Top

International Journal of Mechanics and Materials in Design

Published in:

08-11-2019

Modeling and characterisation of depletion of aluminium in bond coat and growth of mixed oxides in thermal barrier coatings

Authors: L. Y. Lim, S. A. Meguid

Published in: International Journal of Mechanics and Materials in Design | Issue 4/2020

Activate our intelligent search to find suitable subject content or patents.

search-config

AI-assisted search

Off

Abstract

Most existing thermal barrier coating (TBC) studies do not account for the depletion of Al in the BC and growth of mixed oxides (MOs). In this complementary study, we modify and extend our earlier (Lim and Meguid in Mater Des, 2019. https://doi.org/10.1016/j.matdes.2018.107543) coupled finite volume (FV)–finite element (FE) formulations to incorporate diffusion reactions of Al and Cr in the BC. The modified/expanded FV–FE formulations are supported by the introduction of appropriate diffusion–reaction equations and high temperature oxidation model. Three aspects of the work were accordingly examined. Firstly, the FV model is used to describe the diffusion and reaction of Al and O₂ in the formation of α-Al₂O₃. The β-phase rate of depletion predicted by the model agrees well with experimental findings. Secondly, the diffusion of Cr through the TGO that leads to the formation of an external layer of MOs is simulated using the FV model. Our simulations reveal that MOs form in the early stage of thermal exposure, although there are sufficient Al in the BC to sustain the growth of α-Al₂O₃ phase. We reasoned this to the formation of internal oxides and diffusion cell in the BC. Lastly, we studied the effect of roughness on β-phase depletion and growth of TGO (α-Al₂O₃ + MOs). We show that β-phase in the peak of undulation depletes faster and the interface between the β + γ phase and γ phase in the BC straightens over time. Furthermore, our results reveal that MOs tend to form in the valley of undulation due to the shorter diffusion path.

next article Dynamic response of the output force of giant magnetostrictive materials

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

inform now

Ali, M.S., Song, S., Xiao, P.: Degradation of thermal barrier coatings due to thermal cycling up to 1150 °C. J. Mater. Sci. (2002). https://doi.org/10.1023/A:1015245920054CrossRef

Bai, Y., Han, Z.H., Li, H.Q., Xu, C., Xu, Y.L., Ding, C.H., Yang, J.F.: Structure–property differences between supersonic and conventional atmospheric plasma sprayed zirconia thermal barrier coatings. Surf. Coat. Technol. (2011). https://doi.org/10.1016/j.surfcoat.2011.01.056CrossRef

Bai, Y., Ding, C., Li, H., Han, Z., Ding, B., Wang, T., Yu, L.: Isothermal oxidation behavior of supersonic atmospheric plasma-sprayed thermal barrier coating system. J. Therm. Spray Technol. (2013). https://doi.org/10.1007/s11666-013-9979-7CrossRef

Bakan, E., Vaßen, R.: Ceramic top coats of plasma-sprayed thermal barrier coatings: materials, processes, and properties. J. Therm. Spray Technol. (2017). https://doi.org/10.1007/s11666-017-0597-7CrossRef

Birks, N., Meier, G.H., Pettit, F.S.: Introduction to the High Temperature Oxidation of Metals, 2nd edn (2006). https://doi.org/10.1017/cbo9781139163903

Borgenstam, A., Engström, A., Höglund, L., Ågren, J.: DICTRA, a tool for simulation of diffusional transformations in alloys. J. Phase Equilib. (2000). https://doi.org/10.1361/105497100770340057CrossRef

Chen, H., Barman, T.: Thermo-Calc and DICTRA modelling of the β-phase depletion behaviour in CoNiCrAlY coating alloys at different Al contents. Comput. Mater. Sci. (2018). https://doi.org/10.1016/j.commatsci.2018.02.013CrossRef

Chen, H., McCartney, D.G.: Some aspects on modelling of the β-phase depletion behaviour under different oxide growth kinetics in HVOF CoNiCrAlY coatings. Surf. Coat. Technol. (2017). https://doi.org/10.1016/j.surfcoat.2017.01.075CrossRef

Chen, W.R., Wu, X., Dudzinski, D., Patnaik, P.C.: Modification of oxide layer in plasma-sprayed thermal barrier coatings. Surf. Coat. Technol. (2006). https://doi.org/10.1016/j.surfcoat.2005.08.141CrossRef

Chen, W.R., Wu, X., Marple, B.R., Lima, R.S., Patnaik, P.C.: Pre-oxidation and TGO growth behaviour of an air-plasma-sprayed thermal barrier coating. Surf. Coat. Technol. (2008a). https://doi.org/10.1016/j.surfcoat.2008.01.021CrossRef

Chen, W.R., Archer, R., Huang, X., Marple, B.R.: TGO growth and crack propagation in a thermal barrier coating. J. Therm. Spray Technol. (2008b). https://doi.org/10.1007/s11666-008-9251-8CrossRef

Chen, H., Jackson, G.A., Voisey, K.T., McCartney, D.G.: Modelling and experimental study on β-phase depletion behaviour of HVOF sprayed free-standing CoNiCrAlY coatings during oxidation. Surf. Coat. Technol. (2016). https://doi.org/10.1016/j.surfcoat.2016.02.008CrossRef

Chen, H., Rushworth, A., Hou, X., He, J., Guo, H.: Effects of temperature on the β-phase depletion in MCrAlYs: a modelling and experimental study towards designing new bond coat alloys. Surf. Coat. Technol. (2019). https://doi.org/10.1016/j.surfcoat.2019.02.024CrossRef

Curry, N., Tang, Z., Markocsan, N., Nylén, P.: Influence of bond coat surface roughness on the structure of axial suspension plasma spray thermal barrier coatings—thermal and lifetime performance. Surf. Coat. Technol. 268, 15–23 (2015). https://doi.org/10.1016/j.surfcoat.2014.08.067CrossRef

Daroonparvar, M., Hussain, M.S., Yajid, M.A.M.: The role of formation of continues thermally grown oxide layer on the nanostructured NiCrAlY bond coat during thermal exposure in air. Appl. Surf. Sci. 261, 287–297 (2012a). https://doi.org/10.1016/j.apsusc.2012.08.002CrossRef

Daroonparvar, M., Hussain, M.S., Yajid, M.A.M.: The role of formation of continues thermally grown oxide layer on the nanostructured NiCrAlY bond coat during thermal exposure in air. Appl. Surf. Sci. (2012b). https://doi.org/10.1016/j.apsusc.2012.08.002CrossRef

Daroonparvar, M., Yajid, M.A.M., Yusof, N.M., Hussain, M.S., Rad, H.R.B.: Formation of a dense and continuous Al₂O₃ layer in nano thermal barrier coating systems for the suppression of spinel growth on the Al₂O₃ oxide scale during oxidation. J. Alloys Compd. (2013). https://doi.org/10.1016/j.jallcom.2013.03.168CrossRef

Deal, B.E., Grove, A.S.: General relationship for the thermal oxidation of silicon. J. Appl. Phys. (1965). https://doi.org/10.1063/1.1713945CrossRef

Doleker, K.M., Karaoglanli, A.C.: Comparison of oxidation behavior of shot-peened plasma spray coatings with cold gas dynamic spray coatings. Oxid. Met. (2017). https://doi.org/10.1007/s11085-016-9691-3CrossRef

Echsler, H., Renusch, D., Schütze, M.: Bond coat oxidation and its significance for life expectancy of thermal barrier coating systems. Mater. Sci. Technol. (2004). https://doi.org/10.1179/026708304225012143CrossRef

Elsaß, M., Frommherz, M., Scholz, A., Oechsner, M.: Interdiffusion in MCrAlY coated nickel-base superalloys. Surf. Coat. Technol. 307, 565–573 (2016). https://doi.org/10.1016/j.surfcoat.2016.09.049CrossRef

Eriksson, R., Sjöström, S., Brodin, H., Johansson, S., Östergren, L., Li, X.H.: TBC bond coat-top coat interface roughness: influence on fatigue life and modelling aspects. Surf. Coat. Technol. (2013). https://doi.org/10.1016/j.surfcoat.2013.09.051CrossRef

Evans, H.E.: Oxidation failure of TBC systems: an assessment of mechanisms. Surf. Coat. Technol. 206, 1512–1521 (2011). https://doi.org/10.1016/j.surfcoat.2011.05.053CrossRef

Evans, H.E., Taylor, M.P.: Diffusion cells and chemical failure of MCrAlY bond coats in thermal-barrier coating systems. Oxid. Met. (2001). https://doi.org/10.1023/A:1010369024142CrossRef

Gell, M., Eric, J., Krishnakumar, V., McCarron, K., Barber, B., Sohn, Y.H., Tolpygo, V.K.: Bond strength, bond stress and spallation mechanisms of thermal barrier coatings. Surf. Coat. Technol. (1999). https://doi.org/10.1016/s0257-8972(99)00338-2CrossRef

Gell, M., Xie, L., Ma, X., Jordan, E.H., Padture, N.P.: Highly durable thermal barrier coatings made by the solution precursor plasma spray process. Surf. Coat. Technol. (2004). https://doi.org/10.1016/j.surfcoat.2003.06.023CrossRef

Giggins, C.S., Pettit, F.S.: Oxidation of Ni–Cr–Al alloys between 1000 °C and 1200 °C. J. Electrochem. Soc. (2007). https://doi.org/10.1149/1.2407837CrossRef

Gil, A., Shemet, V., Vassen, R., Subanovic, M., Toscano, J., Naumenko, D., Singheiser, L., Quadakkers, W.J.: Effect of surface condition on the oxidation behaviour of MCrAlY coatings. Surf. Coat. Technol. (2006). https://doi.org/10.1016/j.surfcoat.2006.07.252CrossRef

Gupta, M., Eriksson, R., Sand, U., Nylén, P.: A diffusion-based oxide layer growth model using real interface roughness in thermal barrier coatings for lifetime assessment. Surf. Coat. Technol. 271, 181–191 (2015a). https://doi.org/10.1016/j.surfcoat.2014.12.043CrossRef

Gupta, M., Eriksson, R., Sand, U., Nylén, P.: A diffusion-based oxide layer growth model using real interface roughness in thermal barrier coatings for lifetime assessment. Surf. Coat. Technol. (2015b). https://doi.org/10.1016/j.surfcoat.2014.12.043CrossRef

Hagel, W.C., Seybolt, A.U.: Cation diffusion in Cr₂O₃. J. Electrochem. Soc. (1961). https://doi.org/10.1149/1.2427973CrossRef

Hasegawa, M., Kagawa, Y.: Microstructural and mechanical properties changes of a NiCoCrAlY bond coat with heat exposure time in air plasma-sprayed Y₂O₃–ZrO₂ TBC systems. Int. J. Appl. Ceram. Technol. (2006). https://doi.org/10.1111/j.1744-7402.2006.02085.xCrossRef

Hille, T.S., Turteltaub, S., Suiker, A.S.J.: Oxide growth and damage evolution in thermal barrier coatings. Eng. Fract. Mech. 78, 2139–2152 (2011). https://doi.org/10.1016/j.engfracmech.2011.04.003CrossRef

Hindam, H., Whittle, D.P.: Microstructure, adhesion and growth kinetics of protective scales on metals and alloys. Oxid. Met. 18, 245–284 (1982). https://doi.org/10.1007/BF00656571CrossRef

Karunaratne, M.S.A., Ogden, S.L., Kenny, S.D., Thomson, R.C.: A multicomponent diffusion model for prediction of microstructural evolution in coated Ni based superalloy systems. Mater. Sci. Technol. (2009). https://doi.org/10.1179/174328408x355415CrossRef

Kumar, V., Balasubramanian, K.: Progress update on failure mechanisms of advanced thermal barrier coatings: a review. Prog. Org. Coat. (2016). https://doi.org/10.1016/j.porgcoat.2015.09.019CrossRef

Li, Y., Li, C.J., Zhang, Q., Yang, G.J., Li, C.X.: Influence of composition of TGO on the thermal shock lifetime of thermal barrier coatings with cold-sprayed MCrAlTaY bond coat. In: Proceedings of International Thermal Spray Conference (2009). https://doi.org/10.1361/cp2009itsc0071

Li, Y., Li, C.J., Yang, G.J., Xing, L.K.: Thermal fatigue behavior of thermal barrier coatings with the MCrAlY bond coats by cold spraying and low-pressure plasma spraying. Surf. Coat. Technol. (2010). https://doi.org/10.1016/j.surfcoat.2010.08.144CrossRef

Lim, L.Y., Meguid, S.A.: Temperature dependent dynamic growth of thermally grown oxide in thermal barrier coatings. Mater. Des. (2019). https://doi.org/10.1016/j.matdes.2018.107543CrossRef

Lima, C.R.C., Guilemany, J.M.: Adhesion improvements of thermal barrier coatings with HVOF thermally sprayed bond coats. Surf. Coat. Technol. (2007). https://doi.org/10.1016/j.surfcoat.2006.10.005CrossRef

Lu, Z., Myoung, S.W., Kim, E.H., Lee, J.H., Jung, Y.G.: Microstructure evolution and thermal durability with coating thickness in APS thermal barrier coatings. Mater. Today Proc. (2014). https://doi.org/10.1016/j.matpr.2014.09.009CrossRef

Lu, X.-L., Liu, X.-B., Yu, P.-C., Qiao, S.-J., Zhai, Y.-J., Wang, M.-D., Chen, Y., Xu, D.: Synthesis and characterization of Ni60-hBN high temperature self-lubricating anti-wear composite coatings on Ti6Al4V alloy by laser cladding. Opt. Laser Technol. 78, 87–94 (2016). https://doi.org/10.1016/j.optlastec.2015.10.005CrossRef

Ma, K., Schoenung, J.M.: Isothermal oxidation behavior of cryomilled NiCrAlY bond coat: homogeneity and growth rate of TGO. Surf. Coat. Technol. (2011). https://doi.org/10.1016/j.surfcoat.2011.05.025CrossRef

Manap, A., Nakano, A., Ogawa, K.: The protectiveness of thermally grown oxides on cold sprayed CoNiCrAlY bond coat in thermal barrier coating. J. Therm. Spray Technol. (2012). https://doi.org/10.1007/s11666-012-9749-yCrossRef

Mori, T., Kuroda, S., Murakami, H., Katanoda, H., Sakamoto, Y., Newman, S.: Effects of initial oxidation on β phase depletion and oxidation of CoNiCrAlY bond coatings fabricated by warm spray and HVOF processes. Surf. Coat. Technol. (2013). https://doi.org/10.1016/j.surfcoat.2013.01.028CrossRef

Moridi, A., Azadi, M., Farrahi, G.H.: Thermo-mechanical stress analysis of thermal barrier coating system considering thickness and roughness effects. Surf. Coat. Technol. 243, 91–99 (2014). https://doi.org/10.1016/j.surfcoat.2012.02.019CrossRef

Müller, J., Neuschütz, D.: Efficiency of α-alumina as diffusion barrier between bond coat and bulk material of gas turbine blades. User Model. User-Adapt. Interact. (2003). https://doi.org/10.1016/s0042-207x(02)00746-7CrossRef

Nakamura, R., Takasawa, K., Yamazaki, Y., Iijima, Y.: Single-phase interdiffusion in the B2 type intermetallic compounds NiAl, CoAl and FeAl. Intermetallics (2002). https://doi.org/10.1016/S0966-9795(01)00125-XCrossRef

Ni, L.Y., Liu, C., Huang, H., Zhou, C.G.: Thermal cycling behavior of thermal barrier coatings with HVOF NiCrAlY bond coat. J. Therm. Spray Technol. 20, 1133 (2011). https://doi.org/10.1007/s11666-011-9647-8CrossRef

Nijdam, T.J., Jeurgens, L.P.H., Sloof, W.G.: Promoting exclusive α-Al₂O₃ growth upon high-temperature oxidation of NiCrAl alloys: experiment versus model predictions. Acta Mater. (2005). https://doi.org/10.1016/j.actamat.2004.12.014CrossRef

Nijdam, T.J., Marijnissen, G.H., Vergeldt, E., Kloosterman, A.B., Sloof, W.G.: Development of a pre-oxidation treatment to improve the adhesion between thermal barrier coatings and NiCoCrAlY bond coatings. Oxid. Met. (2006). https://doi.org/10.1007/s11085-006-9036-8CrossRef

Pint, B.A., Garrattreed, A., Hobbs, L.W.: Analytical electron-microscopy study of the breakdown of α-Al₂O₃ scales formed on oxide dispersion-strengthened alloys. Oxid. Met. 56(1–2), 119–145 (2001)CrossRef

Rabiei, A.: Failure mechanisms associated with the thermally grown oxide in plasma-sprayed thermal barrier coatings. Acta Mater. 48, 3963–3976 (2000). https://doi.org/10.1016/S1359-6454(00)00171-3CrossRef

Ranjbar-Far, M., Absi, J., Mariaux, G., Dubois, F.: Simulation of the effect of material properties and interface roughness on the stress distribution in thermal barrier coatings using finite element method. Mater. Des. 31, 772–781 (2010). https://doi.org/10.1016/j.matdes.2009.08.005CrossRef

Renusch, D., Schorr, M., Schütze, M.: The role that bond coat depletion of aluminum has on the lifetime of APS–TBC under oxidizing conditions. Mater. Corros. 59, 547–555 (2008). https://doi.org/10.1002/maco.200804137CrossRef

Richer, P., Yandouzi, M., Beauvais, L., Jodoin, B.: Oxidation behaviour of CoNiCrAlY bond coats produced by plasma, HVOF and cold gas dynamic spraying. Surf. Coat. Technol. (2010). https://doi.org/10.1016/j.surfcoat.2010.03.043CrossRef

Saremi, M., Afrasiabi, A., Kobayashi, A.: Microstructural analysis of YSZ and YSZ/Al2O3 plasma sprayed thermal barrier coatings after high temperature oxidation. Surf. Coat. Technol. (2008). https://doi.org/10.1016/j.surfcoat.2007.11.029CrossRef

Sarioglu, C., Schumann, E., Blachere, J.R., Pettit, F.S., Meier, G.H.: X-ray determination of stresses in alumina scales on high temperature alloys. Mater. High Temp. 17, 109–115 (2000). https://doi.org/10.1179/mht.2000.017CrossRef

Schlichting, K.W., Vaidyanathan, K., Sohn, Y.H., Jordan, E.H., Gell, M., Padture, N.P.: Application of Cr³⁺ photoluminescence piezo-spectroscopy to plasma-sprayed thermal barrier coatings for residual stress measurement. Mater. Sci. Eng. A 291, 68–77 (2000). https://doi.org/10.1016/S0921-5093(00)00973-4CrossRef

Stiger, M.J., Yanar, N.M., Topping, M.G., Pettit, F.S., Meier, G.H.: Thermal barrier coatings for the 21st century. Zeitschrift Fur Met. 90, 1069–1078 (1999)

Strauss, D., Müller, G., Schumacher, G., Engelko, V., Stamm, W., Clemens, D., Quaddakers, W.J.: Oxide scale growth on MCrAlY bond coatings after pulsed electron beam treatment and deposition of EBPVD-TBC. Surf. Coat. Technol. (2001). https://doi.org/10.1016/S0257-8972(00)00916-6CrossRef

Tang, F., Ajdelsztajn, L., Schoenung, J.M.: Influence of cryomilling on the morphology and composition of the oxide scales formed on HVOF CoNiCrAlY coatings. Oxid. Met. (2004). https://doi.org/10.1023/B:OXID.0000025332.26757.41CrossRef

Tang, J.J., Bai, Y., Zhang, J.C., Liu, K., Liu, X.Y., Zhang, P., Wang, Y., Zhang, L., Liang, G.Y., Gao, Y., Yang, J.F.: Microstructural design and oxidation resistance of CoNiCrAlY alloy coatings in thermal barrier coating system. J. Alloys Compd. 688, 729–741 (2016). https://doi.org/10.1016/j.jallcom.2016.07.018CrossRef

Taylor, M.P., Pragnell, W.M., Evans, H.E.: The influence of bond coat surface roughness on chemical failure and delamination in TBC systems. Mater. Corros. (2008). https://doi.org/10.1002/maco.200804135CrossRef

Tsai, K.Y., Tsai, M.H., Yeh, J.W.: Sluggish diffusion in Co-Cr-Fe-Mn-Ni high-entropy alloys. Acta Mater. (2013). https://doi.org/10.1016/j.actamat.2013.04.058CrossRef

Vaidyanathan, K., Gell, M., Jordan, E.: Mechanisms of spallation of electron beam physical vapor deposited thermal barrier coatings with and without platinum aluminide bond coat ridges. Surf. Coat. Technol. (2000). https://doi.org/10.1016/S0257-8972(00)00891-4CrossRef

Wang, L., Li, D.C., Yang, J.S., Shao, F., Zhong, X.H., Zhao, H.Y., Yang, K., Tao, S.Y., Wang, Y.: Modeling of thermal properties and failure of thermal barrier coatings with the use of finite element methods: a review. J. Eur. Ceram. Soc. (2016). https://doi.org/10.1016/j.jeurceramsoc.2015.12.038CrossRef

Xie, F., Sun, Y., Li, D., Bai, Y., Zhang, W.: Modelling of catastrophic stress development due to mixed oxide growth in thermal barrier coatings. Ceram. Int. (2019). https://doi.org/10.1016/J.CERAMINT.2019.02.214CrossRef

Zhang, W.-W., Li, G.-R., Zhang, Q., Yang, G.-J., Zhang, G.-W., Mu, H.-M.: Self-enhancing thermal insulation performance of bimodal-structured thermal barrier coating. J. Therm. Spray Technol. 27, 1064–1075 (2018). https://doi.org/10.1007/s11666-018-0754-7CrossRef

Zhu, H.X., Fleck, N.A., Cocks, A.C.F., Evans, A.G.: Numerical simulations of crack formation from pegs in thermal barrier systems with NiCoCrAlY bond coats. Mater. Sci. Eng. A 404, 26–32 (2005). https://doi.org/10.1016/j.msea.2005.05.033CrossRef

Title: Modeling and characterisation of depletion of aluminium in bond coat and growth of mixed oxides in thermal barrier coatings
Authors: L. Y. Lim
S. A. Meguid
Publication date: 08-11-2019
Publisher: Springer Netherlands
Published in: International Journal of Mechanics and Materials in Design / Issue 4/2020
Print ISSN: 1569-1713
Electronic ISSN: 1573-8841
DOI: https://doi.org/10.1007/s10999-019-09482-w

Springer Professional

Abstract

Please log in to get access to your license.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Springer Professional "Technik"

Other articles of this Issue 4/2020

An efficient inverse algorithm for load identification of stochastic structures

Dynamic response of the output force of giant magnetostrictive materials

Thermal buckling of porous symmetric and non-symmetric sandwich plate with homogenous core and S-FGM face sheets resting on Pasternak foundation

Thermo-mechanical interactions in a functionally graded elastic material with voids and gravity field

Partially debonded circular inclusion in one-dimensional quasicrystal material with piezoelectric effect

A dielectric elastomer membrane integrated with protective passive layers under explicit and implicit prestretch

Premium Partners