Microstructure Based Material-Sand Particulate Interactions and Assessment of Coatings for High Temperature Turbine Blades

Gas turbine engines for military/commercial fixed-wing and rotary wing aircraft use thermal barrier coatings in the high-temperature sections of the engine for improved efficiency and power. The desire to further make improvements in gas turbine engine efficiency and high power-density is driving the research and development of thermal barrier coatings and the effort of improving their tolerance to fine foreign particulates that may be contained in the intake air. Both commercial and military aircraft engines often are required to operate over sandy regions such as in the Middle-East nations, as well as over volcanic zones. For rotorcraft gas turbine engines, the sand ingestion is adverse during take-off, hovering near ground, and landing conditions. Although, most of the rotorcraft gas turbine engines are fitted with inlet particle separators, they are not 100 percent efficient in filtering fine sand particles of size 75 microns or below. The presence of these fine solid particles in the working fluid medium has an adverse effect on the durability of turbine blade thermal barrier coatings and overall performance of the engine. Typical turbine blade damages include blade coating wear, sand glazing, Calcia-Magnesia-Alumina-Silicate (CMAS) attack, oxidation, plugged cooling holes, all of which can cause rapid performance deterioration including loss of aircraft. The objective of this research is to understand the fine particle interactions with typical ceramic coatings of turbine blades at the microstructure level. A finite-element based microstructure modeling and analysis has been performed to investigate particle-surface interactions, and restitution characteristics. Experimentally, a set of tailored thermal barrier coatings and surface treatments were down-selected through hot burner rig tests and then applied to first stage nozzle vanes of the Gas Generator Turbine of a typical rotorcraft gas turbine engine. Laser Doppler velocity measurements were performed during hot burner rig testing to determine sand particle incoming velocities and their rebound characteristics upon impact on coated material targets. Further, engine sand ingestion tests were carried out to test the CMAS tolerance of the coated nozzle vanes. The findings from this on-going collaborative research to develop the next-gen sand tolerant coatings for turbine blades are presented in this paper

Interfacial characteristics and microstructural evolution of ceramics exposed to high temperature sand laden combustion environments

Sand laden combustion environments are a current challenge plaguing ceramic thermal barrier coatings (TBCs) and environmental barrier coatings (EBCs) on metallic and emerging ceramic matrix composite (CMC) turbomachinery components. Exposure of thermal and environmental barrier coatings on ceramic matrix composites to environmental particulate laden deteriorates the ceramic structure via chemical reactions and infiltration into pore structures. The challenge of environmental particulates, collectively referred to as calcium-magnesium-aluminosilicate (CMAS), is expected to be exacerbated in future components that utilize ceramic matric composites (CMCs), since the higher operating temperatures will accelerate particulate melting, infiltration, and diffusion kinetics. This study first presents efforts at ARL to develop sandphobic coatings resistant to CMAS infiltration and deposition. The results of a recent full scale sand ingestion engine test used to evaluate several ARL layered and blended coating compositions are presented. The study also includes the evaluation of interactions of CMAS plasma sprayed environmental barrier coatings and HfO2-Si bond coats on SiC/SiC CMCs in rig simulated engine test conditions. The focus is on the microstructural evolution of the coatings and the interfacial characteristics between the TBCs and EBCs and CMAS. Interfaces between coating constituents are also of interest in order to tailor coatings with superior thermal, structural, and chemical characteristics. Controlled studies on YSZ-based ceramic compacts are also performed in order to gain a more fundamental understanding of the effect of porosity on infiltration kinetics, as well as the nature of interfaces and interfacial products wrought by CMAS infiltration into YSZ ceramic grain boundaries. These model studies on YSZ are conducted by immersing the ceramic compacts into AFRL-02 sand and exposing the system to temperatures of up to 1300 °C. X-ray diffraction, scanning electron microscopy, transmission electron microscopy, electron back scattered diffraction, and focused ion beam (milling and imaging) are utilized for microstructural and interfacial characterization of the CMAS reacted thermal and environmental barrier coating systems

A simple, yet effective, demonstration of polymeric mechanical behavior

Developing an appreciation for the mechanical behavior of polymers materials in a lecture mode can be challenging for students if they have not bad the benefit of a laboratory experience . We have developed a simp le demonstration of thermoplastic polymeric behav ior using low-density polyethylene bags. The demonstration illustrates strengthening, rate effects, and directionality of strengthening and stiffness. Following the demonstration, students are better ab le to articulate the influence of structure, properties, processing , and performance as it applies to thermoplastic polymers