Thermal barrier coating life prediction model development

In order to fully exploit thermal barrier coatings (TBCs) on turbine components and achieve the maximum performance benefit, the knowledge and understanding of TBC failure mechanisms must be increased and the means to predict coating life developed. The proposed program will determine the predominant modes of TBC system degradation and then develop and verify life prediction models accounting for those degradation modes. The successful completion of the program will have dual benefits: the ability to take advantage of the performance benefits offered by TBCs, and a sounder basis for making future improvements in coating behavior

Cost benefit study of advanced materials technology for aircraft turbine engines

The cost/benefits of eight advanced materials technologies were evaluated for two aircraft missions. The overall study was based on a time frame of commercial engine use of the advanced material technologies by 1985. The material technologies evaluated were eutectic turbine blades, titanium aluminide components, ceramic vanes, shrouds and combustor liners, tungsten composite FeCrAly blades, gamma prime oxide dispersion strengthened (ODS) alloy blades, and no coat ODS alloy combustor liners. They were evaluated in two conventional takeoff and landing missions, one transcontinental and one intercontinental

Thermal barrier coating life prediction model development

The objectives are to determine the predominant modes of degradation of a plasma sprayed thermal barrier coating system, and then to develop and verify life prediction models accounting for these degradation modes. Two possible predominant failure mechanisms being evaluated are bond coat oxidation and bond coat creep

Thermal barrier coating life prediction model

This is the first report of the first phase of a 3-year program. Its objectives are to determine the predominant modes of degradation of a plasma sprayed thermal barrier coating system, then to develop and verify life prediction models accounting for these degradation modes. The first task (Task I) is to determine the major failure mechanisms. Presently, bond coat oxidation and bond coat creep are being evaluated as potential TBC failure mechanisms. The baseline TBC system consists of an air plasma sprayed ZrO2-Y2O3 top coat, a low pressure plasma sprayed NiCrAlY bond coat, and a Rene'80 substrate. Pre-exposures in air and argon combined with thermal cycle tests in air and argon are being utilized to evaluate bond coat oxidation as a failure mechanism. Unexpectedly, the specimens pre-exposed in argon failed before the specimens pre-exposed in air in subsequent thermal cycles testing in air. Four bond coats with different creep strengths are being utilized to evaluate the effect of bond coat creep on TBC degradation. These bond coats received an aluminide overcoat prior to application of the top coat to reduce the differences in bond coat oxidation behavior. Thermal cycle testing has been initiated. Methods have been selected for measuring tensile strength, Poisson's ratio, dynamic modulus and coefficient of thermal expansion both of the bond coat and top coat layers

Thermal barrier coating life prediction model development

This report describes work performed to determine the predominat modes of degradation of a plasma sprayed thermal barrier coating system and to develop and verify life prediction models accounting for these degradation modes. The primary TBC system consisted of a low pressure plasma sprayed NiCrAlY bond coat, an air plasma sprayed ZrO2-Y2O3 top coat, and a Rene' 80 substrate. The work was divided into 3 technical tasks. The primary failure mode to be addressed was loss of the zirconia layer through spalling. Experiments showed that oxidation of the bond coat is a significant contributor to coating failure. It was evident from the test results that the species of oxide scale initially formed on the bond coat plays a role in coating degradation and failure. It was also shown that elevated temperature creep of the bond coat plays a role in coating failure. An empirical model was developed for predicting the test life of specimens with selected coating, specimen, and test condition variations. In the second task, a coating life prediction model was developed based on the data from Task 1 experiments, results from thermomechanical experiments performed as part of Task 2, and finite element analyses of the TBC system during thermal cycles. The third and final task attempted to verify the validity of the model developed in Task 2. This was done by using the model to predict the test lives of several coating variations and specimen geometries, then comparing these predicted lives to experimentally determined test lives. It was found that the model correctly predicts trends, but that additional refinement is needed to accurately predict coating life

Does the Third Law of Thermodynamics hold in the Quantum Regime?

The first in a long series of papers by John T. Lewis, G. W. Ford and the present author, considered the problem of the most general coupling of a quantum particle to a linear passive heat bath, in the course of which they derived an exact formula for the free energy of an oscillator coupled to a heat bath in thermal equilibrium at temperature T. This formula, and its later extension to three dimensions to incorporate a magnetic field, has proved to be invaluable in analyzing problems in quantum thermodynamics. Here, we address the question raised in our title viz. Nernst's third law of thermodynamics

Thermal barrier coating life prediction model

The objectives of this program are to determine the predominant modes of degradation of a plasma sprayed thermal barrier coating system, and then to develop and verify life prediction models accounting for these degradation modes. The program is divided into two phases, each consisting of several tasks. The work in Phase 1 is aimed at identifying the relative importance of the various failure modes, and developing and verifying life prediction model(s) for the predominant model for a thermal barrier coating system. Two possible predominant failure mechanisms being evaluated are bond coat oxidation and bond coat creep. The work in Phase 2 will develop design-capable, causal, life prediction models for thermomechanical and thermochemical failure modes, and for the exceptional conditions of foreign object damage and erosion

Thermal barrier coating life prediction model

This is the second annual report of the first 3-year phase of a 2-phase, 5-year program. The objectives of the first phase are to determine the predominant modes of degradation of a plasma sprayed thermal barrier coating system and to develop and verify life prediction models accounting for these degradation modes. The primary TBC system consists of an air plasma sprayed ZrO-Y2O3 top coat, a low pressure plasma sprayed NiCrAlY bond coat, and a Rene' 80 substrate. Task I was to evaluate TBC failure mechanisms. Both bond coat oxidation and bond coat creep have been identified as contributors to TBC failure. Key property determinations have also been made for the bond coat and the top coat, including tensile strength, Poisson's ratio, dynamic modulus, and coefficient of thermal expansion. Task II is to develop TBC life prediction models for the predominant failure modes. These models will be developed based on the results of thermmechanical experiments and finite element analysis. The thermomechanical experiments have been defined and testing initiated. Finite element models have also been developed to handle TBCs and are being utilized to evaluate different TBC failure regimes