toppcoat - trimis...2012/06/26 · 4 project plan basics wp0 management wp1 technical...
TRANSCRIPT
1
EU joint project
TOPPCOAT
TOwards design and Processing of advanced, comPetitive
thermal barrier COATing systems
Aerodays2011
Matthias Karger, Robert VaßenIEK-1, Forschungszentrum Jülich GmbH
2
Outline
• Short project description
• Main objectives
• Development of new TBC systems
• Testing new TBC systems
• Coating of real components
• Summary, outlook
3
Project
Coordinator Forschungszentrum Jülich
Budget 4.2 Mio.€, (EC contribution 2.1 Mio. €)
Period Feb. 2006 – Jan. 2010
Consortium
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Project plan
Basics
WP0 Management WP1 Technical specifications, material procurement WP2 Powders and materials
Main objective:
Significant improvement of thermal barrier coating systems
used for gas turbine applications
Development
WP3 Interface modificationWP4 Advanced technology for manufacture of strain tolerant coatings WP5 Screening of key properties and full characterisation
Evaluation
WP6 Transfer & application of technologyWP7 Final evaluation under close-to-service conditions
Increase temperature capability
Increase engine efficiency
Provide cost effective alternative to EB-PVD
Improve APS coating lifetimes comparable to those of EB-PVD (segmentation, 3D interface)
Introduce gas phase processes for industrial application (coating of complex shaped specimen)
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Project approaches for new TBC systems
Advanced APS process with
conventional feedstock
•Highly segmented coatings
•Feedstock: fused and crushed
or spray dried YSZ
Interface modifications to induce
seg.cracks /stop horizontal cracks
New processes
•Advanced processes using gas
phase deposition
•Processes: LPPS-TF, PE-CVD
New materials
•Advanced APS process with nano
sized feedstock or alternative TBC
material
•Feedstock: suspension with
agglomerated nano particles
Transfer of technology � coating of real components
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IP / know how situation at project start:
T.A. Taylor, Patent (1991)
P. Bengtsson, J. Wigren (1999)
M. Madhwal, E. H. Jordan, M. Gell (2004)
S. Ahmaniemi (2004)
H. Guo, R. Vaßen, D. Stöver (2005)
State of the art: 3-5 cracks/mm
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Vertical structured TBCs
Tensile stress
Vertical structured coating
Compressive stress
supports crack growth
Hot
Hot
Conventional non-columnar coating
Cooling down,
Relaxation
Compressive stress level lower at surface!!!!
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Advanced APS coatings
Milestones:
Coatings on bond-coated substrates
• Plasma-sprayed coatings with segmentation crack densities > 10 cracks mm-1
• Gas-phase deposited coatings with homogeneous, columnar, well-bonded structure
• Process conditions for coating of complex shaped parts established
500µm
Triplex II technology
Feedstock: 8YSZ fused & crushed (TIAG)
Porosity: Overall: ~6% (Mercury porosimetry)
Crack density: ~9 cracks/mm @500µm thickness
F4 technology
Feedstock: 8YSZ spray dried (SM)
Crack density: ~9 cracks/mm @500µm thickness
Advanced APS process with conventional feedstock
• Highly segmented coatings
Further development of Taylor (1991), Bengtsson et.al. (1999), state of the art were 3-4 cracks/mm
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Interface modifications New processes
500µm
Surface modified by application of
laser-cladded 3D structures
to induce seg.cracks /stop
horizontal cracks
PVD-LPPS (fka LPPS-TF)
•2 – 5 mbar
•High power input
•Enables growth of columnar structures
PVD-LPPS
APS Plasmajet
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New processes
Suspension plasma spraying
Triplex II
•Nano suspension, agglomaterated, nano
sized YSZ particles in ethanol
•High segmentation crack density, combined
with high porosity values (~35%)
•Low thermal conductivity
SPS coating
SPS plasma jetinjecton
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Midterm status
Start: 21 bondcoat/topcoat systems (~250 specimen) tested
Selection criteria:
Microstructure
Furnace cycling
1st Burner rig test
• 2 Systems 3D interface APS top coat
• VPS bondcoat, F4 APS top coat
• VPS bondcoat, Triplex II APS top coat
• PtAl bondcoat, LPPS-TF top coat
• Porous APS reference
• EB-PVD reference
commercial PtAl+EB-PVD
reference
Bondcoat:
Thickness 150–200µm
Ra 12-14 µm
commercial. APS referenceTBC evaluation
•Long term stability
• furnace cycling test
•Thermal shock resistance
• burner rig tests
•Erosion resistance
•Corrosion resistance
Reference systems
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Specimen procurement
Cyclix oxidation
Erosion
Burner Rig
Corrosion
Mechanical response
Thermography
~250 CMSX4 specimen with different geometries were needed
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Characterisation: Furnace Cycling Test
Test conditions:
TBC thickness FT Cycling
150µm 1100 23hFT,1h RT
300µm-400µm 1050 23hFT,1h RT
500µm 1000 23hFT,1h RT
Test results
3D APS
LPPS-TF
F4 APS
Triplex II APS
APS Ref.
EB-PVD Ref.
LPPS-TF
Seg. APS
Hast Du da noch ein Foto ohne die oberflächliche Abplatzung?
Das war auch Triplex (unser)?
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Characterisation: Burner Rig Test
Test conditions:
CMSX4 pipes, 150x16mm
Surface Temp. 1200°C
Temp. Gradient >100°C
Cycle 210s hot
75 cooling (<100°C)
Test Results
3D APS
LPPS-TF
F4 APS
Triplex II APS
APS Ref.
EB-PVD Ref.
Burner Rig (NLR)
Test specimen
Failure: Triplex II APS
Failure: LPPS-TF
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Test conditions:
Test temperature 700°C
Impingement angles 30°, 90°
Erosive Material Quartz
Particle feeding rate 2g/min
Impaction speed 25-40m/s
Test Results
3D APS
LPPS-TF
F4 APS
Triplex II APS
APS Ref.
EB-PVD Ref.
LPPS-TF
Seg. APS
Characterisation: Erosion
Erodet surfaces
LPPS-TF
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Characterisation: Corrosion
Test conditions:
Test temperature 900°C
Test medium 75% NaSo4,
25% NaCl
Test specimen massive Pins
CMAS-like test
Test Results
3D APS
LPPS-TF
F4 APS
Triplex II APS
APS Ref.
EB-PVD Ref.
Sample after 100 h
FailureEDX mapping, 3D structure
Furnace
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Characterisation: Cyclic oxidation
Test conditions:
Dwell temperature 1050°C/‘
1100°C(*)
Cycle duration 2h
Heating/cooling 15min
Seg. APS, 400h/270c
Test Results
3D APS
LPPS-TF (*)
F4 APS
Triplex II APS
APS Ref.
EB-PVD Ref.(*)
EB-PVD 800h@1100°C
LPPS-TF 700h@1100°C
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Characterisation: Summary & Ranking
0,00
0,25
0,50
0,75
1,00
3D new FZJ LPPS-TF SM
(~300µm)
APS
SM204BNS
HTU
APS f&c FZJ APS ref TUC EB-PVD ref
SNS
NLR Burner Rig VAC Burner Rig
ALSTOM FCT AVIO corrosion
Cesi Erosion
3D APS LPPS TF F4 APS TriplexII APS APS ref. EB-PVD ref
Main obejective: Properties of developed system
superior to EB-PVD coatings, evaluated performace
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Thermal conductivity
0
0,5
1
1,5
2
2,5
3
0 200 400 600 800 1000 1200
Temperature (°C)
Therm. conductivity (W/mK) 3D + seg APS 2.5
Porous APS (ref) 0.6
Triplex 2 APS seg. 1.9
EB-PVD (ref) 2.0
F4 APS seg. 2.1
LPPS-TF 1.6
Measured via Laser Flash Technology
[ W/mK
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Technology transfer - Coating of real components
AVIO Combustor Splash Plate
ALSTOM blade Airfoil
Triplex II
Highly segmented
LPPS-TF
ColumnarF4
Highly segmented
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Spraying transfer evaluationT
BC
th
ickn
ess
0
200
400
600
800LPPS
APS TR2
Ref
LEPS
SS
TE
0
10
20
30
PS/TE PS
PS
PS/LE LE
SS/LE SS
SS
SS/TE
PS/TE
PS
PS
PS/LE
LE
SS/LE SS
SS
SS/TE
TB
C p
oro
sity
TB
C thic
kness
TBC thickness and porosity on real components
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YSZ
Eu/Dy doped YSZ layer
Bondcoat/Substrate
LaserLuminescence
Sensor Coatings Repair technology
EB-PVD coating
LPPS-TF coating
Defect
Modelling / FEM analysis of 3D
modifications
Monitoring the process
Further activities
0 20 40 60 80 100 120 140 160
-3.5
-3.0
-2.5
-2.0
-1.5
-1.0
-0.5
0.0
linear fit
ln ( intensity ratio)
Thickness Topcoat (µµµµm)
YSZ Thickness
Inte
nsity R
atio Mechanical tests
• 4-point bending
• Pulse exccitation
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Summary, Outlook
- Development of innovative coatings succesful
- Highly segmented, columnar LPPS-TF, sensor coatings, HVOF bondcoat, SPS
- Enhancements in understanding processes
- 3D modified surfaces, suspension plasma spraying, repair of TBC
- Testing and evaluation of new TBC systems with promising results
- Highly segmented APS and LPPS show performance at least comparable to EB-PVD coatings
- Transfer of spraying processes and microstructures to real components
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Thank you for your attendance.
Thanks to:
EC for support
TOPPCOAT project partner for
the good collaboration.