Mechanisms of spallation of solution precursor plasma spray thermal barrier coatings

被引:44
作者
Gell, M [1 ]
Xie, LD
Jordan, EH
Padture, NP
机构
[1] Univ Connecticut, Inst Mat Sci, Dept Met & Mat Engn, Storrs, CT 06269 USA
[2] Univ Connecticut, Inst Mat Sci, Dept Mech Engn, Storrs, CT 06269 USA
关键词
thermal barrier coatings; plasma spray; solution precursor plasma spray; failure mechanisms;
D O I
10.1016/j.surfcoat.2004.08.004
中图分类号
TB3 [工程材料学];
学科分类号
0805 ; 080502 ;
摘要
The durability and failure mechanisms of solution precursor plasma spray (SPPS) thermal barrier coatings (TBCs) are investigated. SPPS TBCs exhibit an average life of 1018 cycles in a 1-h 1121 degreesC cycle furnace test, that is more than 2.5 times of that of a commercial APS TBC in the same test. Failure of the SPPS TBC starts with crack initiation along the unmelted particles in the ceramic top coat and the non-alumina oxides. The cracks propagate and coalesce with thermal cycling. The extensive cracking of the rapidly formed non-alumina oxides, resulting from the depletion of aluminum in the bond coat, leads to the development of a large separation between the TBC and substrate. When a crack of sufficient size emerges, the TBC separates from the metal substrate by large scale buckling. The greatly improved durability of the SPPS TBCs compared to APS TBCs on the same substrate and bond coat is attributed to the reduced stress near the bond coat-SPPS ceramic interface as a result of the vertical microcracks in the SPPS microstructure. (C) 2004 Elsevier B.V. All rights reserved.
引用
收藏
页码:101 / 106
页数:6
相关论文
共 21 条
[1]  
[Anonymous], 1996, Metallurgical and Ceramic Protective Coatings
[2]   Delamination of multilayer thermal barrier coatings [J].
Choi, SR ;
Hutchinson, JW ;
Evans, AG .
MECHANICS OF MATERIALS, 1999, 31 (07) :431-447
[3]   Mechanisms controlling the durability of thermal barrier coatings [J].
Evans, AG ;
Mumm, DR ;
Hutchinson, JW ;
Meier, GH ;
Pettit, FS .
PROGRESS IN MATERIALS SCIENCE, 2001, 46 (05) :505-553
[4]   Highly durable thermal barrier coatings made by the solution precursor plasma spray process [J].
Gell, M ;
Xie, LD ;
Ma, XQ ;
Jordan, EH ;
Padture, NP .
SURFACE & COATINGS TECHNOLOGY, 2004, 177 :97-102
[5]  
Johner G., 1988, P 1 NAT THERM SPRAY, P155
[6]   Influence of bondcoat pre-treatment and surface topology on the lifetime of EB-PVD TBCs [J].
Lau, H ;
Leyens, C ;
Schulz, U ;
Friedrich, C .
SURFACE & COATINGS TECHNOLOGY, 2003, 165 (03) :217-223
[7]   An analytical solution for stress relaxation in cracked coatings [J].
Mézin, A .
SURFACE & COATINGS TECHNOLOGY, 2003, 166 (2-3) :160-166
[8]   Thermal barrier coatings for aircraft engines: History and directions [J].
Miller, RA .
JOURNAL OF THERMAL SPRAY TECHNOLOGY, 1997, 6 (01) :35-42
[9]   Materials science - Thermal barrier coatings for gas-turbine engine applications [J].
Padture, NP ;
Gell, M ;
Jordan, EH .
SCIENCE, 2002, 296 (5566) :280-284
[10]   Towards durable thermal barrier coatings with novel microstructures deposited by solution-precursor plasma spray [J].
Padture, NP ;
Schlichting, KW ;
Bhatia, T ;
Ozturk, A ;
Cetegen, B ;
Jordan, EH ;
Gell, M ;
Jiang, S ;
Xiao, TD ;
Strutt, PR ;
García, E ;
Miranzo, P ;
Osendi, MI .
ACTA MATERIALIA, 2001, 49 (12) :2251-2257