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The Effect of APS-HVOF Bond Coating Thickness Ratio on TBC Furnace Cycle Lifetime

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Abstract

Combinations of NiCoCrAlY APS and high-velocity oxygen fuel (HVOF) bond coatings were deposited on alloy 247 disk substrates with APS yttria-stabilized zirconia (YSZ) top coatings to assess the benefit of air plasma sprayed (APS) ‘flash’ bond coatings. Using 1-h cycles at 1100 ℃ in air with 10% H2O and HVOF-only and APS-only bond coatings as a baseline, it was found that APS flash coatings extended the average coating lifetime by 16% to 35% with the thicker flash coating performing best. Principal component analysis and energy dispersive spectroscopy (EDS) compositional mapping on coatings characterized after 0, 100, 300 and 500 cycles and after failure showed that the Al in the bond coatings was depleted due to both oxidation and back diffusion into the substrate. The APS-only bond coating had significant oxidation throughout the bond coating and was so depleted in Al, that Al diffused from the substrate to the coating. Residual stress maps of the thermally-grown alumina scale were obtained every 100 cycles using photo-stimulated luminescence piezospectroscopy (PLPS) revealing that the Thick Flash coating had the slowest rate of damage accumulation in the oxide scale.

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Acknowledgements

The authors would like to thank Prof. S. Sampath and E. Gildersleeve at Stony Brook University's Center for Thermal Spray Research for the coating fabrication. At ORNL, G. Garner, and T. Geer assisted with the experimental work and J. A Haynes, Y.-F. Su and E. Lara-Curzio provided helpful comments on the manuscript. This research was sponsored by the U.S. Department of Energy, Office of Fossil Energy and Carbon Management, Turbine Program (R. Dennis program manager and P. Burke project manager).

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Authors and Affiliations

  1. Materials Science and Technology Division, Oak Ridge National Laboratory, 1 Bethel Valley Rd., Oak Ridge, TN, 37831, USA

    M. J. Lance, K. A. Kane & B. A. Pint

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  1. M. J. Lance
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  2. K. A. Kane
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  3. B. A. Pint
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Contributions

Michael Lance and Bruce Pint wrote the main manuscript text. Michael Lance conducted the research. Ken Kane conducted the furnace cycle testing. All authors reviewed the manuscript.

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Correspondence to M. J. Lance.

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Lance, M.J., Kane, K.A. & Pint, B.A. The Effect of APS-HVOF Bond Coating Thickness Ratio on TBC Furnace Cycle Lifetime. Oxid Met 98, 385–397 (2022). https://doi.org/10.1007/s11085-022-10127-1

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