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D. Wett
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Proceedings Papers
ITSC2016, Thermal Spray 2016: Proceedings from the International Thermal Spray Conference, 156-160, May 10–12, 2016,
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In this investigation, an air plasma sprayed TBC system consisting of a CoNiCrAlY bond coat (BC) and a YSZ topcoat (TC) is produced with a PVD AlOx interlayer in order to study its effect on thermally grown oxides. For comparative purposes, a reference TBC without the AlOx interlayer was also prepared and studied. A cyclic thermal load was applied to both systems and the coatings were examined after 6, 12, 24, 40, and 80 cycles. Crack lengths were measured in the YSZ layer and TGO thicknesses were assessed at the BC-TC interface. An examination of coating microstructures revealed the expected mixed-mode failure in both TBCs. In comparison to the reference TBC, the system with the AlOx interlayer showed reduced crack formation in the TC and slowed TGO formation at the BC-TC interface both during and after thermal treatment.
Proceedings Papers
ITSC 2015, Thermal Spray 2015: Proceedings from the International Thermal Spray Conference, 873-877, May 11–14, 2015,
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The physical characteristics and volume growth of TGOs in TBC systems lead to TBC failure. It is proved that enriching the BC/TC interface with α-Al 2 O 3 is beneficial to an extended operational time by prolonging the steady-state growth stage of the TGO. The corresponding phase reactions in TBC systems with heightened Al activity, however, are not studied yet. In this work, the stage formation of TGO layers of TBC systems with PVD-Al interlayers is described. The study uses thermal cyclic loading with dwell time at maximum high temperature of 1,150 °C. The crack formation in the ceramic top coat and the TGOs thickness at the interface are investigated by SEM/EDS after 1, 6, 12, 24, 40 and 80 thermal cycles. The results plot the interface change and crack formation as a function of the thermal cycle number. The corresponding failure mode is discussed.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 273-278, May 21–23, 2014,
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Thermal barrier coatings typically incorporate a YSZ topcoat and a metallic bond coat. During service, a reaction zone consisting of different thermally grown oxides forms at the interface. Although most such oxides are detrimental, one (α-Al 2 O 3 ) improves service life due to its barrier effect on oxygen diffusion. In this study, Al and AlOx films are deposited on metallic bond coats by dc magnetron sputtering prior to topcoat deposition. The resulting TBCs were thermally cycled to determine the effect of the interlayer films on service life and TGO formation. It is shown that the Al films transform in situ into dense Al 2 O 3 layers that act as oxygen diffusion barriers. TBCs with interlayer alumina, whether deposited directly or formed in situ, showed less cracking and were more mechanically stable during thermal cycle tests.