Thermalbarriercoating

1
Seminar Presentation
on
Thermal Barrier Coating
Presented by:
Bharat Chhabria
2
Contents
Introduction
Structure of Thermal Protection System
Material Selection
TBC Failure
TBC Deposition Methods
TBC on Turbine Blades and Engines
Conclusion
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Introduction
 TBCs are refractory-oxide ceramic coatings applied to the
surfaces of hot metallic parts.
 TBCs perform the important function of insulating components

operating at elevated temperature.
 Coatings can allow higher operating temperatures beyond the

limiting temperature of metal parts.
 TBC not only consist of oxide ceramic coating (topcoat) itself but
also the underlying superalloy engine part, and two other layers
in between.
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5
Structure of Thermal
Protection System
Thermal
Protection
System
Thermally
Superalloy
Top Coat/TBC Grown Bond Coat
Substrate
Oxide (TGO)
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7
Material Selection
Material selected for TBC should have following properties:-
Low Thermal Conductivity.
High Thermal Expansion Coefficient.
Good Erosion Resistance.
Therefore we use Porous Zirconia (ZrO2) partially stabilized with yttria

(Y2O3) popularly known as YSZ.
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TBC Failure
Thermal cycle is the main cause of TBC failure due to Thermal mismatch.
Spallation: It is a process by which the TBC peels off of the substrate; and
naturally, after the coating has spalled, the continuous thermal protection
layer no longer exists.
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TBC Deposition Methods
EBPVD APS
TBC
Production
Direct Vapour
ESAVD
Deposition
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EBPVD
 Electron Beam Physical Vapour Deposition or EBPVD is a form of
physical vapour deposition in which a target anode is bombarded
with an electron beam which causes atoms from the target to
transform into the gaseous phase.
 These atoms then precipitate into solid form, coating everything in

the vacuum chamber (within line of sight) with a thin layer of the
anode material.
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APS(Air Plasma Spray)
 In plasma spraying process, the material to be deposited

(feedstock) is introduced into the plasma jet, emanating from
a plasma torch.
 In the jet, where the temperature is of the order of 10,000 K,
the material is melted and propelled towards a substrate.
 There, the molten droplets flatten, rapidly solidify and form a
deposit.
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TBC on Turbine Blades and

Engines
Aircraft Gas Turbine:-
As we know that increase in turbine inlet temperature results in increased

thermal efficiency.
TBC can be applied on both Turbine

blades and combustion chambers.
Earlier calcia and magnesia stabilized

zirconia were used for coating (less durable).
Various tests were done at NASA on

Turbine blades for various temperature and
all coated blade were in good conditions.
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Diesel Engines:-
TBC can allow higher working temperature which increase efficiency and
decrease CO and NOx emission.
Increase in engine power by 8% and decrease in fuel consumption by 15-

20% is noted by applying TBC.
Although not yet met with wide success.

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Conclusion
TBC is a very useful technique and has a wide application in industries as well
as in automobile manufacturing.
Detailed analysis of coating stresses and controlled process, plasma spray

technology has significantly improved the reliability of TBC turbines, diesel
engines and other heat engines.
Thermal barrier coating allows engineers to improve product and

performance, reduce maintenance time, cost, save energy and reduce production
cost.
Application of TBC on Turbine blades made dramatic change in increasing

efficiency of Engine.
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References
Materials Research Society (MRS) Bulletin, Thermal Barrier Coatings for
more efficient Gas Turbine Engines; October 2012 Vol. 37 No. 10.
Thermal Barrier Coating,

http://en.wikipedia.org/wiki/Thermal_barrier_coating
Plasma Spray, http://en.wikipedia.org/wiki/Plasma_Spray
A.G. Evans, D.R. Mumm, J.W. Hutchinson, G.H. Meier, F.S. Pettit.
Mechanism controlling the durability of Thermal Barrier Coatings: Progress
in Material Science 46 (2001) 505-553.
Carlos G. Levi. Emerging materials and processes for thermal barrier

systems: Current Opinion in Solid State and Materials Science 8 (2004) 77–
91.
18
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You

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1

 TBCs perform the important function of insulating components

 Coatings can allow higher operating temperatures beyond the

Low Thermal Conductivity.

High Thermal Expansion Coefficient.

Good Erosion Resistance.

Therefore we use Porous Zirconia (ZrO2) partially stabilized with yttria

TBC Deposition Methods

 These atoms then precipitate into solid form, coating everything in

APS(Air Plasma Spray)

 In plasma spraying process, the material to be deposited

TBC on Turbine Blades and

As we know that increase in turbine inlet temperature results in increased

TBC can be applied on both Turbine

Earlier calcia and magnesia stabilized

Various tests were done at NASA on

Increase in engine power by 8% and decrease in fuel consumption by 15-

Although not yet met with wide success.

Detailed analysis of coating stresses and controlled process, plasma spray

Thermal barrier coating allows engineers to improve product and

Application of TBC on Turbine blades made dramatic change in increasing

Thermal Barrier Coating,

Plasma Spray, http://en.wikipedia.org/wiki/Plasma_Spray

Carlos G. Levi. Emerging materials and processes for thermal barrier

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