Corrosion resistant thermal barrier coating materials for industrial gas turbine applications

Michael D. Hill, Davin P. Phelps, Douglas Edward Wolfe

Research output: Chapter in Book/Report/Conference proceedingConference contribution

4 Citations (Scopus)

Abstract

Thermal Barrier Coatings are ceramic materials that are deposited on metal turbine blades in aircraft engines or industrial gas turbines which allow these engines to operate at higher temperatures. These coatings protect the underlying metal superalloy from creep, oxidation and/or localized melting by serving as an insulating barrier to protect the metal from the hot gases in the engine core. While for aircraft engines, pure refined fuels are used, it is desirable for industrial gas turbine applications that expensive refining operations be minimized. However, acidic impurities such as sulfur and vanadium are common in these "dirty" fuels and will attack the thermal barrier coating causing reduced coating lifetimes and in the worse case catastrophic failure due to spallation of the coating. The industry standard coating material is stabilized zirconia with seven weight percent yttria stabilized zirconia being the most common. When used in industrial gas turbines, the vanadium oxide impurities react with the tetragonal zirconia phase causing undesirable phase transformations. Among these transformations is that from tetragonal to monoclinic zirconia. This transformation is accompanied by a volume expansion which serves to tear apart the coating reducing the coating lifetime. Indium oxide is an alternative stabilizing agent which does not react readily with vanadium oxide. Unfortunately, indium oxide is very volatile and does not readily stabilize zirconia, making it difficult to incorporate the indium into the coating. However, by pre-reacting the indium oxide with samarium oxide or gadolinium oxide to form a stable perovskite (GdInO3 or SmInO 3) the indium oxide volatilization is prevented allowing the indium oxide incorporation into the coating. Comparison of EDX data from evaporated coatings containing solely indium oxide and those containing GdInO3 are presented and show that the indium is present in greater quantities in those coatings containing the additional stabilizer. Corrosion tests by reaction with vanadium pentoxide were performed to determine the reaction sequence and to optimize the chemical composition of the coating material. Lastly, select x-ray diffraction phase analysis will be presented.

Original languageEnglish (US)
Title of host publicationAdvanced Ceramic Coatings and Interfaces III - A Collection of Papers Presented at the 32nd International Conference on Advanced Ceramics and Composites
Pages123-131
Number of pages9
Edition4
StatePublished - Mar 27 2009
EventAdvanced Ceramic Coatings and Interfaces III - 32nd International Conference on Advanced Ceramics and Composites - Daytona Beach, FL, United States
Duration: Jan 27 2008Feb 1 2008

Publication series

NameCeramic Engineering and Science Proceedings
Number4
Volume29
ISSN (Print)0196-6219

Other

OtherAdvanced Ceramic Coatings and Interfaces III - 32nd International Conference on Advanced Ceramics and Composites
CountryUnited States
CityDaytona Beach, FL
Period1/27/082/1/08

Fingerprint

Thermal barrier coatings
Gas turbines
Corrosion
Indium
Coatings
Oxides
Zirconia
Vanadium
Aircraft engines
Metals
Impurities
Engines
Samarium
Gadolinium
Excipients
Yttria stabilized zirconia
Ceramic materials
Superalloys
Vaporization
Sulfur

All Science Journal Classification (ASJC) codes

  • Ceramics and Composites
  • Materials Chemistry

Cite this

Hill, M. D., Phelps, D. P., & Wolfe, D. E. (2009). Corrosion resistant thermal barrier coating materials for industrial gas turbine applications. In Advanced Ceramic Coatings and Interfaces III - A Collection of Papers Presented at the 32nd International Conference on Advanced Ceramics and Composites (4 ed., pp. 123-131). (Ceramic Engineering and Science Proceedings; Vol. 29, No. 4).
Hill, Michael D. ; Phelps, Davin P. ; Wolfe, Douglas Edward. / Corrosion resistant thermal barrier coating materials for industrial gas turbine applications. Advanced Ceramic Coatings and Interfaces III - A Collection of Papers Presented at the 32nd International Conference on Advanced Ceramics and Composites. 4. ed. 2009. pp. 123-131 (Ceramic Engineering and Science Proceedings; 4).
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Hill, MD, Phelps, DP & Wolfe, DE 2009, Corrosion resistant thermal barrier coating materials for industrial gas turbine applications. in Advanced Ceramic Coatings and Interfaces III - A Collection of Papers Presented at the 32nd International Conference on Advanced Ceramics and Composites. 4 edn, Ceramic Engineering and Science Proceedings, no. 4, vol. 29, pp. 123-131, Advanced Ceramic Coatings and Interfaces III - 32nd International Conference on Advanced Ceramics and Composites, Daytona Beach, FL, United States, 1/27/08.

Corrosion resistant thermal barrier coating materials for industrial gas turbine applications. / Hill, Michael D.; Phelps, Davin P.; Wolfe, Douglas Edward.

Advanced Ceramic Coatings and Interfaces III - A Collection of Papers Presented at the 32nd International Conference on Advanced Ceramics and Composites. 4. ed. 2009. p. 123-131 (Ceramic Engineering and Science Proceedings; Vol. 29, No. 4).

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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N2 - Thermal Barrier Coatings are ceramic materials that are deposited on metal turbine blades in aircraft engines or industrial gas turbines which allow these engines to operate at higher temperatures. These coatings protect the underlying metal superalloy from creep, oxidation and/or localized melting by serving as an insulating barrier to protect the metal from the hot gases in the engine core. While for aircraft engines, pure refined fuels are used, it is desirable for industrial gas turbine applications that expensive refining operations be minimized. However, acidic impurities such as sulfur and vanadium are common in these "dirty" fuels and will attack the thermal barrier coating causing reduced coating lifetimes and in the worse case catastrophic failure due to spallation of the coating. The industry standard coating material is stabilized zirconia with seven weight percent yttria stabilized zirconia being the most common. When used in industrial gas turbines, the vanadium oxide impurities react with the tetragonal zirconia phase causing undesirable phase transformations. Among these transformations is that from tetragonal to monoclinic zirconia. This transformation is accompanied by a volume expansion which serves to tear apart the coating reducing the coating lifetime. Indium oxide is an alternative stabilizing agent which does not react readily with vanadium oxide. Unfortunately, indium oxide is very volatile and does not readily stabilize zirconia, making it difficult to incorporate the indium into the coating. However, by pre-reacting the indium oxide with samarium oxide or gadolinium oxide to form a stable perovskite (GdInO3 or SmInO 3) the indium oxide volatilization is prevented allowing the indium oxide incorporation into the coating. Comparison of EDX data from evaporated coatings containing solely indium oxide and those containing GdInO3 are presented and show that the indium is present in greater quantities in those coatings containing the additional stabilizer. Corrosion tests by reaction with vanadium pentoxide were performed to determine the reaction sequence and to optimize the chemical composition of the coating material. Lastly, select x-ray diffraction phase analysis will be presented.

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Hill MD, Phelps DP, Wolfe DE. Corrosion resistant thermal barrier coating materials for industrial gas turbine applications. In Advanced Ceramic Coatings and Interfaces III - A Collection of Papers Presented at the 32nd International Conference on Advanced Ceramics and Composites. 4 ed. 2009. p. 123-131. (Ceramic Engineering and Science Proceedings; 4).