Zhu, Dongming

NASA Technical Reports Server

National Aeronautics and Space Administration 
• 
Advanced Environmental Barrier Coating Development 
and Testing for SiC/SiC Ceramic Matrix Composites 
Dongming Zhu 
Structures and Materials Division 
NASA John H. Glenn Research Center 
Cleveland , Ohio 44135 
Workshop on the Design of Ceramic-Fiber Based Composites for Service Above 14oo•c 
Boulder, Colorado 
June 9 to June 16, 2012 
National Aeronautics and Space Administration 
Acknowledgements • The work was supported by NASA Fundamental Aeronautics Program (FAP) 
Supersonics project and Environmentally Responsible Aviation (ERA) Project 
Dennis S. Fox, James DiCarlo, James L. Smialek, Janet Hurst, Bryan Harder, Ram Bhatt, 
Nate Jacobson, Yoshiki Yamada, Louis Ghosn, Martha H. Jaskowiak, Michael Halbig 
Durability and Protective Coatings Branch (Chief: Joyce A. Dever), Ceramic Branch (Chief: 
Joseph E. Grady), and Life Prediction Branch (Chief: Steve M. Arnold) 
Collaborators: Directed Vapor Technologies, International; Sulzer Metco US; Praxair; GE 
Aviation; Hypertherm; Ceramatec, Inc. 
1 
https://ntrs.nasa.gov/search.jsp?R=20150010207 2019-08-31T07:50:18+00:00Z
National Aeronautics and Space Administration 
Outline • 
Environmental barrier coating system development: needs and 
challenges 
Advanced environmental barrier coating systems for CMC 
airfoils and combustors 
NASA coating development goals 
Current turbine and combustor EBC coating emphases 
Development of next generation environmental barrier coatings 
• Advanced processing 
• Advanced CMC-EBC rig testing 
• Subelement and subcomponent demonstrations 
Summary 
National Aeronautics and Space Administration 
NASA Environmental Barrier Coating (EBC) - Ceramic Matrix 
Composite (CMC) Program Overview 
- NASA Fundamental Aeronautics Program (FAP): Next generation high 
pressure turbine airfoil environmental barrier coatings with advanced CMCs 
• N+3 generation (2020-2025) with advanced 2700oF CMCs/2700-3000oF 
EBCs (uncooled/cooled) 
• 
- NASA Environmentally Responsible Aviation (ERA) Program: Advanced 
environmental barrier coatings for SiC/SiC CMC combustor and turbine vane 
components, technology demonstrations in engine tests 
• N+2 generation (2020-2025) with 2400°F CMCs/2700°F EBCs (cooled) 
CMC 
Fuel 
Instability 
Control 
Low emission combustor High Pressure Turbine CMC vane and blade 
2 
National Aeronautics and Space Administration 
NASA EBC and CMC System Development 
Emphasize temperature capability, performance and long-term durability 
Develop innovative coating technologies and life prediction approaches 
Meet 9,000 h supersonic engine and 1000 h subsonic engine hot-time life 
requirements 
- Recession: <5 mg/cm2 per 1 000 h 
• 
Highly loaded EBC-CMCs capable of thermal and mechanical (static/low cycle 
and dynamic) loading 
- (Strength requirements: 15-30 ksi , or 100- 207 MPa) 
T t Step 1ncrease 1n the matenal 's temperature capability empera ure n r;;:s,----.,--. ---,..---..,.-,...,--,-.,--:-::--,-,-.,...,.,..,--:-.,...,..,..,----, 
C b.1.ty uperson1cs proJect 30oo•F SiC/SiC CMC apa II (TIEBC) surface / ·rt ·1 d b 
• 30oo•F+ (1sso·c+) .r a1 01 an co~ ustor 2800 F ~ technologies 
~~~busto 2700.F (1482.C) - 2700°F SiC/SiC thin 
turbine EBC systems for 
CMC airfoils 
2soo•F 
2100•F (1482.C) Gen 111 · SiC/SiC CMCs 
Ceramic ~!gWi~J ~J~_b?J~i!~J -- -· 24oo·F (1316°C) Gen 1 and Gen II SiC/SiC 
CMCs 
·ngle Crystal Superalloy '-----------------' 
--I..: _ __,.. - ---------- - ------ - - ------ -- 2ooo•F (1093.C) 
National Aeronautics and Space Administration 
Environmental Barrier Coating Development: Challenges and 
Limitations • 
Current EBCs limited in their temperature capability, water vapor stability 
and long-term durability, especially for advanced high pressure, high 
bypass turbine engines 
Advanced EBCs also require higher strength and toughness 
In particular, resistance to combined high-heat-flux, engine high pressure, 
combustion environment, creep-fatigue, loading interactions 
EBCs need improved erosion, impact and calcium-magnesium-alumino-
silicate (CMAS) resistance and interface stability 
Critical to reduce the EBC Si/Si02 reactivity and their concentration tolerance 
EBC-CMC systems need advanced processing for realizing complex 
coating compositions, architectures and thin turbine configurations for 
next generation high performance engines 
Advanced high temperature processing of high stability nano-composites using 
advanced Plasma Spray, Plasma Spray - Physical Vapor Deposition , EB-PVD and 
Directed Vapor EB-PVD, and Polymer Derived Coating processing 
3 
National Aeronautics and Space Administrat ion 
NASA EBC Development Objectives and Approaches • CMC combu s t or EBC C MC Turbin e Vane/Blade EBC ,.,...,.. 2700-3000oF capable EBC 2600-2700°F capable EBC 
<15 mil thickness <5-1 0 mils in thickness 
Overall plasma-sprayed or hybrid plasma-spray-EB-PVD thin film processing 
Objectives processing on 2400°F Prepreg Ml Gen II SiC/SiC on 2400°F Prepreg Ml Gen II SiC/SiC and CVI woven high 
CMCsystem strength SiC/SiC CMC systems 
> 1 000 hr durable life 1000 hr durable life 
High stabi lity (recession < 5 mg/cm2 in 1000 hr) High stabi lity (recession : 5-10 mg/cm2 specific weight loss, 
Low thermal conductivity (<1 .0 W/m-K) and/or less than 20 micrometer thickness in 1000 hr) 
Coating Multilayer coating systems • Thin, multi-component, multi layer coating systems 2700F bond coat development • Advanced bond coats· HfO,-Si composite and other Development Fretting wear and CMAS resistance candidates Approach 
Advanced processing (including conventional APS , 
Triplex-Pro APS, Thin EBC DVM APS, and Directed Thin film processing (EB-PVD and Directed Vapor EB-PVD, 
Vapor EB-PVD); PVD, and Polymer Derived for EBC Plasma Spray - Thin Film and Plasma Spray-PVD) 
developments 
Property databases for airfoil EBC-CMCs - coupons AND 
Property database for combustor ESC-coated CMCs subelements: 
-specimens AND subelements (e.g. film-cooling - impingement and fi lm cool ing hole features 
Properties elements and metal component integration) - leading edge and trailing edge geometries 
Databases, - reinforcement rib and endwall features 
Life Models 
- high temperature interlaminar strength 
and Validation - recession data 
-mechanical properties - thermomechanical LCF and HCF 
- high temperature dynamic, impact and erosion performance 
Incorporate data into life prediction models Incorporate data into life prediction models and design tools 
High temp subelement long-term creep rupture , LCF High thermal gradient, heat flux, and mechanical loading 
Component and HCF performance with attachments performance of coated systems 
Durability Coated liner systems durability in: 
Demonstration 
- high pressure burner rig CMC turbine vane viabi lity and durability in high pressure 
- NASA ASCR test 
National Aeronautics and Space Administration 
The Development of Plasma Spray - Physical Vapor Deposition 
(PS-PVD) for CMC Airfoil Coating Processing • 
Established for next-generation SiC/SiC CMC turbine airfoil coating processing 
• Currently focusing on several advanced model EBC systems processing and evaluation 
• Aiming at better understanding processing-property relationship for improving coating 
performance 
Nozzk .... cct Jo ll 'JC\\ 
NASA Hybrid PS-PVD coater system 
(b) Full powder feeding 
High enthalpy plasma vapor stream for efficient and 
complex thin fi lm coati ng processing 
4 
National Aeronautics and Space Administration 
Development of Directed Vapor Electron Beam - Physical Vapor 
Deposition (EB-PVD) for NASA CMC Combustor and Turbine 
Airfoil Environmental Barrier Coating Processing • 
- In collaboration with Directed Vapor Technologies, NASA has developed turbine airfoil 
environmental barrier coating compositions and Directed Vapor EB-PVD processing 
- Advanced coatings processed for higher TRL ERA combustor and turbine component EBCs 
(TRL 4-5) 
'"""w...r...a1 bond kAp~ Hybrid 
coat on SiC/SiC EBC on SiC/SiC Advanced multi-component and multilayer turbine EBC systems 
Directed Vapor Processing Systems 
National Aeronautics and Space Administration 
Advanced High Pressure Burner Rig Testing Capabilities Established for 
Turbine Airfoil and Combustor CMC-EBC Testing • 
- Jet fuel & air combustion with mass air flow 2.0 lb/s and gas temperature 3000°F+ 
- Adjustable testing pressures from 4 to 16 atmospheres, independent controls of sample 
temperature, testing pressure, and gas velocity 
- 24-30 KW cooling air heater system for up to 1200°F cooling air (upgraded to 40 KW planned) 
- Up to 850 m/s combustion gas velocity in the turbine testing section 
- Cooled , pressurized (600 psi) subelement and subcomponent testing, air impingement cooled 
combustor segments and liner testing 
10 
5 
National Aeronautics and Space Administration 
NASA Laser Heat Flux and Mechanical Testing in Simulated Engine 
Environments- Emphasizing Stress - Environment Interactions • 
High heat flux flexural - 0 hz) , 
LCF, interlaminar and biaxial strengths 
Frame is being 
incorporated 
creep rupture and 
TMF and testing 
11 
National Aeronautics and Space Administration 
SiC/SiC and Environmental Barrier Coating Recession in Turbine 
Environments • 
- Recession of Si-based Ceramics 
(a) convective; (b) convective with film-cooling 
- Advanced rig testing and modeling (coupled with 3-D CFD analysis) to 
understand the recession behavior in High Pressure Burner Rig 
- Work primarily supported under the ERA Combustor and FAP Supersonics 
projects 
- Also closely collaborate with GE Aviation and GE Global Research 
Recession rate = const. V'12 P(H2o/f(Ptotal)112 
~Combustion gas ~Combustion gas 
piM2 H~J. ·~I 
Cooling gas 
.',' EaF J~ ' . (b) - / 
12 
6 
National Aeronautics and Space Administration 
High Pressure High Velocity SiC/SiC Recession. Studies Under 
Film Cooling Conditions • 
-Determine recession under very high pressure and high velocity- impingement 
recession completed at 2400F up to 16 atm pressure and 200 m/s gas velocity 
-Incorporated both impingement and impingement+ film cooled test capabilities 
- Validating 30 CFD modeling capabilities 
- Establishing comprehensive recession model ... s...,.....,......, 
The CFD modeling of film cooled CMC 
included 7, I 0 and 17 hole subelements, and 
water vapor fractions CMC specimen CMC specimen 
13 
National Aeronautics and Space Administration 
• Environmental Stability of Selected Environmental Barrier 
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Coatings Tested in NASA High Pressure Burner Rig 
EBC stability evaluated on SiC/SiC CMCs in high velocity, high pressure 
burner rig environment 
Stability gaps exist for future high bypass, high operating pressure ratio 
engines Temperature, °C 
10 e--1,60_0_1,50_0 __ 14, 0_0_ 1, 3,00 ___ 1,20_0 ___ 1,10, 0 ____ N IMM~M 
JJ~JJ~f~~ } Gas velocity 30rn/s 
• HC02 (doped) 
e HrRE Aluminosilicate 
~ ~i~~W~~~c (200 m's) ~ Gas 
SiC/SiC under high velocity 
A \ 
• ti~ [j33 0.1 
0.01 
0.001 
·~o~i o ISl 
e BSAS Basehne 
---- ,/ Jl''\ ~kApA EBC-dev; loprnentstab-thty-goal 
Stability and temperature capability improvements 
through coating composition and architecture innovations 
0.0005 0.00055 0.0006 0.00065 0.0007 0.00075 0.0008 
lff, K-1 
A Tyranohex SA SiC composite (200m's) velocity 
~ ~~~~Ji2~2°oDWD!sg 200rn/s 
e SiC. 20rnls. 6 atm; Robinson and Smialek, J. Am 
Cerarn Soe. I 999 ; 
Stability of selected coatings systems 
14 
7 
National Aeronautics and Space Administration 
Recession of Film-Cooled SiC/SiC Specimens under NASA High • Pressure Burner Rig A 10 hole film-cooled SiC/SiC specimen tested w1th the cooling air heater 
operating at 11 00°F and CMC, 16 atm testing pressure, 0.085 lb/s cooling air 
flow in the High Pressure Burner Rig 
0.0 0.2 
Non· film cooling recession at 2400F 
(model extmpolnted to 300m/s gas velocity) 
Film cooled reccssio not2400°F 
Non· film cooling ~cession at 21 00°F 
300 m/s, 16atm 
0.4 0.6 0.8 1.0 
Recession rate, mg/cnl -hr 
1.2 
High temperature recession kinetics for film-cooled and 
non-film cooled SiC/SiC specimens 
15 
National Aeronautics and Space Administration 
The NASA Hf02+Si Bond Coats Showed Significantly Improved 
Temperature Capability as Compared to Si Bond Coats • 
Higher stability and observed even after 1450°C+ temperature testing 
6 10' ,--..,.---,--,-----,,--,--..,---, 6 1 o' 
.~ 
-<>- Hf0
2
-25wt"/oSi-1350' C 
510, -<>-- Hto,-50wt%Si-1350' C 
~J Hto,-75wt%Si-1400' C 
4 10' 
• Hf0 2 
~ Si 
• HfSi04 
~NMD ~JJ_we~~~~~~~~~~~~~ 
"' 
-1 1 o' L_--'---'-----'---'----'--_L_- -' 
10 20 30 40 50 60 70 80 
Diffraction angle , 2G 
5 10' 
410' 
-"' ·~ 
2 
3104 -; 
.~ 
o; 
o; 
"' 210' 
Cross-section, Hot-pressed Hf02-50wt%Si 
on CMC, 13so·c tested 
Cross-section , Type II EB-PVD Hf02-Si 
bond coat, 1soo•c tested 
16 
8 
National Aeronautics and Space Administration 
Advanced Next Generation 2700°F CMC Bond Coat • Developments 
Develop advanced APS, PVD and polymer derived ceramic composite higher 
temperature bond coats for high strength and fatigue resistance 
Develop nanotube and nano-composite based coatings for high toughness 
SiC nanotube (SiCNT) and Hf02-based 
nanotube composite coatings 
Annealing and Si addition improved the Hot-
Pressed SiCNT Specimen strength 
100 200 300 400 
Biaxia bend strengh, MPa 
500 
17 
National Aeronautics and Space Administration 
Advanced NASA EBC and EBC Top Coat Technologies • 
• Focus on high stability environmental barrier and advanced bond coat 
developments Hf02 layer with graded interlayer, 
• BSAS, alloyed mullite and rare earth (RE) silicate EBCs 
Broad range, new series compositions including Hf02/Zr02 , Zr02/Hf02-Rare Earth 
Silicates, Hf02-Rare Earth Alumino-Silicates, and Rare Earth Alumino-Silicates 
Alternating Composition Layered Coatings (ACLCs) and nano-composite coatings 
Advanced processing approaches developed for vapor deposition , plasma spray, PVD, 
and polymer derived ceramics addressing high stability multi-component and nano-
composite systems 
~!!!!!!!l!!!!!!!!!!!!!Dl!!!!!!!"!g!!D!!!!D!!fg!!f!!!!!!!"!D!!JINJfiow expansion alloyed-Hf02, and Hf02 aluminosilicate 
I" ·1 lnterlayer: compositional layer graded system 
IEB!J!IIIIIB!J!Il;;!RE doped mullite-Hf02, and/or advanced rare earth silicate EBCs ~ Ceramic composite bond coats 
SiC/SiCCMC 
U Hf02 and Hf02 composites 
Increased ! 
Si/Si02 activity 
Doped mullite j Increased dopant REfTransition 
with ACLC metal concentrations & increased 
(Hf rich bands) AI/Si ratio 
(IB Doped mullite, Hf02/Si (SiC/Si3N4) composite bond coat 
(High temperature capable with self-healing) 
18 
9 
National Aeronautics and Space Administration 
Thermal Gradient Tensile Creep Rupture Testing of Advanced • Environmental Barrier Coating SiC/SiC CMCs Advanced high stability multi-component hafnia-rare earth silicate based turbine 
environmental barrier coatings being successfully tested for 1000 hr creep rupture 
EBC-CMC fatigue and environmental interaction is bein em~hasized 
:::R 1.0 
,:: 
"(il 
t; 
""(il 
~ 0.5 
200 400 600 800 
Time, hours 
1000 1200 
FEM models for delamination cracking under thermal 
gradient and tensile creep loading 
19 
National Aeronautics and Space Administration 
Thermal Gradient Tensile Creep Rupture Testing of Advanced 
Environmental Barrier Coating SiC/SiC CMCs - Continued • 
Coating microstructures after 1000 hr, 1482°C (2700°F), 103 MPa (15 ksi) testing 
SiC/SiCCMC 
HfYt-tens:l)l..22cmmx15liGWBSE1v/12/2011 D~olumD 
20 
10 
National Aeronautics and Space Administration 
NASA Laser Heat Flux and Mechanical Testing of EBC-
Subelements • CMC and ESC-coated subelement testing to simulate turbine vane loading 
Specimen GE TE specimen test 
3SO 
300 
2SO 
. 
. 200 
"' "' 
~ < ----•, ' ' .~. a ~ 
ISO 
100 
so 
O.OS 0.1 O. IS 0.2 0.2S 0.3 0.3S 0.4 
Displacement, mm 
21 
National Aeronautics and Space Administration 
NASA Laser Heat Flux and Mechanical Testing of EBC-
Subelements - Continued • 
Displacements, mm 
FEM and damage model to 
simulate the subelement 
behavior 
22 
11 
National Aeronautics and Space Administration 
Advanced Rig Tests for SiC/SiC CMC EBC Demonstrations • Advanced EBC coated turbine airfoils and subelements are being demonstrated 
in high pressure burner rig and high heat flux laser rig simulated engine 
environments -s-o-hr_E_ac---2.-so--, 
50 hr EBC-CMC 
vane laser rig 
testing 
NASA EBC coated turbine airfoils and testing 
CMC Sub-element 
demo in HPBR 
23 
National Aeronautics and Space Administration 
High Pressure Burner Rig Demonstrations for Validating EBC 
Coating and SiC/SiC Components (Gen II SiC/SiC CMC 
Subcomponents with Advanced Gen V EBCs) • 
Improve technology readiness and develop physics-based life prediction models 
~JIW.;JWWW.WWWl.WWW""~ ""D"" "D•WIclI.W"D~~ ·•·•~ ~~•• 
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; t.~I . 
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".~ f ~ .I . . [' :::; 
Subcomponent and EBC demos and Modeling based on simulated engine subelement and 
subcomponent tests 
24 
12 
National Aeronautics and Space Administrat ion 
• Summary 
• Advanced high temperature SiC/SiC CMC environmental barrier 
coatings development 
Developed several series of new compositions for meeting various 
performance requirements 
Emphasized advanced thinner coating configurations with long-term stability 
and durability 
Demonstrated higher temperature capability, improved environmental stability 
and coating thermal - mechanical stress and creep-rupture resistance 
Focused on coating composition developments and architecture designs to 
improve stability and durability at 2700-3000°F 
• Advanced high temperature SiC/SiC CMC environmental barrier 
coatings Testing Developments t 
Developed advanced coating and subelement testing methods relevant to 
turbine CMC combustors and vanes, establishing initial property database, 
degradation and lifing prediction models 
Developed advanced combustor and turbine vane EBC component 
technologies, and demonstrating the full feature EBC - CMC sub-components 
in relevant rig simulated engine environments 
25 
13 


Advanced Environmental Barrier Coating Development and Testing for SiC/SiC Ceramic Matrix Composites

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