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EU joint project

TOPPCOAT

TOwards design and Processing of advanced, comPetitive

thermal barrier COATing systems

Aerodays2011

Matthias Karger, Robert VaßenIEK-1, Forschungszentrum Jülich GmbH

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Outline

• Short project description

• Main objectives

• Development of new TBC systems

• Testing new TBC systems

• Coating of real components

• Summary, outlook

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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.