Investigation of Solid Particle Erosion (SPE) Behaviors of Thermal Barrier Coatings (TBCs) with YSZ Ceramic Top Coating

Öz

Under operating conditions, gas turbine engines are subjected to a wide range of damage mechanisms. One of them is foreign object damage (FOD) and damage structures that occur on the surface formed by other foreign particles (volcanic ash etc.). Depending on these situations, damage formations such as spalling and flaking occur in components such as turbine blades and fins that comprise the turbine components. Solid-particle erosion (SPE) damages occur as a result of the repeated impact of the specified particles on the material surface at high speeds and at different angles. In this study, a CoNiCrAlY bond coat and ceramic top coat with yttria stabilized zirconia (YSZ) content on an Inconel 718 superalloy substrate were produced using the atmospheric plasma spray (APS) spraying method. Microstructural and surface changes resulting from SPE in the produced thermal barrier coating (TBC) system were investigated. Using alumina (Al2O3) particles, SPE tests were done at impact angles of 25°, 50° and 75°, which are not commonly studied in the literature. The damage mechanisms and erosive wear rates that occurred in the tests conducted at these angles were examined in detail. While the highest erosion rate in TBC coated samples occurred at an impact angle of 50°, this value was followed by those of 75° and 25°, respectively. In the areal roughness measurements carried out in the studies, it was seen that the erosion rates were directly proportional to the areal roughness values. It has been observed that the highest areal roughness values occur at an impact angle of 50°.

Anahtar Kelimeler

• Solid Particle Erosion (SPE)
• Thermal Barrier Coatings (TBCs)
• Yttria stabilized zirconia (YSZ).
• Super alloy
• CoNiCrAlY
• Damage Mechanism

YSZ Seramik Üst Kaplamaya Sahip Termal Bariyer Kaplamaların (TBCs) Katı Partikül Erozyon (SPE) Davranışlarının İncelenmesi

Öz

Gaz türbin motorları servis kullanım koşulları altında farklı birçok hasar mekanizmasına maruz kalmaktadır. Bunlardan birisi de yabancı madde hasarı (FOD) ve diğer yabancı partiküllerin (volkan küller vb.) oluşturduğu yüzey üzerinde meydana gelen hasar yapılarıdır. Bu durumlara bağlı olarak türbin bileşenlerini oluşturan türbin bıçağı ve kanatçık gibi komponentlerde dökülme ve pullanarak kalkma gibi hasar oluşumları meydana gelmektedir. Belirtilen partiküllerin yüksek hızlarda ve farklı açılarda malzeme yüzeyine tekrarlı çarpması sonucunda katı partikül erozyon (SPE) hasarları meydana gelmektedir. Bu çalışmada, Inconel 718 süper alaşım altlık malzeme üzerine CoNiCrAlY bağ ve yitriya ile stabilize edilmiş zirkonya (YSZ) içeriğine sahip seramik üst kaplamalar atmosferik plazma sprey (APS) püskürtme yöntemi kullanılarak üretilmiştir. Üretilen termal bariyer kaplama (TBC) sistemindeki SPE sonucu oluşan mikroyapısal ve yüzey üzerindeki oluşum gösteren değişimler incelenmiştir. SPE testleri alümina (Al2O3) partiküllerinin kullanılmasıyla literatürde yaygın olarak çalışılmayan 25°, 50° ve 75°’lik püskürtme açılarında çalışılmış ve bu açılarda yapılan erozif aşınma testlerinde ortaya çıkan hasar mekanizmaları ve erozif aşınma oranı ayrıntılı olarak incelenmiştir. TBC kaplamalı numunelerde en yüksek erozyon oranı 50°’lik çarpma açısında gerçekleşirken bu değeri sırasıyla 75° ve 25°’lik çarpma açısı takip etmiştir. Çalışmalarda gerçekleştirilen alansal pürüzlülük ölçümlerinde erozyon oranlarının alansal pürüzlülük değerleri ile doğru orantılı olduğu görülmüştür. En yüksek alansal pürüzlülük değerlerinin 50°’lik çarpma açısında oluşum gösterdiği görülmüştür.

Anahtar Kelimeler

• Katı Partikül Erozyonu (SPE)
• Termal Bariyer Kaplamalar (TBCs)
• Yitriya ile stabilize edilmiş zirkonya (YSZ)
• Hasar mekanizması
• Süper alaşım
• CoNiCrAlY

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