• Journal of the Korean Ceramic Society
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• v.48 no.5
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• pp.396-403
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• 2011

In this study, we investigated the mechanical behaviors of layered thermal barrier coatings by indentations. Various single and double-layered thermal barrier coatings were deposited by air plasma spray process using different type of commercialized YSZ (Yttria stabilized zirconia) starting powders. Indentation stress-strain curve, load-displacement curve and hardness of the single and the double-layered thermal barrier coatings were obtained experimentally and analyzed. The indentation damages at the same loads were compared, and thus, the results depend on the structure of each coating. The result indicates improvement in damage resistances from tailoring of layered structures in the component of gas turbine system is expected.

• The Korean Journal of Ceramics
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• v.4 no.4
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• pp.340-344
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• 1998

Failure mechanisms were investigated for the two layer thermal barrier coatings consisting of NiCrAlY bond coat and $ZrO_2$-8wt.% $Y_2O_3$ ceramic coating during cyclic oxidation. $Al_2O_3$ developed at the ceramic coating/bond coat interface first, followed by the Cr/Ni rich oxides such as $NiCr_2O_4$ and $Ni(Al, Cr)_2O_4$ during cyclic oxidation. It was observed that the spalling of ceramic coatings took place primarily within the NiCrAlY bond coat oxidation products or at the interface between the bond coat oxidation products and zirconia based ceramic coating or the bond coat. It was also observed that the fracture within these oxidation products occurred with the formation of $Ni(Cr, Al)_2O_4$ spinel or Cr/Ni rich oxides. It was therefore concluded that the formation of these oxides was a life-limiting event for the thermal barrier coatings.

• Proceedings of the Korean Society of Propulsion Engineers Conference
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• v.y2005m4
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• pp.106-111
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• 2005

Failure mechanisms were investigated for the two layer thermal barrier coatings consisting of NiCrAlY bond coat and $ZrO_2-8wt.\% Y_{2}O_3$ ceramic coating during cyclic oxidation. $Al_{2}O_3$ developed at the ceramic coating/bond coat interface first, followed by the Cr/Ni rich oxides such as $NiCr_{2}O_4 and Ni(Al,Cr)_{2}O_4$ during cyclic oxidation It was observed that the spalling of ceramic coatings took place primarily within the NiCrAlY bond coat oxidation products or at the interface between the bond coat oxidation products and zirconia based ceramic coating or the bond coat. It was also observed that the fracture within these oxidation products occurred with the formation of $Ni(Cr,Al)_{2}O_4$ spinel or Cr/Ni rich oxides. It was therefore concluded that the formation of these oxides was a life-limiting event for the thermal barrier coatings.

• Journal of Surface Science and Engineering
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• v.34 no.1
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• pp.3-9
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• 2001

The purpose of this study is to evaluate the properties of the functional gradient thermal barrier coatings by plasma spray process. The evaluations of mechanical and thermal properties such as fatigue, oxidation and wear-resistance at high temperatures have been conducted. Furthermore, residual stress and bond strength have been evaluated. The range of thickness of coated layers was 550~600$\mu\textrm{m}$. The range of hardness of layers was 800~900 Hv and the porosity range of coatings was about 7 to 14%. The top coating layer of $ZrO_2$ in thermal barrier was composed of tetragonal structure after spraying. The coated layers of $ZrO_2$ on the Inconel substrate is the best resistance for thermal fatigue. Those coatings had the least compressive stress in comparison with other coatings. In high temperature oxidation test, the coatings on Inconel substrate was better than the coatings on SUS substrate. The bond strength of the concave type was greater than that of linear types and convex types coatings.

• Journal of Surface Science and Engineering
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• v.50 no.6
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• pp.460-464
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• 2017

As increasing thermal efficiency of the gas turbine, the performance improvement of thermal barrier coatings is also becoming important. Ytrria stabilized zirconia(YSZ) is the most popular materials for ceramic top coating because of its low thermal conductivity. In order to enhance the performance of thermal barrier coatings for hot sections in the gas turbine, suspension plasma spraying was developed in order to feed nano-sized powders. YSZ coatings formed by suspension plasma spraying showed better performance than YSZ coatings due to its exclusive microstructure. In this research, two YSZ coatings were deposited by suspension vacuum plasma spraying at 400 mbar and 250 mbar. Microstructures of YSZ coatings were analyzed by scanning electron image(SEM) on each spraying conditions, respectively. Crystalline structure transformation was not detected by X-ray diffraction. Thermal conductivity of suspension vacuum plasma sprayed YSZ coatings were measured by laser flash analysis. Thermal conductivity of suspension vacuum plasma sprayed YSZ coatings containing horizontally oriented nano-sized pores and vertical cracks showed $0.6-1.0W/m{\cdot}K$, similar to thermal conductivity of YSZ coatings formed by atmospheric plasma spraying.

• Journal of Surface Science and Engineering
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• v.47 no.6
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• pp.316-322
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• 2014

With increase in demand for higher operating temperatures of gas turbines, extensive research efforts have been carried out to enhance the performance of thermal barrier coatings (TBCs) in the field of coating processing as well as materials. In this study, thermal barrier coatings in lanthanum/gadolinium zirconate system, which is one of the most promising candidates for replacing yttira-stabilized zirconia (YSZ) in thermal barrier coating applications, are fabricated via suspension plasma spray. Dense, $300{\sim}400{\mu}m$ thick coatings of fluoritephase zirconate with modest amount of segmented microstructures are obtained by using suspension plasma spray with suspensions of planetary-milled mixture between lanthanum and/or gadolinium oxide and nano zirconia. These coatings exhibit thermal conductivities of 1.6 ~ 1.7 W/mK at $1000^{\circ}C$, which is relatively lower than that of YSZ.

• Structural Engineering and Mechanics
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• v.4 no.6
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• pp.679-702
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• 1996

The finite element method is employed in conjunction with micromechanical modelling in order to assess the performance of ceramic thermal barrier coatings applied to structural components. The study comprises the conditions of the deposition of the coating by plasma spraying as well as the thermal cycling of the coated component, and it addresses particularly turbine blades. They are exposed to high temperature changes strongly influencing the behaviour of the core material and inducing damage in the ceramic material by intense straining. A concept of failure analysis is discussed starting from distributed microcracking in the ceramic material, progressing to the formation of macroscopic crack patterns and examining their potential for propagation across the coating. The theory is in good agreement with experimental observations, and may therefore be utilized in proposing improvements for a delayed initiation of failure, thus increasing the lifetime of components with ceramic thermal barrier coatings.

• Journal of Surface Science and Engineering
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• v.49 no.6
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• pp.604-611
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• 2016

In order to comply with demand for high efficient gas turbines operating at higher temperatures, considerable amounts of research efforts have been performed with searching for the next-generation thermal barrier coatings (TBCs) with respect to coating materials as well as processing methods. In this study, thermal barrier coatings in the $(La_{1-x}Gd_x)_2Zr_2O_7$ system, which is one of the most versatile materials replacing yttria-stabilized zirconia (YSZ), are fabricated by suspension plasma spray with suspension made of synthesized powders via solidstate reaction. Dense, $100{\sim}400{\mu}m$ thick coatings of fluorite-phase zirconate with moderate amount of segmented microstructures are obtained by using suspension plasma spray. Phase formation and thermal diffusivity are characterized with coating compositions. The feasibility of $(La_{1-x}Gd_x)_2Zr_2O_7$ coatings for TBC applications is also discussed.

• Proceedings of the KWS Conference
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• 2006.05a
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• pp.45-47
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• 2006

The rotating components in the hot sections of land-based gas turbine are exposed to severe environments during several tens thousand operation hours at above $1100^{\circ}C$ operation temperature. To protect such components from high temperature oxidation, an intermediate bond coat is applied, typical of a MCrAlY-type metal alloy. This study is concerned with the thermal cyclic behavior of thermal barrier coatings. The MCrAlY bond coatings are deposited by HVOF (High Velocity Oxygen Fuel) method on a nickel-based superalloy (GTD-111). Thermal cyclic tests at $1100^{\circ}C$ in ambient air for various periods of time were used to evaluate the thermal cyclic resistance of the TBC coating. The microstructure and morphology of as-sprayed and of thermal cycled coatings were characterized by scanning electron microscopy (SEM) equipped with energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD).

• Journal of Surface Science and Engineering
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• v.27 no.2
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• pp.91-98
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• 1994

For the plasma sprayed as well as the EB-PVD thermal barrier coatings, the fracture paths within the oxidation products developed at the interface between the partially stabilized zirconia ceramic coating and NiCoCrAlY bond coat during cyclic thermal oxidation has been investigated. It was observed that the fracture in the oxidation products primarily took place within the oxide such as $Ni_{1-x}Co_3(Al_,Cr)_2O_4$ or at the interface between the oxide and $Al_2O_3$. It was found that Al2O3 developed first, followed by the Ni/Co/Cr rich oxides such as ,,$Ni_{1-x}Co_x(Al_,Cr)_2O_4$ $Cr_2O_3$and NiO at the interface between the ceramic coating and the bond coat in a cyclic high temperature environment. It was therfore concluded that the formation of the oxide containing Ni, Cr and Co was a life-limiting event for thermal barrier coatings during cyclic thermal oxidation.