Whitney

In particular, the contributions from the following:

• Dr. Ajay Misra, Ms. Joyce A. Dever, Dr. Joe Grady, Mr. Dale Hopkins and Ms. Janet Hurst;

• Dr. Anindya Ghoshal, Mr. Waldo Acosta and the ARL team; Ms. Lynne Pfledderer and Ms. Ruth Sikorski

of ARFL; Ms. Mary Anne Alvin of NETL of DoE

Also,

• Ron Phillips (Vantage Partners, LLC) and Ralph Pawlik (University of Toledo), mechanical testing

• Mike Cuy, Furnace Cyclic Oxidation Testing

• Don Humphrey (Vantage Partners, LLC) and John Setlock, TGA Testing

• Terry McCue (SAIC/NASA GRC, SEM/EDS)

• Joy Buehler (Vantage Partners, LLC, Met Lab)