cleveland, ohio 44135 nasa john h. glenn research center ...€¦ · (ebcs) development objectives...

DEVELO

T OF N

ASA'S AD

TAL BAR

/SIC C

POSITES: PR

ELIANT D

ILITY PERSPEC

ing Zhu

Materials and S

tructures Division

John H. G

lenn Research C

enter C

leveland, Ohio 44135

The work w

as supported by NASA

Fundamental Aeronautics Program

(FAP) Transformational Tools

and Technologies (TTT) Project

Advanced Ceram

ic Matrix C

omposites:

Science and Technology of Materials, D

esign, Applications, Performance and Integration

I Conference, Santa Fe, N

ber 5-9, 2017

’s Advanced Environmental B

arrier Coating System

s for C

eramic M

atrix Com

posites (CM

Enabling Technology for N

ext Generation Low

ission, High E

fficiency and Light-W

eight Propulsion, and E

xtreme E

nvironment M

aterial System

Environmental B

arrier Coatings (EB

Cs) developm

ent objectives •

Help achieve future engine tem

perature and performance goals

nsure system durability – tow

ards prime reliant coatings and m

aterial systems

stablish database, design tools and coating lifing methodologies

Hybrid E

lectric Propulsion A

ircraft and C

oatings (UH

• Im

prove technology readiness

Entry, D

escending and Landing: U

ltra High C

eramics

Fixed Wing S

ubsonic and Supersonics A

ircraft

Temperature

Capability

SA Environm

ental Barrier C

oating Developm

ent Goals

mphasize tem

perature capability, performance and durability

• Develop 2700°F environm

ental barrier coating technologies -For 2400°F (1316°C

) and 2700°F (1482°C) C

eramic M

atrix Com

posites (CM

Cs) in

support of next generation turbine engines -Focus on advanced C

combustors and highly loaded turbine airfoils

-Particularly also em

phasize highly loaded turbine blades

Step increase in the m

aterial’s temperature capability

Temperature

3000°F SiC/SiC

CCapability

(T/E(T/EBBC)C) ssuurfarfaccee

airfoil and combustor

3000°F+ (1650°C+)

technologies 2700°F SiC

/SiC thin

2700°F (1482qC)

turbine EBC

systems for

* Recession: <5 m

g/cm2 per 1000 hr (40-50 atm

., Mach 1~2)

** Com

ponent strength and toughness requirements

Gen II –

Currentcomm

ercialG

en IIIG

en. IV

Increase in 'T

across T/EBC

Single Crystal Superalloy

Ceramic M

atrix Composite

Gen II – Current com

mercial

en III G

en. IV

Increase in 'T across T/EB

Single Crystal Superalloy

Ceramic M

atrix Composite

2800ºFcom

bustor TB

2500ºFTurbine TB

C airfoils

2700°F (1482°C) G

en III SiC

2400°F (1316°C) G

en I and Gen II SiC

2000°F (1093°C)

GGenen II

YYearear

Outline

─ Environm

ental barrier coating systems: tow

ards Prime-R

eliant system

Thermom

echanical, environment and therm

ochemical stability of E

e-reliant EB

Cs, initial design approach and requirem

dvanced environmental barrier coating system

s (EBC

s) for C

airfoils and combustors

A advanced turbine EB

C coating system

status •

Developm

ent and testing, durability perspectives

esign tool and life prediction perspectives of coated CM

components

dvanced Testing •

phasizing thermom

echanical, environment and therm

ochemical

interactions

─ Sum

mary and future directions

Prime-R

elaiant EBC

Systems for Si-B

ased Ceram

ic Matrix

posites−

NASA’s advanced environm

ental barrier and bond coat development: P

rime-reliant

designs •

High toughness and low

conductivity EB

C top coat

lternating Com

position Layered Coatings (A

s) and composite coatings,

including improving im

pact resistance •

Advanced doped m

ulticomponent E

e-reliant designed bond coats •

ately environmental resistant C

s with high therm

al conductivities H

fO2 -Y

2 O3 -Yb

2 O3 -G

3 -(SiO

2 )e.g.,

2 -Y2 O

3 -Yb2 O

2 O3 -Ta

2 O2 -TiO

2 -(SiO

2 ) Low

expansion alloyed-HfO

2 , and HfO

2 aluminates

Interlayer R

E doped Hf, H

f RE silicate and/or m

ulti-rare earth silicate EBC

s 2700F bond coats

Fundamental R

ecession Issues of CM

Cs and EB

ecession of Si-based Ceram

ics (a) C

onvective; (b) Convective w

ith film-cooling

-Low S

iO2 activity E

systems

-Advanced rig testing and modeling

plex recession behavior of CM

C and E

s studied in NA

ressure Burner R

ig, included film-cooled recession

SiO2 + 2H

2 O(g) = Si(O

H)4 (g)

Recession rate = const. V

1/2 P(H

2O) 2/(P

total ) 1/2

bustion gas

SiO2 + 2H

2 O(g) = Si(O

H)4 (g)

bustion gas

Cooling gas

(a) (b)

Continued

ions of environm

ental barrier coatings -EB

C system

s, improved stability in

tability evaluated on S

s in high velocity, high pressure burner

Fundamental R

Cs and EB

rig environment

SiC Wt. Loss (mg/cm2)

-10 -5 0

1385 C

1446 C

1252 C

1343 C

Robinson and Sm

ialek, J. Am

. Ceram

Soc. 1999

80 100

Exposure Tim

e (hrs)

-Early generat

turbine environments

bustor coating Turbine coating

2 based low k -A

fO2 based low

k – EB-PV

Fundamental R

Cs and EB

Continued

stability evaluated on SiC

Cs in high velocity, high pressure burner rig environm

0.1 1 100.0005 0.00055 0.0006 0.00065 0.0007 0.00075 0.0008

Specific weight change, mg/cm2-h

1/T, K-1

1300Tem

perature, °C

1400 1500

12001600

SiC/SiC

under high velocity BSA

S Baseline

1100 1000

Tyranohex SA (6 atm

, 200m/s)

Tyranohex SA (16 atm

, 30m/s)

C stability devlopm

ent goal: 5 mg/cm

bustor coating Turbine coating

2 based low k -A

fO2 based low

k – EB-PV

High pressure burner rig, 16 atm

, 31 hr -E

arly generations of environmental barrier coatings -E

systems

failure

Environmental B

arrier Coating in Sim

ulated Load-Fatigue Testing

Environments (Laser H

igh Heat Flux R

5 /Yb2 S

i2 O7 /S

i on Melt Infiltrated (M

I) Prepreg S

substrates -

Tested in air, furnace isothermal at 1316°C

; and in heat flux steam, at T

EBC 1316°C

at ~1200°C

Lower C

failure strain observed in the steam-heat flux test environm

failure

Fatigue strains (amplitudes) – Tim

e Plot Therm

al conductivity – Time Plot

In steam-jet, EB

C cracking and

recession

-Ytterbium

mono-silicate recession observed in the test

-Therm

al conductivity for monitoring coating delam

ination

Environm

ental Barrier C

oating in Simulated Load-Fatigue

Testing Environments (Laser H

igh Heat Flux R

ig) -Continued

rack and recession failure in air and steam tests

In Air; EB

C cracking

In steam; EB

C cracking and volatility

p onent

Type C

onc., A

Conc.,

alc 49.07

9.59 Si

9.79 3.36

alc 41.14

87.04 Total

100.00 100.00

EDS 25D

Advanced NASA

Developm

advanced EB

C system

s emphasizing high stability H

fO2 -and ZrO

2 O3 -S

system

s and HfO

2 -Si and R

are Earth – S

ilicon bond coat systems

ulticomponent R

are Earth R

i2-x O7-2x , such as (Yb,G

d,Y) 2 Si2-x O

7-2x environmental

barrier systems

are earth-doped HfO

2 -ZrO2 , and H

fO2 -doped R

are Earth (R

E) silicates are am

ong the advanced E

systems

• Im

proved high temperature stability and creep strength;

• Facilitating nano-cluster form

ation with high concentration rare earth com

pound phases; •

Improving C

S resistance

TEM-EELS

position map

ond Coat System

System

2 O3 -S

iO2 /R

i2-x O7-2x environm

ental barrier systems

ontrolled silica content and rare earth dopants to improve E

stability, toughness, erosion and C

S resistance

fO2 -S

i based bond coat, controlled oxygen partial pressure •

Advanced rare earth-S

i composition system

s for 2700°F+ long-term applications

arly RE

2 O3 -S

iO2 -A

l2 O3 or YA

ystems

evelop prime-reliant com

posite EB

s, HfS

) systems

Bond coat systems for prime reliant EBCs; capable of self-healing %

Developm

ent of Advanced H

fO2 -Si B

ond Coats

oating architecture and HfO

2 contents can be effectively controlled and optim

ized –

f atomic ratio preferably 2:1 – 1:1

eported Spinodal decom

position of hafnium-silicate system

100 100

Silicon concentration, at%

Oxygen concentration, at% 0

afnium concentration, at%

Microstructures of Furnace C

yclic Tested GdYbSi(O

System

yclic tested cross-sections of PV

D processed YbG

) bond coat —

elf-grown rare earth silicate E

s and with som

-containing SiO

2 rich phase separations —

elatively good coating adhesion and cyclic durability

1500°C, in air, 500, 1 h cycles /

omplex coating architectures

after the testing -

Designed w

ith EB

C like

compositions – Self-grow

position (mol%

) spectrum A

rea #1 SiO

2 67.98

3 11.95

3 20.07

position (mol%

) spectrum A

rea #2 SiO

2 66.03

B Gd2O

3 10.07

3 23.9

Microstructures of C

yclic Tested GdYbSi(O

System

s-Continued

Cyclic tested cross-sections of P

processed YbGdS

i(O) bond coat

Self-grow

n rare earth silicate EB

Cs and w

ith some R

E-containing S

iO2 rich phase separations

Interface growth instability

1500°C, in air, 500, 1 hr cycles

Outlined area

omposition (m

66.72 G

8.62 Y

position (mol%

2 96.15

3 2.64

Advanced EBC

developments – Som

e Hybrid Air-Plasm

a Spray/EB

-PVD Turbine C

ombustor EB

C System

s and Qualification

Surface spallation

Tests •

Achieved low

thermal conductivity ranging from

1.0 -1.7 W

onstrated high pressure environmental

stability at 2600-2650°F, 12-20 atm. in the high

pressure burner rig •

Surface recession or m

icro-spallation for less tougher coating system

2” diameter N

specimen after

testing in the high pressure burner rig A

t 2600°F+, 200 m

High pressure burner rig tested new

series Hybrid

systems coated on 2” diam

eter Gen II P

repreg S

Erosion and Impact A

spects: Early Mach 0.3 B

allistic Im

pact Tests of HfO

2 -Si Bond C

oat EBC

Systems

Advanced high toughness E

s tested with com

parable performance of best TB

ore advanced EB

positions currently also in developments

Spalled area, cm2

Projectile velocity, m/s

150 200 250 300 350

400 450

1.6 7Y

SZ and low k TB

Cs ZrR

TES series N

7.4 EBC

t'-ZrO

Cubic low

k ZrO2 k-N

7.4 EBC

t'/ NA

EBC Spalled

SUP7.1A

0.2 SU

7.4 0.00.0

0.5 1.0

1.5 2.0

2.5 Energy, J

SUP-ER

A 7.4 EB

Advanced EB

oating Material Strength Evaluations

igh strength EB

Cs and bond coats are critical for prim

e-reliant designs •

Multicom

ponent EB

Cs and first-generation H

fO2 -S

i bond coat achieved 150-200 MP

a strength at high tem

perature (1400°C+)

ulticomponent silicates show

ed improved high tem

perature strengths compared to

baseline yttrium and ytterbium

silicates •

High strength and high toughness are critical for erosion and fatigue cracking

669-Yb

2 Si 2 O 7

660-Y 2 Si2 O

659-Yb

2 SiO5

Strength, MPa

resistance 350

646-Specially toughened t' like HfO

2 648-EB

ond Coat C

onstituent 658-A

E9932 660-Y

2Si2O7

657-Zr-RE silicate (M

ulti-component)

669-Yb2Si2O

7 670-R

are Earth Disilicate (M

ulti-component)

681-HfO

2-Si 696-EB

ond Coat C

onstituent 150

500 0 200

400 600

800 1000

1200 1400

1600 Tem

perature, °CFlexure strengths of selected E

materials

High H

eat Flux and CM

AS Resistance are Ensured by Advanced

High M

elting Point Coating, and M

ulti-Com

ponent Com

positions –

Non stoichiom

etric characteristics of the CM

– rare earth silicate reacted apatite phases – up to 200 h testing

ifference in partitioning of ytterbium vs. yttrium

in apatite •

Average AE

3 ratio ~ 0.68 for ytterbium silicate – C

S system

Average AE

3 ratio ~ 0.22 for yttrium silicate – C

S system

Ahlborg and Zhu, Surface &

Coatings Technology 237 (2013) 79–87.

position in apatite (100 hr):

Yttrium

Silicate EBC

position in apatite (100 hr):

Ytterbium

Silicate EBC

High H

eat Flux and CM

AS Resistance Tests of Advanced EB

Systems

ulticomponent rare earth silicate E

showed im

proved performance

ilicate based coatings still sensitive to CM

concentrations (estimated

variation between average C

S at 25 m

g/cm2 to m

ore concentrated region C

S at 75 m

g/cm2)

ome coating dam

age occurred for EB

Cs in JE

TS tests at higher C

S loading

regions

Initially infiltrated /

Temperature, C

25h / 50h

100h 4450 Cycles

2000 C

S tempertaure

Tsurface, C

Tback, C

Turbine vane EB

0 0 50

100 150

tests (100 h) Tim

e, hours

Laser rig test of advanced coating systems

Thermal G

radient Tensile Creep R

upture Testing of Advanced Turbine Environm

ental Barrier C

oating SiC/SiC

Advanced high stability m

ulti-component hafnia-rare earth silicate based turbine

environmental barrier coatings being successfully tested for 1000 hr creep rupture

creep, fatigue and environmental interaction is being em

phasized

C coated tensile specim

Laser beam

delivery optic system

ooling show

er head

Total strain, %

en II CMC w

ith advanced EBC Tested at 15 ksi &

heat flux Tsurface = 2700°F

Gen II CM

C-uncoated Tinterface= 2500°F

1.0 2400 F

TCMC back=2320°F

Tested at 20 ksi, 1316°C Typical prem

ature failure

Gen II CM

C with advanced EBC

tested 20 ksi, 1316°C 2400 F

en II CMC w

ith advanced EBC Tested at 20 ksi &

heat fluxjets

Tsurface = 2750ºF G

en II CMC uncoated

Tinterface = 2450ºF H

igh tem

perature 2400 F

Tested at 15 ksi, 1316°CTCM

C back = 2250ºC2250 F

extensometer

400 600

800 1000

1200Test specim

en Tim

e, hours

Thermal G

radient Fatigue-Creep Testing of A

dvanced Turbine Environm

ental Barrier C

oating SiC/SiC

Continued

Advanced environm

ental barrier coatings – Prepreg C

systems dem

onstrated long-term

system creep rupture capability at stress level up to 20 ksi at T

EBC 2700°F, T

interface ~2500°F

The HfO

2 -Si based bond coat show

ed excellent durability in the long term creep tests

s on Gen II C

after 1000 h fatigue H

ybrid EBC

s on Gen II C

after 1000 h testing

low cycle creep fatigue testing

High H

eat Flux Thermom

echanical fatigue Tests of A

dvanced NA

ond Coats System

s on CM

• Laser H

igh Heat Flux them

omechanical fatigue testing of a H

fO2 -S

i and NA

advanced E

baseline with steam

at 3 Hz, 2600-2700°F, and 69 M

aximum

stress with stress

ratio 0.05, completed 500 h testing

• Tsurface = 1500-1600°C

T= 1320-1350°C

eat Flux = 170 W/cm

2 3 hz fatigue testing at 10 ksi loading C

ompleted 500 hr testing

Testing proving vital failure m

echanisms in a sim

ulated test environm

pecimen had som

e degradations

igher Si content HfO

C Therm

al Gradient C

reep Rupture and

ination Modeling

n equivalent stress model is established for E

multicrack stress intensity m

odeling: em

phasize creep, thermal gradient and stress rupture interactions

D. Zhu and L. G

hosn, “Creep, Fatigue and Fracture B

ehavior of Environmental B

arrier Coating and SiC

-SiC C

eramic M

atrix Com

posite Systems: The R

ole of Environment Effects”, in

The 11th International C

onference on Ceram

ic Materials and C

omponents for E

nergy and Environm

ental Applications, V

ancouver, British C

olumbia, C

anada, June 15-19, 2015.

enchmark failure m

odes established in EB

C system

s, strong bond coat beneficial

Finite Elem

ent Analysis (FE

odeling

C Therm

al Gradient C

reep Rupture and

ination Modeling – B

ond Coat Stiffness Effect

dvanced EB

Cs designed w

ith higher strength and stiffness to improve

creep, fatigue, and cyclic durability

D. Zhu and L. G

hosn, “The Developm

ent of Environmental B

arrier Coating System

s for SiC-SiC

ic Matrix C

omposites: Environm

ent Effects on the Creep and Fatigue R

esistance”, in A

erospace Coatings C

onference & E

xposition 2014: Developm

ent and Manufacturing T

rend for the 21st Century, H

artford, CT, U

ctober 8, 2014

Fatigue Tests of Advanced RESi B

ond Coats and EB

C System

S and P

processed 2700°F bond coats on CM

C: focus on fatigue testing at

temperatures 2400-2700°F

bond coats critical to prime-reliant coating system

designs Fatigue Tested

002_#17A

ir Plasm

a Sprayed A

Silicate 1316°C

, 10ksi, 1000 h fatigue (3 Hz, R

=0.05)

1169 h fatigue (3 Hz, R

=0.05) on GE

i2-x O7-x E

/GdYbS

i(O) bond

Prepreg S

iCcoat on C

(with C

1537°C, 10ksi, 300 h fatigue (3 H

z, R=0.05)

i2-x O7-x E

2 -Si bond coat on 3D

VI+PIP

1482°C, 10ksi, S

F fatigue at 3 H

z, R=0.5 (300 h furnace tested, 500 h in laser

thermal gradient

Creep and Fatigue Test w

ith CM

dYSi(O

) coated on Hyper Them

12C-461-

dYbSi(O

) bond coat,1316°C, 15ksi,

ond Coat series on R

oyce Royce H

I-MI S

ith CM

) 1400°C

,at 10 ksi, 400 h

C Turbine Elem

ent Fatigue Testing

• Testing approaches developed for E

C trailing edge therm

omechanical testing

igh heat flux capability to simulate required high therm

al gradients and more com

plextem

perature distributions in a turbine engine•

Mechanical loading to sim

ulate the high pressure turbine airfoil pressure (ballooning) effects•

durability being evaluated, planned incorporation of stream jet environm

rincipal Strain vs. A

irfoil Internal Pressure

C coated Trailing E

dge (TE)

“wedge” testing in high heat flux and

80 100

120 140

160 180

Maxium Principal Strain (%)

Internal Pressure (psi)

mechanical fatigue loading

Modeled testing /

Strains Measurem

ents for Coated A

irfoil Trailing Edge Subelem

ents at High Loads

-The results show

ed complex coating cycling behavior, and out of phase strain cycles

also on the EB

C coated sides

ossibly changed neutral axes of the deflections of the CM

C thin and thick w

alls -

Challenges for m

odeling along with therm

al in-phase and out-phase loading

Load, N

SiC/SiC

Turbine Airfoil Trailing Edge Tests

ubelement w

edge testing and high temperature tests, aim

ing at understanding the C

and EB

C degradation

TEST_HT

odel TEST_H

00.00 0.05

0.10 0.15

0.20 0.25

0.30 0.35

Displacements, m

TEST DAM

Von Mises

Stress Plot

4000 CV

30003000

Load, N

No reduction 2000

1000 Subelem

ent Load-Displacem

ent curve – P

repreg MI C

trailing edge

0-0.1 -0.1 0.0 0.1 0.1 0.2 0.2 0.3 0.3 0.4 0.4 0.4 0.5 0.5 0.6

Displacem

ents, mm

dvanced EB

C coated vanes tests

Subelem

ent Load-Displacem

ent curve – CV

C trailing edge

ary •

Prime-R

eliant and durable EBC

s are critical to emerging SiC

/SiC C

Hot-Section

component technologies

The EB

C developm

ent built on a solid foundation from past experience, evolved w

ith the current state of the art com

positions with higher tem

perature capabilities and stabilities •

Multicom

ponent EB

C oxide-doped silicates show

ed promise w

ith improved

stabilities, strength and toughness, and durability in various tests •

2 -Si and R

i bond coats, along with R

N potentially for realizing prim

e-reliant E

-designs •

Advanced testing help scale-up for com

ponents and EV

modeling

Current em

phases and future paths: ─

etter understanding of the coating failure mechanism

s, and helping develop coating property databases and validate life m

odels, aiming at m

ore robust EB

designs ─

ontinue to focus on coating composition and processing im

provements, sim

ulated engine environm

ent testing and performance m

odeling ─

esign high strength, strain tolerant, CM

resistant top coat; and dense, low diffusion

and high toughness EB

C and bond coats

Self-repairing and/or self-grow

ing of slow grow

th adherent EB

C coatings, m

inimizing

silica separation

cknowledgem

ents •

The work w

as supported by NASA

Fundamental Aeronautics Program

(FAP) Transform

ational Tools and Technologies (TTT) Project

In particular, the contributions from the follow

Team, In particular, Jim

arlo, Jim Sm

ialek, Dennis Fox, Bryan H

arder, Robert A

. Miller,

Janet Hurst, M

artha Jaskowiak, R

hatt, Mike H

albig, Valerie Wiesner, N

ate Jacobson, Narottam

ansal, Francisco Sola-Lopez, and S

erene Farmer, (N

Collaborators include:

Sulzer M

etco (US

) -Mitch D

orfman; C

his Dam

irected Vapor Technologies, International – Derek H

ass and Balvinder G

ogia P

raxair Surface Technologies – John A

nderson and Li Li S

outhwest R

esearch Institute – Ronghua W

ei (PV

D coating processing)

in supporting the coating processing

cleveland, ohio 44135 nasa john h. glenn research center ...€¦ · (ebcs) development objectives...

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