Evaluation of Erosion Resistance of Advanced ... · National Aeronautics and Space Administration 1...

Nat

iona

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1

Eval

uatio

n of

Ero

sion

Res

ista

nce

of A

dvan

ced

Turb

ine

Ther

mal

Bar

rier C

oatin

gsEv

alua

tion

of E

rosi

on R

esis

tanc

e of

Adv

ance

d Tu

rbin

e Th

erm

al B

arrie

r Coa

tings

This

wor

k w

as s

uppo

rted

by

NA

SA U

EET

and

Fund

amen

tal A

eron

autic

sPr

ogra

ms

The

31st

Inte

rnat

iona

l Coc

oa B

each

Con

fere

nce

& E

xpos

ition

on

Adv

ance

d C

eram

ics

& C

ompo

site

sD

ayto

na B

each

, Flo

rida,

Jan

uary

22-

26, 2

007

Don

gmin

g Zh

u, M

aria

A. K

uczm

arsk

i, R

ober

t A. M

iller

, an

d M

icha

el D

. Cuy

Dur

abili

ty a

nd P

rote

ctiv

e C

oatin

gs B

ranc

hM

ater

ials

and

Stru

ctur

es D

ivis

ion

NA

SA J

ohn

H. G

lenn

Res

earc

h C

ente

rC

leve

land

, Ohi

o 44

135,

USA

https://ntrs.nasa.gov/search.jsp?R=20070018152 2020-01-07T08:11:17+00:00Z

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2

Abs

trac

t

The

eros

ion

resi

stan

t tur

bine

ther

mal

bar

rier c

oatin

g sy

stem

is

crit

ical

to a

ircra

ft en

gine

per

form

ance

and

dur

abili

ty. B

y de

mon

stra

ting

adva

nced

turb

ine

mat

eria

l tes

ting

capa

bilit

ies,

w

e w

ill b

e ab

le to

faci

litat

e th

e cr

itica

l tur

bine

coa

ting

and

subc

ompo

nent

dev

elop

men

t and

hel

p es

tabl

ish

adva

nced

er

osio

n-re

sist

ant t

urbi

ne a

irfoi

l the

rmal

bar

rier c

oatin

gs d

esig

n to

ols.

The

obj

ectiv

e of

this

wor

k is

to d

eter

min

e er

osio

n re

sist

ance

of a

dvan

ced

ther

mal

bar

rier c

oatin

g sy

stem

s un

der

sim

ulat

ed e

ngin

e er

osio

n an

d/or

ther

mal

gra

dien

t env

ironm

ents

, va

lidat

ing

adva

nced

turb

ine

airf

oil t

herm

al b

arrie

r coa

ting

syst

ems

base

d on

nan

o-te

trag

onal

pha

se to

ughe

ning

des

ign

appr

oach

es.

Nat

iona

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3

─H

igh-

heat

-flux

ero

sion

test

cap

abili

ty d

evel

opm

ent

─A

dvan

ced

low

con

duct

ivity

and

ero

sion

-res

ista

nt th

erm

al b

arrie

r co

atin

gs p

erfo

rman

ce e

valu

atio

n

─D

eter

min

e er

osio

n re

sist

ance

of a

dvan

ced

low

con

duct

ivity

th

erm

al b

arrie

r coa

ting

syst

ems

unde

r sim

ulat

ed e

ngin

e er

osio

n an

d hi

gh-h

eat-f

lux

ther

mal

gra

dien

t env

ironm

ents

─Er

osio

n an

d im

pact

mec

hani

sms

─Su

mm

ary

and

futu

re d

irect

ions

Out

line

OB

JEC

TIVE

: Dev

elop

adv

ance

d th

erm

al b

arrie

r coa

ting

syst

ems

with

sup

erio

r ero

sion

resi

stan

ce in

eng

ine

eros

ion

and

ther

mal

gr

adie

nt e

nviro

nmen

ts, a

nd e

stab

lish

coat

ing

perf

orm

ance

m

odel

s

Nat

iona

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4

Adv

ance

d Lo

w C

ondu

ctiv

ity T

herm

al B

arrie

r Coa

ting

Dev

elop

men

t Req

uire

men

ts

—Lo

w c

ondu

ctiv

ity (“

1/2”

of th

e ba

selin

e) re

tain

ed u

nder

ther

mal

gra

dien

t at

240

0°F

—Im

prov

ed s

inte

ring

resi

stan

ce a

nd p

hase

sta

bilit

y (u

p to

300

0°F)

—Ex

celle

nt d

urab

ility

and

mec

hani

cal p

rope

rtie

s•C

yclic

life

•Tou

ghne

ss•E

rosi

on/im

pact

resi

stan

ce•C

MA

S a

nd c

orro

sion

resi

stan

ce•C

ompa

tibili

ty w

ith th

e su

bstra

te/T

GO

—Pr

oces

sing

cap

abili

ty u

sing

exi

stin

g in

fras

truc

ture

and

alte

rnat

ive

syst

ems

—O

ther

des

ign

cons

ider

atio

ns•F

avor

able

opt

ical

pro

perti

es•P

oten

tially

sui

tabl

e fo

r var

ious

met

al a

nd c

eram

ic c

ompo

nent

s

Nat

iona

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onau

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5

Dev

elop

men

t of A

dvan

ced

Def

ect C

lust

er L

ow

Con

duct

ivity

The

rmal

Bar

rier C

oatin

gs—

Mul

ti-co

mpo

nent

oxi

de d

efec

t clu

ster

ing

appr

oach

(Zhu

and

Mill

er, U

S

Pat

ents

No.

6,8

12,1

76 a

nd N

o.7,

001,

859;

US

pat

ent a

pplic

atio

n 11

/510

,574

)

—D

efec

t clu

ster

s as

soci

ated

with

dop

ants

egre

gatio

n—

A n

ew s

ix-c

ompo

nent

, hig

h to

ughn

ess

coat

ings

als

o de

velo

ped

(pat

ent

pend

ing)

EELS

ele

men

tal m

aps

of E

B-P

VD Z

rO2-

14m

ol%

(Y, G

d,Yb

) 2O3

Plas

ma-

spra

yed

ZrO

2-13

.5m

ol%

(Y, N

d,Yb

) 2O3

EB-P

VD Z

rO2-1

2mol

%(Y

, N

d,Yb

) 2O3

e.g.

: ZrO

2-Y 2

O3-

Nd 2

O3(

Gd 2

O3,S

m2O

3)-Y

b 2O

3(Sc

2O3)

–TT

syst

ems

Prim

ary

stab

ilizer

Oxi

de c

lust

er d

opan

ts w

ith d

istin

ctiv

e io

nic

size

sTo

ughe

ning

dop

ants

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iona

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6

Ther

mal

Con

duct

ivity

and

Cyc

lic D

urab

ility

Eva

luat

ions

—A

new

ser

ies

of E

B-P

VD Z

rO2-

Y 2O

3-G

d 2O

3-Yb

2O3

and

ZrO

2-Y 2

O3-

Gd 2

O3-

Yb2O

3-TT

coa

tings

des

igne

d fo

r im

prov

ed to

ughn

ess

and

eros

ion

resi

stan

ce—

Ther

mal

con

duct

ivity

and

cyc

lic d

urab

ility

ch

arac

teriz

edS

elec

ted

coat

ing

spec

imen

co

nfig

urat

ions

0

0.2

0.4

0.6

0.81

ZrYGdYb t'

ZrYGdYb t'

ZrYGdYb t'

ZrYGdYb t'

ZrYGdYb t'

ZrYGdYb t'

Cubic TT

ZrYGdYb Cubic+TT

ZrYGdYb Cubic+TT

tZrYGdYb TT t'

ZrYGdYb t'" and Cubic multilayer

ZrYGdYb t'" and Cubic multilayer

ZrYGdYb t'

ZrYGdYb t'

YSZ +TT

YSZ +TT

ZrYGdYb t'+TT

ZrYGdYb t'+TT

ZrYGdYb t'+TT

ZrYGdYb t'+TT

ZrYGdYb t'+TT

ZrYGdYb t'+TT

ZrYGdYb Cubic

The

rmal

con

duct

ivity

of E

B-P

VD

ero

sion

TB

Cs

Normalized conductivity

base

line

0

100

200

300

400

500

ZrYGdYb t'

ZrYGdYb t'

ZrYGdYb t'

ZrYGdYb t'

ZrYGdYb t'

ZrYGdYb t'

ZrYGdYb t'

ZrYGdYb t'

ZrYGdYb t'

ZrYGdYb Cubic+TT

ZrYGdYb Cubic+TT

ZrYGdYb Cubic+TT

ZrYGdYb t'+High TT

ZrYGdYb t'+High TT

ZrYGdYb t'+High TT

ZrYGdYb t' and Cubic multilayer

ZrYGdYb t' and Cubic multilayer

ZrYGdYb t' and Cubic multilayer

YSZ Baseline

YSZ Baseline

Furn

ace

cycl

ic li

fe o

f EB

-PV

D e

rosi

on c

oatin

gs

Furnace cyclic life at 2125F

2125

°F

base

line

Nat

iona

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7

Ther

mal

Con

duct

ivity

and

Cyc

lic D

urab

ility

Eva

luat

ions

(con

tinue

d)

―Ef

fect

of t

empe

ratu

re o

n co

atin

g cy

clic

life

0

200

400

600

800

1000

ZrO

2-7w

t%Y

2O3 b

asel

ine

Zr4

Y3G

d3Y

b5T

i5T

a

Cycles to failure

Coa

ting

Typ

e

2125

°F(1

163°

C),

1 hr

cyc

les

2075

°F(1

135°

C),

1 hr

cyc

les

0

200

400

600

800

1000

ZrO

2-7w

t%Y

2O3 b

asel

ine

Zr4

Y3G

d3Y

b5T

i5T

a

Cycles to failure

Coa

ting

Typ

e

2125

°F(1

163°

C),

1 hr

cyc

les

2075

°F(1

135°

C),

1 hr

cyc

les

ZrO

2-(Y

,Gd,

Yb,

TT)

Nat

iona

l Aer

onau

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8

Hig

h-H

eat-F

lux

Test

App

roac

hes

─H

igh-

heat

-flux

lase

r tes

ts fo

r the

rmal

bar

rier c

oatin

g de

velo

pmen

t•T

empe

ratu

re g

radi

ent r

equi

rem

ents

: 20-

200°

F/m

il fo

r typ

ical

5-1

5 m

il th

ick

coat

ings

NA

SA C

O2

Lase

r Rig

Cur

rent

cap

abili

ty u

p to

315

W/c

m2 fo

r TB

Cs

T Dis

tanc

e fr

om s

urfa

ce

Hea

t flu

xco

olin

g

Nat

iona

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onau

tics

and

Spac

e Ad

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tion

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9

Lase

r Hig

h-H

eat-F

lux

Eros

ion

Test

Rig

Eros

ion

jet d

irect

ion

Eros

ion

jet

0.5

1.0

1.5

2.0

0400

800

1200

1600

010

2030

4050

60

kcer

a

Tsur

face

Tint

erfa

ceTb

ack

Thermal conductivity, W/m-K

Temperature, °C

Tim

e, h

ours

Tint

erfa

ce=1

125C

Tsur

face

=136

0C

Test

cyc

les o

f ero

sion

-hea

t-flu

x te

st

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iona

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10

Mac

h 0.

3-1.

0 H

igh

Velo

city

Bur

ner E

rosi

on T

est R

ig─

Bur

ner e

rosi

on ri

g w

as d

evel

oped

usi

ng a

new

ly d

esig

ned

exha

ust

nozz

le a

nd b

y ac

com

mod

atin

g in

crea

sed

burn

er g

as fl

ow to

ach

ieve

high

er-h

eat f

luxe

s w

ith fl

ame

stab

ility

and

uni

form

ity

Hig

h pr

ecis

ion

part

icle

fe

eder

sys

tem

Spec

imen

s und

er te

stin

g

Bur

ner e

xhau

st

nozz

le

Nat

iona

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11

CFD

Mod

ling

of th

e H

igh

Velo

city

Bur

ner E

rosi

on R

ig

usin

g Fl

uent

Cod

es—

Com

puta

tiona

l Flu

id D

ynam

ics

(CFD

) mod

elin

g of

bur

ner f

low

and

pa

rtic

le v

eloc

ities

pro

vidi

ng v

ital e

rosi

on te

st in

form

atio

n

0

100

200

300

400

500

00.

10.

20.

30.

40.

50.

60.

70.

8

Mac

h 0.

3, 5

0 m

icro

n pa

rticl

esM

ach

0.3,

560

mic

ron

parti

cles

Mac

h 0.

7, 5

0 m

icro

n pa

rticl

esM

ach

0.7,

560

mic

ron

parti

cles

Particle velocity, m/s

Dis

tanc

e fr

om in

ject

or, m

nozz

le e

xit

spec

imen

loca

tion

Nat

iona

l Aer

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tics

and

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tion

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12

Bur

ner E

rosi

on R

ig H

eat F

lux

Cha

ract

eriz

atio

ns

0

200

400

600

800

1,00

0

050100

150

200

02

46

810

1214

Hea

t flu

x m

atri

x Da

ta 7

Tsur

face

Tmid

TC

Tbac

k

Hea

t flu

x, W

/cm

2

Temperature, °C

Heat flux, W/cm2

Tim

e, m

in

100%

air,

30%

fuel,

cool

ing

air 2

psi

—B

urne

r rig

hea

t flu

xes

char

acte

rized

usi

ng a

n em

bedd

ed th

erm

ocou

ple

(TC

) sen

sor a

ppro

ach.

—A

hea

t flu

x of

50

W/c

m2

achi

eved

at M

ach

0.7-

0.8.

TC

Hea

t flu

x

Pyro

met

er b

ack

Nat

iona

l Aer

onau

tics

and

Spac

e Ad

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istra

tion

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13

Eros

ion

Res

ista

nce

of A

dvan

ced

Mul

ticom

pone

ntLo

w

Con

duct

ivity

The

rmal

Bar

rier C

oatin

gs―

Impr

oved

impa

ct/e

rosi

on re

sist

ance

obs

erve

d fo

r adv

ance

d lo

w

cond

uctiv

ity s

ix-c

ompo

nent

coa

tings

0.0

0.5

1.0

1.5

2.0

2.5

ZrYGdYb t' -1

ZrYGdYb t' -2

ZrYGdYb t' -3

ZrYGdYb t' -4

ZrYGdYb Cubic multilayer

ZrYGdYb Cubic +TT

ZrO2-4Y (baseline)

Adv

ance

d co

atin

gsB

asel

ine

Erosion resistance(Erodant amount required

per mg coating removal, g/mg)

2200

°F56

0 µm

Al 2O

3

Nat

iona

l Aer

onau

tics

and

Spac

e Ad

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tion

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14

Adv

ance

d M

ultic

ompo

nen

Low

Con

duct

ivity

The

rmal

B

arrie

r Coa

tings

―Im

prov

ed e

rosi

on re

sist

ance

dem

onst

rate

d fo

r adv

ance

d lo

w

cond

uctiv

ity th

erm

al b

arrie

r coa

tings

051015202530

ZrYGdYb t'

ZrYGdYb t'+TT

ZrYGdYb Cubic+TT

ZrYGdYb Cubic

ZrO2-4Y (baseline)

Adv

ance

d co

atin

gsB

asel

ine

Erosion resistance(Erodant amount required

per mil coating removal, g/mil)

2175

°F50

µm

Al 2O

3

Nat

iona

l Aer

onau

tics

and

Spac

e Ad

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istra

tion

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15

Eros

ion/

Impa

ct F

ailu

re M

echa

nism

s of

The

rmal

Bar

rier

Coa

tings

―Su

rfac

e si

nter

ing

and

impa

ct d

ensi

ficat

ion

zone

s ob

serv

ed, w

ith

subs

eque

nt s

palla

tion

unde

r the

ero

dant

furt

her i

mpa

ct

30 u

m30

um

Surf

ace

sint

erin

g an

d im

pact

den

sific

atio

n zo

ne

SEM

mic

rogr

aphs

of a

dvan

ced

ther

mal

bar

rier c

oatin

g af

ter i

mpa

ct/e

rosi

on d

amag

e

Bac

ksca

ttere

d el

ectr

on im

age

Seco

ndar

y el

ectr

on im

age

Nat

iona

l Aer

onau

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and

Spac

e Ad

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16

—H

igh

heat

-flux

and

sim

ulat

ed e

ngin

e er

osio

n te

sts

esta

blis

hed

for

adva

nced

ther

mal

bar

rier c

oatin

gs d

evel

opm

ent

—Lo

w c

ondu

ctiv

ity a

nd e

rosi

on re

sist

ant t

herm

al b

arrie

r coa

tings

de

velo

ped

base

d on

nan

o-te

trago

nal p

hase

toug

heni

ng d

esig

n ap

proa

ches

—Th

e op

timiz

ed c

oatin

gs d

emon

stra

ted

exce

llent

con

duct

ivity

ben

efit

and

impr

oved

ero

sion

resi

stan

t cap

abili

ty

—C

ompl

eted

initi

al s

imul

ated

eng

ine

eros

ion

test

ing

for v

alid

atin

g co

atin

g pe

rfor

man

ce m

odel

s—

Com

plet

ed 6

00 h

r cyc

lic d

urab

ility

test

s at

207

5°F

and

50 h

rs c

ombi

ned

lase

r ero

sion

-hig

h he

at fl

ux te

sts

at 2

350°

F fo

r dow

n-se

lect

ed tu

rbin

e ai

rfoil

coat

ing

syst

ems

—D

emon

stra

ted

the

coat

ing

syst

ems

in th

e M

ach

0.3-

1 bu

rner

ero

sion

rig

unde

r sim

ulat

ed tu

rbin

e en

gine

and

ero

sion

env

ironm

ents

Sum

mar

y