The role of reactive elements in improving the cyclic oxidation performance of Β- NiAl coatings

the bond coat in thermal barrier coating (TBC) system. However, the oxide scale grown on NiAl spalls readily during high-temperature cyclic oxidation. Reactive elements (REs) as well as their oxides dispersions were investigated to improve the cyclic oxidation performance. In this work, the effects of several REs on the adherence of Al2O3/NiAl interface were investigated by first principles theory calculations and experiments. We find that the solubility of the REs in NiAl alloy arrive at an order of Hf \u3eZr\u3eDy\u3eY\u3eLa, all the REs exhibit an affinity for sulfur, with an order of La\u3eDy\u3eY\u3eZr\u3eHf, and direct effects of the REs on the Al2O3/NiAl interface exhibit an order of Hf\u3eY\u3eHf\u3eZr\u3eclean interface\u3eLa. Combined with experimental results, we provide some suggestions on how to choose an appropriate RE. Co-doping of appropriate REs exhibits promising potential in improving the oxide scale adherence but also in reducing the growth rate of the oxides formed on the NiAl alloy or coating as compared to the single RE doping

CMAS-resistance of a yttria graded thermal barrier coating fabricated by plasma activated EB-PVD

EB-PVD yttria stabilized zirconia (YSZ) thermal barrier coatings (TBCs) are susceptible to calcia-magnesia-aluminum-silicate (CMAS) corrosion. The service lifetime of typical 8YSZ TBCs can be significantly reduced by CMAS attack. Currently, composition and microstructure modifications are the most commonly used methods for CMAS infiltration resistance. It has been reported by previous researchers that reactive elements, including Y, Gd, La, and etc., doped in TBCs can promote the formation of a dense protective layer by a sacrificing reaction with CMAS. It is therefore that the CMAS infiltration can be retarded. Besides, tailored columnar grains of TBCs are are also proved to be effective for CMAS mitigation. In this work, TBCs specimens with graded microstructure were fabricated by EB-PVD. The upper region of the TBC was doped with a higher Y2O3 content up to 25 wt.%, compared with the conventional 8YSZ composition. Besides, plasma activation was also introduced in the EB-PVD process to yield a tailored coating morphology and prosity. The coating specimens were tested at 1250 oC for evaluating CMAS resistance. Conventional YSZ coatings and graded coatings without plasma activation were also investigated for comparison

Influence of Gd2O3 and Yb2O3 Co-doping on Phase Stability, Thermo-physical Properties and Sintering of 8YSZ

AbstractThe role of multicomponent rare earth oxides in phase stability, thermo-physical properties and sintering for ZrO2-based thermal barrier coatings (TBCs) materials is investigated. 8YSZ co-doped with 3 mol(Gd2O3 and 3 mol% Yb2O3 (GYb-YSZ) powders are synthesized by solid state reaction for 24 h at various temperatures. As temperature increases, stabilizers are dissolved into zirconia matrix gradually. Synthesized at 1 500 °C, GYb-YSZ is basically composed of cubic phase. GYb-YSZ exhibits excellent phase stability and sinters lower than 8YSZ by nearly three times. The thermal conductivity of GYb-YSZ is much lower than that of 8YSZ, and the thermal expansion coefficient of GYb-YSZ is comparable to that of 8YSZ. The influence of Gd2O3 and Yb2O3 co-doping on phase stability, thermal conductivity and sintering of 8YSZ is discussed

Effect of thermal exposure on the stress-rupture life and microstructure of a low Re-containing single crystal alloy

AbstractIn this paper, the stress-rupture tests of a low Re-containing single crystal alloy IC21 before and after thermal exposure at 1100°C for various periods of time were conducted under the test condition of 1100°C/137MPa, and the microstructure of the tested specimens was characterized by SEM and TEM. The experimental results showed that the stress rupture life of this alloy was over 150h after the standard heat treatment of 1320°C, 10h/AC+870, 32h/AC, however the stress rupture life decreased with the increase of exposure time due to the microstructure degradation. The TEM analysis revealed that the interface mismatch dislocation networks were well established. It was observed that these mismatch networks could form at 1100°C even after thermal exposure for 1h without the external stress, which is quite different from that in the traditional single crystal superalloys

PS-PVD thermal/environmental barrier coatings with novel microstructures

Plasma spray physical vapor deposition (PS-PVD) technology has attracted increasing attention due to it promising potential in processing advanced functional coatings such as thermal/environmental barrier coatings (TBCs) by flexibly tailoring the coating microstructure architecture in a broad range. In this work, yttria stabilized zirconia (YSZ) TBCs with a novel quasi-columnar structure was prepared by co-deposition of vapor phase and nano-clusters using PS-PVD and the associated deposition mechanism was discussed. The thermo-physical and mechanical properties, sintering resistance and thermal shock life of the coating were investigated. The thermal conductivity is in a range of 0.7~1.0 W/mk between 200 °C and 1200 °C and the average life is ~4000 cycles during thermal shock testing in which the coating surface was heated to 1200 °C within 20 s and held at the temperature for 5 min by gas flame. Noted that the quasi-columnar TBC revealed much better resistance to glassy CaO-MgO-Al2O3-SiO2 (CMAS) adsorption than those TBCs produced by air plasma spray (APS) and electron beam physical vapor deposition (EB-PVD) and some attempts were made to understand the related mechanisms. Ytterbium silicate/mullite/Si environmental barrier coatings (EBCs) were sprayed onto SiC ceramic matrix composites (CMC) by PS-PVD. The dense ytterbium silicate coating deposited at 65 kw is mainly composed of ytterbium disilicate resulting from vapor-phase deposition, whereas the layered coating at 40 kw is mainly ytterbium monosilicate from liquid deposition

Orientation Dependence of High Cycle Fatigue Behavior of a <111> Oriented Single-Crystal Nickel-Based Superalloy

High cycle fatigue failure has been recognized as one of the major forms of failure of aero-engine blades. This paper presents the high cycle fatigue testing of a Ni-based superalloy near <111> orientation at 800 °C. The fracture morphology and dislocation configuration were analyzed in detail by scanning electron microscopy (SEM) and transmission electron microscopy (TEM) to indicate the influence of orientation deviation degree on the high cycle fatigue properties. The results show that the orientation deviation significantly affects the initiation of the slip systems, which is closely related to fatigue performance. The best fatigue life appears on the precise <111> orientation, and the deformation behavior is controlled by multiple sets of equivalent <110> {111} slip systems. With the increase in orientation deviation, the fatigue properties of the alloy degenerate significantly. On the boundary of <111>-<001>, two groups of <110> {111} slip systems with the maximum Schmid shear stress dominate the deformation behavior. On the other hand, on the <111>-<011> boundary, the formation of stacking faults and rapid cutting of γ’ precipitates results in a negative effect on the fatigue life

Influence of Mo and Ta additions on solidification behavior of Ni3Al single crystal alloys

Ni3Al (Ni75Al25) and Ni3Al–2Mo/Ta (Ni73.5Al24.5Mo/Ta2) single crystals were prepared by the Bridgman method under high temperature gradient (~170 °C/cm) at the withdrawal rates of 5 and 20 μm/s. The experimental results showed that the addition of Mo decreased the liquidus and solidus temperatures, and the addition of Ta increased the liquidus and solidus temperatures. Meanwhile, both Mo and Ta additions were found to increase the solidification range of experimental alloy. It has been found that for solidification of stoichiometric Ni3Al at low withdrawal rate (5 μm/s), β/γ′ eutectic first solidified from liquid (L→β+γ′) and then β phase completely transformed into pure γ′ (β→γ′) after the completion of solidification. However, at high withdrawal rate of 20 μm/s, the remaining β phase was found in the as-cast microstructure of Alloy Ni3Al. Different from stoichiometric Ni3Al, the solidification sequence of Alloy Ni3Al–2Mo was identified as L→β+γ′+Mo-rich phase (ternary eutectic reaction). In addition, the addition of Ta led to the formation of primary γ′ phase and then subsequent intercellular/interdendritic β/γ′ eutectic microstructure. Based on above study, a new Ta and Mo containing Ni3Al based single crystal alloy with superior tensile strength at ultra-high temperature (>1100 °C) was designed

Evaluation of plasma sprayed YSZ thermal barrier coatings with the CMAS deposits infiltration using impedance spectroscopy

AbstractThe yttria-stabilized zirconia (YSZ) thermal barrier coatings (TBCs) prepared by atmospheric plasma spraying with different heat treatment period at the temperature of 1250°C were studied in the present investigation. Electrochemical impedance spectroscopy (EIS) was employed to non-destructively examine the impedance and capacitance behavior of free standing YSZ coatings deposited by plasma spray with CMAS (calcium–magnesium–alumino-silicate) infiltration. Equivalent circuit was established on the basis of the biomodal structure in coatings. The sintering behavior of the coatings can be reflected by the changes of resistance and capacitance of the coating. By EIS, the microstructure evolution of the coating with CMAS deposits was discussed in detail