Development and Optimization of Tailored Composite TBC Design Architectures for Improved Erosion Durability

Michael P. Schmitt, Jeremy Schreiber, Amarendra K. Rai, Timothy John Eden, Douglas Edward Wolfe

Research output: Contribution to journalArticle

5 Citations (Scopus)

Abstract

Rare-earth pyrochlores, RE2Zr2O7, have been identified as potential thermal barrier coating (TBC) materials due to their attractive thermal properties and CMAS resistance. However, they possess a low fracture toughness which results in poor erosion durability/foreign object damage resistance. This research focuses on the development of tailored composite air plasma spray (APS) TBC design architectures utilizing a t′ Low-k secondary toughening phase (ZrO2-2Y2O3-1Gd2O3-1Yb2O3; mol.%) to enhance the erosion durability of a hyper-stoichiometric pyrochlore, NZO (ZrO2-25Nd2O3-5Y2O3-5Yb2O3; mol.%). In this study, composite coatings have been deposited with 30, 50, and 70% (wt.%) t′ Low-k toughening phase in a horizontally aligned lamellar morphology which enhances the toughening response of the coating. The coatings were characterized via SEM and XRD and were tested for erosion durability before and after isothermal heat treatment at 1100 °C. Analysis with mixing laws indicated improved erosion performance; however, a lack of long-term thermal stability was shown via isothermal heat treatments at 1316 °C. An impact stress analysis was performed using finite element analysis of a coating cross section, representing the first microstructurally realistic study of mechanical properties of TBCs with the results correlating well with observed behavior.

Original languageEnglish (US)
Pages (from-to)1062-1075
Number of pages14
JournalJournal of Thermal Spray Technology
Volume26
Issue number6
DOIs
StatePublished - Aug 1 2017

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Thermal barrier coatings
Composite coatings
durability
erosion
Erosion
Toughening
Durability
coatings
optimization
composite materials
Coatings
Heat treatment
heat treatment
Stress analysis
Rare earths
Fracture toughness
Thermodynamic stability
Thermodynamic properties
stress analysis
fracture strength

All Science Journal Classification (ASJC) codes

  • Condensed Matter Physics
  • Surfaces, Coatings and Films
  • Materials Chemistry

Cite this

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abstract = "Rare-earth pyrochlores, RE2Zr2O7, have been identified as potential thermal barrier coating (TBC) materials due to their attractive thermal properties and CMAS resistance. However, they possess a low fracture toughness which results in poor erosion durability/foreign object damage resistance. This research focuses on the development of tailored composite air plasma spray (APS) TBC design architectures utilizing a t′ Low-k secondary toughening phase (ZrO2-2Y2O3-1Gd2O3-1Yb2O3; mol.{\%}) to enhance the erosion durability of a hyper-stoichiometric pyrochlore, NZO (ZrO2-25Nd2O3-5Y2O3-5Yb2O3; mol.{\%}). In this study, composite coatings have been deposited with 30, 50, and 70{\%} (wt.{\%}) t′ Low-k toughening phase in a horizontally aligned lamellar morphology which enhances the toughening response of the coating. The coatings were characterized via SEM and XRD and were tested for erosion durability before and after isothermal heat treatment at 1100 °C. Analysis with mixing laws indicated improved erosion performance; however, a lack of long-term thermal stability was shown via isothermal heat treatments at 1316 °C. An impact stress analysis was performed using finite element analysis of a coating cross section, representing the first microstructurally realistic study of mechanical properties of TBCs with the results correlating well with observed behavior.",
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Development and Optimization of Tailored Composite TBC Design Architectures for Improved Erosion Durability. / Schmitt, Michael P.; Schreiber, Jeremy; Rai, Amarendra K.; Eden, Timothy John; Wolfe, Douglas Edward.

In: Journal of Thermal Spray Technology, Vol. 26, No. 6, 01.08.2017, p. 1062-1075.

Research output: Contribution to journalArticle

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