TOPPCOAT. TOwards design and Processing of advanced, competitive thermal barrier COATing systems. EU joint project. Aerodays2011

Transcription

1 EU joint project TOPPCOAT TOwards design and Processing of advanced, competitive thermal barrier COATing systems Aerodays2011 Matthias Karger, Robert Vaßen IEK-1, Forschungszentrum Jülich GmbH 1

2 Outline Short project description Main objectives Development of new TBC systems Testing new TBC systems Coating of real components Summary, outlook 2

3 Project Coordinator Forschungszentrum Jülich Budget 4.2 Mio., (EC contribution 2.1 Mio. ) Period Feb Jan Consortium 3

4 Project plan Basics Main objective: Significant improvement of thermal barrier coating systems used for gas turbine applications WP0 Management WP1 Technical specifications, material procurement WP2 Powders and materials Development WP3 Interface modification WP4 Advanced technology for manufacture of strain tolerant coatings WP5 Screening of key properties and full characterisation Evaluation WP6 Transfer & application of technology WP7 Final evaluation under close-to-service conditions 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) Increase temperature capability Increase engine efficiency Provide cost effective alternative to EB-PVD 4

5 Project approaches for new TBC systems Advanced APS process with conventional feedstock Highly segmented coatings Feedstock: fused and crushed or spray dried YSZ New materials Advanced APS process with nano sized feedstock or alternative TBC material Feedstock: suspension with agglomerated nano particles New processes Advanced processes using gas phase deposition Processes: LPPS-TF, PE-CVD Interface modifications to induce seg.cracks /stop horizontal cracks Transfer of technology coating of real components 5

6 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 6

7 Vertical structured TBCs Conventional non-columnar coating Compressive stress level lower at surf Hot Tensile stress Compressive stress supports crack growth Vertical structured coating Cooling down, Relaxation Hot 7

8 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 Advanced APS process with conventional feedstock Highly segmented coatings 500µm Triplex II technology F4 technology Feedstock: 8YSZ fused & crushed (TIAG) Feedstock: 8YSZ spray dried (SM) Porosity: Overall: ~6% (Mercury porosimetry) Crack density: ~9 thickness Crack density: ~9 thickness Further development of Taylor (1991), Bengtsson et.al. (1999), state of the art were 3-4 cracks/mm 8

9 Interface modifications New processes PVD-LPPS (fka LPPS-TF) APS Plasmajet PVD-LPPS 2 5 mbar High power input Enables growth of columnar structures 500µm Surface modified by application of laser-cladded 3D structures to induce seg.cracks /stop horizontal cracks 9

10 New processes Suspension plasma spraying injecton SPS plasma jet SPS coating Triplex II Nano suspension, agglomaterated, nano sized YSZ particles in ethanol High segmentation crack density, combined with high porosity values (~35%) Low thermal conductivity 10

11 Midterm status Reference systems Start: 21 bondcoat/topcoat systems (~250 specimen) tested Selection criteria: Microstructure Furnace cycling 1 st 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 TBC evaluation Long term stability furnace cycling test Thermal shock resistance burner rig tests Erosion resistance Corrosion resistance commercial. APS reference Bondcoat: Thickness µm R a µm 11

12 Specimen procurement Burner Rig Thermography Cyclix oxidation Corrosion Erosion Mechanical response ~250 CMSX4 specimen with different geometries were needed 12

13 Characterisation: Furnace Cycling Test Test conditions: TBC thickness FT Cycling 150µm hFT,1h RT 300µm-400µm hFT,1h RT 500µm hFT,1h RT LPPS-TF Test results 3D APS LPPS-TF F4 APS Triplex II APS APS Ref. EB-PVD Ref. Das war auch Triplex (unser)? Seg. APS Hast Du da noch ein Foto ohne 13

14 Characterisation: Burner Rig Test Test conditions: CMSX4 pipes, 150x16mm Surface Temp C Temp. Gradient Cycle >100 C 210s hot 75 cooling (<100 C) Burner Rig (NLR) Failure: Triplex II APS Test Results 3D APS LPPS-TF F4 APS Triplex II APS APS Ref. EB-PVD Ref. Test specimen Failure: LPPS-TF 14

15 Characterisation: Erosion 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. Erodet surfaces Seg. APS LPPS-TF LPPS-TF 15

16 Characterisation: Corrosion Test conditions: Test temperature 900 C Test medium Test specimen CMAS-like test 75% NaSo4, 25% NaCl massive Pins Furnace Test Results 3D APS LPPS-TF Sample after 100 h F4 APS Triplex II APS APS Ref. EB-PVD Ref. Failure EDX mapping, 3D structure 16

17 Characterisation: Cyclic oxidation Test conditions: Dwell temperature Cycle duration Heating/cooling 1050 C/ 1100 C(*) 2h 15min Seg. APS, 400h/270c LPPS-TF C Test Results 3D APS LPPS-TF (*) F4 APS Triplex II APS APS Ref. EB-PVD Ref.(*) EB-PVD C 17

18 Characterisation: Summary & Ranking 1,00 NLR Burner Rig ALSTOM FCT Cesi Erosion VAC Burner Rig AVIO corrosion 0,75 0,50 0,25 0,00 3D 3D new APS FZJ LPPS-TF LPPS TF SM F4 APS TriplexII APS f&c APS FZJ APS ref. TUC EB-PVD EB-PVD ref ref (~300µm) SM204BNS SNS HTU Main obejective: Properties of developed system superior to EB-PVD coatings, evaluated performace 18

19 Thermal conductivity Measured via Laser Flash Technology Therm. conductivity (W/mK) 3 2,5 2 1,5 1 0, Temperature ( C) 3D + seg APS 2.5 F4 APS seg. 2.1 EB-PVD (ref) 2.0 Triplex 2 APS seg. 1.9 LPPS-TF 1.6 Porous APS (ref) 0.6 W/mK 19

20 Technology transfer - Coating of real components AVIO Combustor Splash Plate ALSTOM blade Airfoil LPPS-TF Columnar F4 Highly segmented Triplex II Highly segmented 20

21 Spraying transfer evaluation LPPS APS TR2 Ref 21 TBC thickness PS/TE PS PS PS/LE LE SS/LE SS SS SS/TE TBC thickness and porosity on real components 0 SS LE PS TE PS/TE PS PS PS/LE LE SS/LE SS SS SS/TE TBC thickness TBC porosity

22 Further activities Sensor Coatings Repair technology Monitoring the process Laser Luminescence LPPS-TF coating YSZ Eu/Dy doped YSZ layer Bondcoat/Substrate Defect EB-PVD coating Intensity Ratio ln ( intensity ratio) linear fit Modelling / FEM analysis of 3D modifications Mechanical tests 4-point bending Pulse exccitation Thickness Topcoat (µm) YSZ Thickness 22

23 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 23

24 Thanks to: EC for support TOPPCOAT project partner for the good collaboration. Thank you for your attendance. 24