Thermal Barrier Coating

THERMAL BARRIER COATING
ABSTRACT
Thermal barrier coatings (TBC) are highly advanced material systems usually applied to metallic surfaces, such as gas turbines or aero-engine parts, operating at elevated temperatures, as a form of Exhaust Heat Management. These coatings serve to insulate components from large and prolonged heat loads by utilizing thermally insulating materials which can sustain an appreciable temperature difference between the load bearing alloys and the coating surface. In doing so, these coatings can allow for higher operating temperatures while limiting the thermal exposure of structural components, extending part life by reducing oxidation and thermal fatigue. In conjunction with active film cooling, TBCs permit working fluid temperatures higher than the melting point of the metal airfoil in some turbine applications.
U.B.D.T.C.E mech dept. davangere
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INTRODUCTION
Hundreds of different types of coatings are used to protect a variety of structural engineering materials from corrosion, wear, and erosion, and to provide lubrication and thermal insulation. Of all these, thermal barrier coatings (TBCs) have the most complex structure and must operate in the most demanding hightemperature environment of aircraft and industrial gas-turbine engines. Heat engines are based on considering various factors such as durability, performance and efficiency with the objective of minimizing the life cycle cost. Metallic coatings were introduced to sustain the high temperatures. The trend for the most efficient gas turbines is to exploit more recent advances in material and cooling technology by going to engine operating cycles which employ a large fraction of the maximum turbine inlet temperature capability for the entire operating cycle. Thermal Barrier Coatings (TBC) performs the important function of insulating components such as gas turbine and aero engine parts operating at elevated temperatures. Thermal barrier coatings (TBC) are layer systems deposited on thermally highly loaded metallic components, as for instance in gas turbines. TBCs are characterized by their low thermal conductivity, the coating bearing a large temperature gradient when exposed to heat flow. The most commonly used TBC material is Yttrium Stabilized Zirconia (YSZ), which exhibits resistance to thermal shock and thermal fatigue up to 1150oC. YSZ is generally deposited by plasma spraying and electron beam physical vapour deposition (EBPVD) processes. It can also be deposited by high velocity oxy-fuel (HVOF) spraying for applications such as blade tip wear prevention, where the wear resistant properties of this material can also be used. The use of the TBC raises the process temperature and thus increases the efficiency.
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STRUCTURE OF THERMAL BARRIER COATINGS

Generally, TBC is a two layers system which incorporates about 250 m thickness layer of ceramic top coating applied to the outer surface of the substrate and about 150 m thickness underlying of metallic bond coating. The metallic bond coating performs two functions: (1) To provide oxidation resistance and (2) To adhere the ceramic to the super alloy substrate physically and chemically. The oxide that is commonly used is Zirconia oxide (ZrO2) and Yttrium oxide (Y2O3). The metallic bond coat is an oxidation/hot corrosion resistant layer. The bond coat is empherically represented as MCrAlY alloy where M Y CrAl Metals like Ni, Co or Fe. Reactive metals like Yttrium. base metal.
Fig. 1: Typical microstructure of TBC By attaching an adherent layer of a low thermal conductivity material to the surface of an internally cooled gas turbine blade, a temperature drop can be induced across the thickness of the layer, Fig2. This results in a reduction in the metal temperature of the component to which it is applied. Using this approach temperature drop of up to 170 oC at the metal surface have been estimated for 150m thick yttria stabilized zirconia coatings. This temperature drop reduces the (thermally activated) oxidation rate of the bond coat applied to metal components, and so delays failure by oxidation. Modern TBCs are required to not only limit heat transfer through the coating but to also protect engine
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components from oxidation and hot corrosion. No single coating composition appears able to satisfy these multifunctional requirements. As a result, a coating system has evolved.
Fig.2: A schematic illustration of a modern thermal barrier coating system First, a thermally protective TBC layer with a low thermal conductivity is required to maximize the thermal drop across the thickness of the coating. This coating is likely to have a thermal expansion coefficient that differs from the component to which it is applied. It must be able to retain its low thermal conductivity during prolonged environmental exposure. A porous, columnar, 100-200 m thick, yttria stabilized zirconia (YSZ) layer is currently preferred for this function. Second, an oxidation and hot corrosion resistant layer is required to protect the under laying turbine blade from environmental degradation. This layer is required to remain relatively stress free and stable during long term exposure and remain adherent to the substrate to avoid premature failure of the TBC system. It is important that it also provide an adherent surface for the TBC top coat. Normally, the thin (< 1m), protective aluminum rich oxide which is thermally grown upon the bond coat is utilized for this purpose. A ~50m thick layer of either a low sulphur platinum aluminide or MCrAlY (where M is Ni or Co) is utilized for this purpose.
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COATING PROPERTIES
Depending on the following material properties we choose the coating materials.
Hardness:
As for all materials, the hardness of a coating is a measure of the resistance to plastic deformation. It is widely recognized that the hardness increases with increasing density, i.e. decreasing number of pores and micro-cracks. The hardness was determined from the average length of the diagonals of each diamond shaped indentation.
Erosion resistance:
TBC degradation by erosion occurs mainly on turbine blades and vanes, especially when the (aircraft) engine operates in a sandy environment (e.g. desert). High erosion resistance is normally obtained by decreasing the porosity. However, high thermal shock resistance is obtained by increasing the porosity.
Adhesion strength:
Coating thickness, bond coat pre oxidation and isothermal heating (1050C/5hr) affect the adhesion strength. The chemical bond also affects the adhesion strength of TBC.
Thermal conductivity:
Thermal conductivity is one of the physical key properties of TBCs. Lowering TBCs thermal conductivity would increase the engine performance by improving the combustion efficiency, reduce the specific fuel consumption, allow a reduction of internal cooling, reduce the metallic component temperature and extend their lifetime. Thus lowering thermal conductivity of the ceramic layer can be achieved by engineering chemical composition and/or coating microstructure.
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COATING MATERIALS
The TBC material should have low thermal conductivity and a thermal expansion coefficient. It should also have long term phase stability at whole service temperature range and adequate corrosion resistance against the impurities present in the process. Sufficient mechanical properties are also needed (bond strength, erosion resistance). Yttria stabilized zirconia (YSZ) is the most used TBC material. The following are materials have been proposed as possible alternative to YSZ.
Zirconates:
Zirconates have drawn the attention of several research groups as a promising alternative to YSZ. The main advantages of zirconates are their low sintering activity, low thermal conductivity, and good thermal cycling resistance. The main problem is the high thermal expansion coefficient (TEC) which results in residual stress in the coating, and can cause coating delamination. The total porosity in plasma sprayed zirconates is less than 10% which is lower than the porosity in plasma sprayed PSZ. As the porosity has a vital role in thermal insulation, process modification is required to increase the level.
Garnets:
Polycrystalline garnet ceramics are used in different applications due to their unique properties. Particularly YAG (Y3Al5O12) is a good choice for many high-temperature applications, due to its excellent high temperature properties and phase stability up to its melting point (1970C). Other advantages which make YAG a candidate as a TBC are their low thermal conductivity and its low oxygen diffusivity.
Cordierite:
Cordierite (2MgO.2Al2O3.5SiO2) has a very low thermal expansion coefficient but, for certain applications, could be an alternative for TBCs. However, after plasma spraying, the cordierite deposition is amorphous. While heating, two phase transformation occur, at 830C and 1000C, which produce a volume change and cause cracking. Increasing the temperature of the substrate to slow the cooling rate of the cordierite increases the crystallinity, however the oxidation of metal substrates is a concern. Finally, another way to increase the crystallinity of deposited cordierite is laser surface melting. Some studies focused on zirconia-cordierite composites. But there are two major problems with this system: the glassy nature of cordierite and its phase transformation is still unsolved. Also U.B.D.T.C.E mech dept. davangere Page 6
yttria diffuses gradually into the cordierite destabilizing the ZrO2 to allow the destructive tetragonal to monoclinic phase transformation to occur.
Forsterite:
The high thermal expansion coefficient of forsterite (2MgO.SiO2), 11x10-6 K-1, permits a good match with the substrate. At thicknesses of some hundred microns, it shows a very good thermal shock resistance.
Spinel:
Although spinel (MgO.Al2O3) has very good high temperature and chemical properties, its thermal expansion coefficient, 7.68x10-6 K-1, prevents its usage as a reliable choice for thermal expansion coefficient. There is only one report of applying spinel on bond coat which failed after 719 thermal cycles.
Mullite:
Mullite is applied on SiC as an oxidation resistant layer to form an environmental barrier coating (EBC). Its low oxygen diffusivity, low creep rate at high temperatures, high thermo-mechanical fatigue resistance and close thermal expansion coefficient match with SiC (4-5x10-6 K-1 vs. 5-6x10-6 K-1) makes it the ideal choice for this application. In thin coatings (up to some hundred microns) on top of a metallic substrate, the durability of mullite has been reported to be better than that of zirconia. The low thermal expansion coefficient of mullite is an advantage relative to YSZ in high thermal gradients and under thermal shock conditions. However, the large mismatch in TEC with metallic substrate leads to poor adhesion. Mullite has excellent creep resistance. Like cordierite, mullite is amorphous as deposited. In service recrystallization occurs at 750 -1000C which is accompanied by a volume contraction, cracking and top coat debonding a solution is to heat the substrate to 1000C.
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THERMAL BARRIER COATING DEPOSITION

There are two different processes for the manufacturing of thermal barrier coatings: (1) The plasma spraying (PS) (2) The electron beam - physical vapour deposition (EB-PVD)
Plasma Spray Process:
Fig.3: Plasma Spray Process It consists of tungsten cathode and water-cooled copper anode. The gas used is Argon, Helium, Hydrogen and Nitrogen. Argon is usually chosen as the base gas due to its ionization characteristics and chemical inertness. An electric arc is initiated between the two electrodes using a high frequency discharge and then sustained using dc power. The arc ionizes the gas, creating high-pressure gas plasma. The resulting increase in gas temperature, which may exceed 30,000oC in turn, increases the volume of the gas and, hence, its pressure and velocity as it exits the nozzle. Power levels in plasma spray torches are usually in the range of 30 kW to 80 kW, but they can be as high as 120 kW. The powder velocities usually range from 300 m/s to 550 m/s. Temperatures are usually at or slightly above the melting point. Powder is usually introduced in to the gas U.B.D.T.C.E mech dept. davangere Page 8
stream either just outside the torch or in the diverging exit region of the nozzle. Prior to coating deposition by plasma spraying the substrate is degreased and roughened by grit blasting to facilitate bonding with MCrAlY bond coat. Some of the important factors to be considered in plasma spray process are: The power settings of the plasma spray gun. The gun to substrate distance. The composition of plasma gas. The motion and orientation of the gun relative to the item being coated. The particle size distribution. The thermal properties and temperature of the substrate. Coating thickness usually ranges from about 0.05 mm to 0.5 mm but may be thicker for some applications. In the as deposited condition, plasma sprayed coatings are composed of many layer of splattered particles. MCrAlY bond coat alloys must have a surface roughness of the order of 7 micron to produce a good mechanical bond with the ceramic.
Electron Beam Physical Vapor Deposition:

EB-PVD is an evaporation process for applying ceramic thermal barrier coatings to gas turbine engine parts. It has been the favored deposition process technique for TBCs because of the increased durability of coating that is produced when compared to other deposition processes. EB-PVD TBCs exhibit a columnar microstructure that provides outstanding resistance against thermal shocks and mechanical strains. The EB-PVD process takes place in a vacuum chamber consisting of a vacuumpumping system, horizontal manipulator, a water-cooled crucible containing a ceramic ingot to be evaporated, an electron-beam gun, and the work piece being coated. The electron beam gun produces electrons, which directly impinge on the top surface on the ceramic coating, located in the crucible, and bring the surface to a temperature high enough that vapor steam is produced. The vapor steam produces a vapor cloud, which condenses on the substrate and thus forms a coating. The substrate is held in the middle of vapor cloud by a horizontal manipulator that allows for height variation in the chamber.
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Fig.4: EB-PVD Coating Chamber During the coating process, oxygen or other gases may be bled into the vapor cloud in order to promote a stoichiometric reaction of ceramic material. An over source heater or an electron beam gun may be used for substrate heating, which keeps the substrate at a desired temperature. The primary control variables for the coating process are: Ingot feed rate & ingot size Gun current Over source heater power
The feed rate and size controls how much mass is to be evaporated by the gun current. The gun current controls how much power is transmitted to the melt pool, and thus controls melt pool temperature for the evaporation rate and deposition rate. The maximum gun current is limited by the stability of the ingot melt surface. Too high a current overheats the ingot surface causing spattering, thus loosing mass evaporated. The melt pool is a major source of heat energy for the substrate as well as substrate heating if used. The substrate temperature is important because it controls many of the deposited coatings material properties. The coating operator must control the primary variables involved in the coating process, as well as beam sweep frequency and rotation rate, which are set prior to the coating process. Beam sweep frequency refers to the irregular scanning pattern the electron beam gun makes on the ingot surface. U.B.D.T.C.E mech dept. davangere Page 10
THE EFFECT OF TBC ON DIESEL ENGINE PERFORMANCE

Thermal Barrier Coatings developed primarily for turbine applications can also be used in diesel engines benefits derived from using this technology includes An improvement in the diesel engine fuel economy. Increase in engine power density. Reduction in the in-cylinder heat rejection. Reduction in the ring groove temperatures. Reduction in the metal piston temperatures. Reduction in the lubricant temperatures Experiments were conducted on a, single-cylinder, air-cooled, direct injection diesel engine developing a power output of 5.2 kW at 1500 rev/min connected with a water cooled eddy current dynamometer. The engine was operated at a constant speed of 1500 rpm and standard injection pressure of 220 bar.
Results and discussion:

Subsequently five fuel blends of dioxane with diesel ranging from 10 to 50% by volume, namely (Dy10, Dy20, Dy30, Dy40 and Dy50) were prepared and tested. Readings were taken, when the engine was operated at a constant speed of 1500 rpm for all loads. Parameter like engine speed, fuel flow and the emission characteristic like NOx and smoke were recorded. The performance of the engine was evaluated in terms of brake thermal efficiency, brake power, brake specific fuel consumption from the above parameters. The engine with a thin layer ZrO2 Al2O3 coated piston, cylinder liner, head and bottom of the valves. As dioxane is having oxygen in its structure, more amount of fuel can be burnt in a given amount of air and hence the BSFC decreases for the blends compared with baseline fuel up to 10% dioxane addition. But, the heat value of the fuel mixture for higher blends decreases as the heat value of dioxane is less than diesel. Hence in order to maintain the same power, more fuels are consumed. As a result, BSFC will increase as the blended fuels with high dioxane concentration are used. Fig.5 shows the BSFC for different dioxane additions with and without thermal insulation. U.B.D.T.C.E mech dept. davangere Page 11
Fig.5: Brake specific fuel consumption for different dioxane blends at full load TBC engine improved the brake thermal efficiency of sole fuel by 3.8% when compared to the standard engine due to the in cylinder heat transfer reduction and increase in combustion duration. The presence of oxygen due to dioxane in the oxygenated fuel, improve the combustion, especially diffusion combustion and hence increase the brake thermal efficiency. Fig6. compares the effect of oxygenated fuel blend on the brake thermal efficiency for the standard and TBC engine. The maximum Brake thermal efficiency occurs for B10 blend ratio on the standard engine.
Fig.6: Brake thermal efficiency for different dioxane blends at full load
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APPLICATIONS
Gas Turbine Engine Applications: Thermal barrier coatings (TBCs) have the most complex structure and must operate in the most demanding high temperature environment of industrial gas-turbine engines. TBCs, which comprise metal and ceramic multilayers, insulate turbine and combustor engine components from the hot gas stream, and improve the durability and energy efficiency of these engines. TBCs For Jet Engine Turbine: Thermal barrier coatings of jet engine turbines are critical for achieving powerful, fuel efficient aircraft. Currently, engines operate under combustion temperatures well beyond the melting point of the metal alloys that compose the engine parts. Cutting Tool Applications: The addition of a TBC is credited for increasing cutting speeds of tools and for providing deeper cuts. In particular, TBCs provide excellent wear resistance which is necessary in the harsh tool environment. Wear mechanisms of cutting tools, include crater, attrition, flank, and abrasive wear. It has been shown that TBCs can limit the crater and attrition wear processes. Thermal barrier coatings can also be applied on furnace components, heat-treating equipments, chemical processing equipments, heat exchangers rocket motor nozzles, exhaust manifolds and nuclear power plant components. It has also been applied to uncoated blades used to drive the high-pressure hydrogen turbo pump of the Space Shuttle Main Engine. Here the coating is applied to provide thermal lag.
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DISADVANTAGES
The main disadvantage is ceramic bond coat interface region which was determined to be the weakest link in the ZrO2-12Y2O3 / NiCrAlY system. Adhesive plus cohesive failure of the ceramic layer in this region occurred when the coating was subjected to a normal tensile load at room temperature as well as when applied on bars subjected to axial tension or compression at elevated temperature. On prolonged high-temperature exposure in air, thermal barrier coatings (TBCs) on bond-coated super alloys fail by spalling. Scientists focused on identifying the underlying mechanisms of failure and sought to establish whether it is a direct consequence of the failure of the underlying thermally grown oxide. They discovered a new TBC failure mode, one in which failure is associated with moisture-enhanced sub-critical crack-growth along the bond-coat/ thermally grown oxide interface.
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CONCLUSION
1. The coating material has been applied successfully to the combustion chamber as the thermal barrier coating of a diesel engine to prevent excessive heat loss during the combustion. 2. Using insulation to reduce the heat loss to the cooling system of the engine causes the cylinder walls to become hotter and increases the effective efficiency. 3. High temperatures on the combustion chamber wall surface due to insulation cause a drop in volumetric efficiency although increased boost pressure from the turbocharger can be used to overcome this problem. 4. Well-insulated engine show significant improvement in fuel consumption over a conventionally cooled engine (standard engine). 5. It was found in tests performed on a naturally aspirated diesel engine with pistons covered with TBCs, that specific fuel consumption was lower by 5-10%. Exhaust gas temperature was found to be 200K higher than in the engine with metal pistons. 6. Processing improvement in the control and development of TBC are required. Further study on, the mechanisms controlling coating adherence and degradation in clean and dirty environments, the effects of coating composition and structure on coating properties and correlation of models of engine tests are necessary to obtain thermal barrier coating that have even better tolerance to high temperature and thermo mechanical stresses.
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REFERENCE
C. Sundar Raj, S. Sendilvelan, S. Arul., June 2010, Performance of a Thermally Insulated Constant Speed Diesel Engine with Dioxane Blended Fuels, Global Journal of Researches in Engineering, Vol. 10. Jeremy Bernier, 2001, Evolution and Characterization of Partially Stabilized Zirconia Thermal Barrier Coatings Deposited by Electron Beam Physical Vapor Deposition, Worcester Polytechnic Institute. Miller, R.A., 1987, Current Status of Thermal Barrier Coatings: an Overview, Surf. Coat. Technol., Vol. 30. G. Moskal, 2009, Thermal barrier coatings: characteristics of microstructure and properties, generation and directions of development of bond, Journal of achievement in Materials & Manufacturing Engineering, Vol. 37. H. Samadi, T.W.Coyle, Alternative Thermal Barrier Coatings for Diesel Engines, Centre for Advanced Coating Technologies, University of Toronto, Toronto. WEBSITES http://dauskardt.stanford.edu/joanna_mroz/Thermal.html http://en.wikipedia.org/wiki/Thermal_barrier_coating
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