Abstract No.:
6373

 Title:
Perspectives on the thermal conductivity and laser-rig thermal-gradient cycle performance of SPS YSZ TBCs

 Authors:
Rogerio Lima* / National Research Council Canada, Canada

 Abstract:

Suspension plasma spray (SPS) processing of ZrO2-Y2O3 (YSZ) thermal barrier coatings (TBCs) is a strong candidate to replace electron beam physical vapour deposition (EB-PVD) and dense-vertically cracked (DVC) YSZ TBCs on the blades of aerospace and power generation gas turbines. However, there are major concerns about the performance of these SPS TBCs; mainly regarding high temperature thermal conductivity and thermal gradient cycling performance. In order to clarify these issues, in this work 3 distinct types of commercial YSZ suspensions (20-25wt%YSZ in ethanol) were sprayed using different sets of spray parameters. The thermal conductivity values of these SPS TBCs were measured from RT up to 1250oC. It was observed that the high temperature thermal conductivity values of SPS YSZ TBCs were below those typically exhibited by EB-PVD YSZ TBCs. In order to investigate the thermal-gradient cycle performance of these SPS YSZ TBCs, a laser-rig was employed. Each cycle had duration of 7 min, consisting in 5 min hot and 2 min cooling until RT is reached. Thermal cycling is performed until TBC failure (e10% spallation area) or 1000 cycles (whichever comes first). The thermally cycled SPS YSZ TBCs were deposited over previously MCrAlY bond-coated CMSX-4 single-crystal (puck-shaped) substrates. The temperature of the substrates at the thermal cycling set-up was ~1100oC, whereas, the temperature values of the YSZ top surface varied from ~1300 to ~1450oC at set-up. Some of the SPS YSZ TBCs tested reached 1000 laser-rig cycles without failure. These are released results of the Surftec Industrial R&D Consortium of the National Research Council of Canada (NRC) and show the promising potential of employing SPS TBCs on gas turbine components.



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