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Impermeable Thin Al2O3 Overlay for TBC Protection From Sulfate and Vanadate Attack in Gas Turbines Quarterly Report

Description: In order to improve the hot corrosion resistance of yttria-stabilized zirconia (YSZ), an Al{sub 2}O{sub 3} overlay has been deposited on the surface of YSZ by electron-beam physical vapor deposition. Currently, hot corrosion tests were performed on the YSZ coatings with and without Al{sub 2}O{sub 3} overlay in molten salt mixture (Na{sub 2}SO{sub 4} + 0 {approx} 15wt%V{sub 2}O{sub 5}) at 950 C in order to investigate the effect of amount of vanadate on the hot corrosion behaviors. The results showed that the presence of in V{sub 2}O{sub 5} the molten salt exacerbates the degradation of both the monolithic YSZ coating and the composite YSZ/Al{sub 2}O{sub 3} system. The formation of low-melting Na{sub 2}O-V{sub 2}O{sub 5}-Al{sub 2}O{sub 3} liquid phase is responsible for degradation of the Al{sub 2}O{sub 3} overlay. The Al{sub 2}O{sub 3} overlay acts as a barrier against the infiltration of the molten salt into the YSZ coating during exposure to the molten salt mixture with <5wt% vanadate. In the next reporting period, we will use XPS and SIMS to study the interactions between alumina overlay and molten salt containing vanadate.
Date: June 10, 2003
Creator: Mao, Scott X.
Partner: UNT Libraries Government Documents Department

Impermeable Thin Al2O3 Overlay for TBC Protection From Sulfate and Vanadate Attack in Gas Turbines Quarterly Report

Description: To improve the hot corrosion resistance of YSZ thermal barrier coatings, a 25 {micro}m thick Al{sub 2}O{sub 3} overlay were deposited by HVOF thermal spray, respectively, onto to the surface of YSZ coating. In the next reporting period, we will measure or calculate the residue stress within Al{sub 2}O{sub 3} overlay and YSZ coating to study the mechanism of effect of Al{sub 2}O{sub 3} overlay on spalling of YSZ coating. However, due to the thermal expansion mismatch between YSZ coating and Al{sub 2}O{sub 3} overlay, such surface modification using Al{sub 2}O{sub 3} overlay might deteriorate strain tolerance of the TBC. In the present work, in order to investigate the effect of Al{sub 2}O{sub 3} overlay on residual stress developed in the samples during cooling after hot corrosion at high temperature, Finite Element method (FEM) was employed to determine the detailed stress states in the test specimens after cooling. The results showed that there is no high stress concentration at the interface between the YSZ and the bond coat for TBCs system without Al{sub 2}O{sub 3} overlay. On the other hand, the maximum compressive stress with a value of approximately, -330 MPa occurred within the Al{sub 2}O{sub 3} overlay. The maximum tensile stress in YSZ coat near the Al{sub 2}O{sub 3} overlay is in the range of 10-133 MPa. The maximum compressive stress of approximately -160 MPa occurred near the YSZ-bond coat interface. X axis stress play a dominant role in influencing the coating failure and spalling. In the next reporting period, we will study the thickness of Al{sub 2}O{sub 3} overlay on hot corrosion resistance and spalling of YSZ coating.
Date: March 31, 2004
Creator: Mao, Scott X.
Partner: UNT Libraries Government Documents Department

Impermeable Thin Al2O3 Overlay for TBC Protection From Sulfate and Vanadate Attack in Gas Turbines Quarterly Report

Description: To improve the hot corrosion resistance of YSZ thermal barrier coatings, a 25 {micro}m and a 2 {micro}m thick Al{sub 2}O{sub 3} overlay were deposited by HVOF thermal spray and by sol-gel coating method, respectively, onto to the surface of YSZ coating. Indenter test was employed to investigate the spalling of YSZ with and without Al{sub 2}O{sub 3} overlay after hot corrosion. The results showed that Al{sub 2}O{sub 3} overlay acted as a barrier against the infiltration of the molten salt into the YSZ coating during exposure, thus significantly reduced the amount of M-phase of ZrO{sub 2} in YSZ coating. However, a thick Al{sub 2}O{sub 3} overlay was harmful for TBC by increasing compressive stress which causes crack and spalling of YSZ coating. As a result, a dense and thin Al{sub 2}O{sub 3} overlay is critical for simultaneously preventing YSZ from hot corrosion and spalling. In the next reporting period, we will measure or calculate the residue stress within Al{sub 2}O{sub 3} overlay and YSZ coating to study the mechanism of effect of Al{sub 2}O{sub 3} overlay on spalling of YSZ coating.
Date: December 16, 2003
Creator: Mao, Scott X.
Partner: UNT Libraries Government Documents Department

Impermeable Thin Al2O3 Overlay for TBC Protection From Sulfate and Vanadate Attack in Gas Turbines Quarterly Report

Description: In order to further improve the hot corrosion resistance of yttria-stabilized zirconia (YSZ), an Al{sub 2}O{sub 3} overlay of 58 {micro}m thick was deposited on the surface of YSZ by electron-beam physical vapor deposition. Hot corrosion tests were performed on the YSZ coatings with {gamma}-Al{sub 2}O{sub 3} overlay and {alpha}-Al{sub 2}O{sub 3} overlay in molten salt mixture (Na2SO4 + 5wt%V2O5) at 950 C. The {alpha}-Al{sub 2}O{sub 3} overlay was obtained by the post-annealing of g-Al{sub 2}O{sub 3} overlay at 1200 C for 1h. The results showed that compared with the hot corrosion resistance of YSZ coating with 25 {micro}m thick {gamma}-Al{sub 2}O{sub 3} overlay, either thickening {gamma}-Al{sub 2}O{sub 3} overlay or employing {alpha}-Al{sub 2}O{sub 3} overlay could impair the hot corrosion resistance of YSZ coating, because the tensile stresses developed in the alumina overlay in both cases due to the mismatch in thermal expansion coefficient (TEC) between alumina and zirconia resulted in cracking of Al{sub 2}O{sub 3} overlay. The formation of cracks increased contact area between molten salt and Al{sub 2}O{sub 3} overlay, and also the penetration rate of molten salt into Al{sub 2}O{sub 3} overlay and YSZ coating, leading a faster and greater degradation of YSZ coating upon exposure. In the next reporting period, we will study the effect of Al{sub 2}O{sub 3} overlay thickness on hot corrosion and spalling of YSZ coatings.
Date: June 30, 2004
Creator: Mao, Scott X.
Partner: UNT Libraries Government Documents Department

Impermeable Thin Al2O3 Overlay for TBC Protection From Sulfate and Vanadate Attack in Gas Turbines Quarterly Report

Description: In order to improve the hot corrosion resistance of conventional YSZ TBC system, the overlay of Al{sub 2}O{sub 3} coating was deposited on the TBC by EB-PVD techniques. Hot corrosion tests were carried out on the TBC with and without Al{sub 2}O{sub 3} coating in molten salts mixtures (Na{sub 2}SO{sub 4} + 5%V{sub 2}O{sub 5}) at 950 C for 10h. The microstructures of TBC and overlay before and after exposure were examined by means of scanning electron microscopy (SEM), energy-dispersive X-ray spectrometer (EDX) and X-ray diffraction (XRD). It has been found that TBC will react with V{sub 2}O{sub 5} to form YVO{sub 4}. A substantial amount of M-phase was formed due to the leaching of Y{sub 2}O{sub 3} from YSZ. Al{sub 2}O{sub 3} overlay coating deposited by EB-PVD was dense, continues and adherent to the TBC. As a result, overlay Al{sub 2}O{sub 3} coating can prevent the YSZ from the attack by molten salts containing vanadium and arrest the penetration of salts into the YSZ along porous and cracks in the YSZ TBC, although there were some cracks in overlay Al{sub 2}O{sub 3} coating and at the interface between alumina and zirconia formed during hot corrosion tests due to the presence of tensile stress in the alumina coating. In the next reporting period, we will study the mechanisms of cracking of the overlay Al{sub 2}O{sub 3} layer and finish the hot corrosion tests of TBC with Al{sub 2}O{sub 3} coating deposited by high velocity oxy-fuel (HVOF) technique. The hot corrosion test of TBC with EB-PVD deposited Al{sub 2}O{sub 3} coating will be again performed. However before hot corrosion tests, a post-annealing will be carried out in vacuum (residual pressure 10{sup -3} Pa) at 1273K for 1h in order to transform the as-sputtered Al{sub 2}O{sub 3} overlay to crystalline {alpha}-Al{sub 2}O{sub ...
Date: January 31, 2002
Creator: Mao, Scott X.
Partner: UNT Libraries Government Documents Department

Impermeable Thin Al2O3 Overlay for TBC Protection From Sulfate and Vanadate Attack in Gas Turbines Quarterly Report

Description: To improve the hot corrosion resistance of YSZ thermal barrier coatings, a 25 {micro}m and a 2 {micro}m thick Al{sub 2}O{sub 3} overlay were deposited by HVOF thermal spray onto to the surface of YSZ coating. Oxidation at high temperature and hot corrosion tests showed that Al{sub 2}O{sub 3} overlay deposited on the YSZ TBCs surface can not only reduce the hot corrosion rate, but also significantly prevents the bond coat from oxidation.
Date: August 31, 2004
Creator: Mao, Scott X.
Partner: UNT Libraries Government Documents Department

Impermeable Thin Al2O3 Overlay for TBC Protection From Sulfate and Vanadate Attack in Gas Turbines Quarterly Report

Description: To improve the hot corrosion resistance of YSZ thermal barrier coatings, a 25 {micro}m and a 2 {micro}m thick Al{sub 2}O{sub 3} overlay were deposited by HVOF thermal spray and by sol-gel coating method, respectively, onto to the surface of YSZ coating. Indenter test was employed to investigate the spalling of YSZ with and without Al{sub 2}O{sub 3} overlay after hot corrosion. The results showed that Al{sub 2}O{sub 3} overlay acted as a barrier against the infiltration of the molten salt into the YSZ coating during exposure, thus significantly reduced the amount of M-phase of ZrO{sub 2} in YSZ coating. However, a thick Al{sub 2}O{sub 3} overlay was harmful for TBC by increasing compressive stress which causes crack and spalling of YSZ coating. As a result, a dense and thin Al{sub 2}O{sub 3} overlay is critical for simultaneously preventing YSZ from hot corrosion and spalling. In the next reporting period, we will measure or calculate the residue stress within Al{sub 2}O{sub 3} overlay and YSZ coating to study the mechanism of effect of Al{sub 2}O{sub 3} overlay on spalling of YSZ coating.
Date: December 16, 2003
Creator: Mao, Scott X.
Partner: UNT Libraries Government Documents Department

Impermeable Thin Al2O3 Overlay for TBC Protection From Sulfate and Vanadate Attack in Gas Turbines Quarterly Report

Description: In order to improve the hot corrosion resistance of conventional YSZ TBC system, a thin and dense {alpha}-Al{sub 2}O{sub 3} overlay has been deposited on the YSZ surface by the composite-sol-gel route (CSG). The YSZ substrates were dipped with boehmite sol containing calcined {alpha}-Al{sub 2}O{sub 3} particles, dried to form a gel film and calcined at 1200 C to form {alpha}-Al{sub 2}O{sub 3} overlay. Hot corrosion tests were carried out on the TBCs with and without Al{sub 2}O{sub 3} coating in molten salt mixtures (Na{sub 2}SO{sub 4} + 5% V{sub 2}O{sub 5}) at 950 C for 10 hours. The results showed that besides a thin and dense alumina overlay with the thickness of about 100-500 nm formed on the YSZ surface, the microcracks and porous near the surface in YSZ was also occupied by alumina because of penetration of the low viscosity precursor. As a result, the Al{sub 2}O{sub 3} overlay remarkably refrained the infiltration of the molten salt into the YSZ coating. The amount of M-phase in the TBC coating with Al{sub 2}O{sub 3} overlay was substantially reduced comparing to that without alumina overlay. In the next reporting period, we will prepare the alumina overlay by CSG route with different thickness and study the hot corrosion mechanism of YSZ TBC with thin Al{sub 2}O{sub 3} overlay coating produced by CSG.
Date: March 10, 2003
Creator: Mao, Scott X.
Partner: UNT Libraries Government Documents Department