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Article history: Calcium magnesium aluminosilicate (CMAS) that is formed from the ingested deposits in gas turbines degrades thermal
Received 10 March 2017 barrier coatings (TBCs), especially for the most widely used material; yttria-stabilized zirconia (YSZ). In the present work, we
Revised 20 July 2017 examine the behavior of yttrium aluminum garnet (YAG) as an alternative material for TBCs. CMAS interaction studies were
Accepted in revised form 8 August 2017
conducted by making composite pellets of YAG-CMAS and YSZ-CMAS pow-ders. These pellets, after being subjected to heat
Available online 9 August 2017
treatment between 1100 °C and 1500 °C were characterized by X-ray Diffraction (XRD), scanning electron microscopy
Keywords:
(SEM) and Energy-dispersive X-ray spectroscopy (EDS), which showed YAG to be almost inert to CMAS whereas YSZ
Thermal barrier coatings exhibited significant phase changes. To test the be-havior of TBCs with YAG and 8YSZ as the topcoat material in a CMAS
Yttrium aluminum garnet environment, cyclic furnace tests were con-ducted in which a controlled amount of CMAS was applied and then the samples
CMAS resistance were cycled to failure. In addition, to simulate the continuous accumulation of CMAS expected in service, a cyclic furnace test
Optical basicity was devised in which a small dose of aqueous solution of CMAS was applied on TBC specimens at the start of every cycle
Solution precursor plasma spray until the samples were cycled to failure. In all these tests YAG TBCs outperformed YSZ in terms of durability. The mech-
anisms of CMAS attack are described and the relative resistance of YAG and YSZ is shown to be consistent with the Optical
Basicity (OB) theory.
http://dx.doi.org/10.1016/j.surfcoat.2017.08.023 0257-
8972/© 2017 Elsevier B.V. All rights reserved.
R. Kumar et al. / Surface & Coatings Technology 327 (2017) 126–138 127
exceptional properties, gadolinium zirconate has some weaknesses as well. pre-made solution, and was then mixed with the nitrate solution as a source
Not only is it commercially expensive because of high stoichiomet-ric of sulfur. After this step titanium sulfate solution and colloidal sil-ica was
amounts of gadolinium, but also it lacks in some other critical mate-rial added. pH of the solution was constantly measured and nitric acid was used
properties. These include poor thermodynamic compatibility with Al 2 O 3 to keep the pH between 4 and 7 to ensure stability of col-loidal silica as per
from the TGO layer [21], worse erosion resistance than air plasma sprayed manufacturer's recommendation. Both CMAS solu-tions were dried overnight
(APS) 8YSZ coatings and lower fracture toughness than YSZ [22]. at 120 °C to convert the solution to gels, which were later heat treated at 600
°C in a tube furnace (CM 1600 Tube Furnace, Bloomfield N.J.). The chemical
In our previous work [23,24], we demonstrated that yttrium alumi-num compositions of the two CMAS are given in Table 1. Melting points of the
garnet (YAG) TBCs deposited by Solution Precursor Plasma Spray (SPPS) two CMAS were deter-mined using simultaneous differential scanning
have superior properties compared to Air Plasma Sprayed (APS) 8YSZ. These calorimetry (DSC) and thermal gravimetric analysis (TGA), (Q600 SDT, 10
desirable properties include phase stability up to 1500 °C, low thermal °C/min, 100 ml/min N 2 flow, TA Instruments, New Castle DE). Viscosity of
conductivity of 0.95 W/m·k at 1300 °C, improved erosion resistance, higher the two CMAS was calculated by Giordano [29] and Fluegel [30] model
thermal cycling lives and increased sintering resistance than APS YSZ [23]. and has been shown in Table 2.
In the current work, we discuss the reac-tivity of YAG with CMAS, while 8YSZ
is used as the reference material. In this paper, we have also compared the
performance of SPPS YAG TBCs with APS 8YSZ coatings that are the current 2.2. Powder pellet testing
industrial standard. Ideally, APS YAG coating would provide a head on
comparison however, previous work show for APS YAG the formation of YAG powder (particle size b 50 μm) was obtained by mechanical grinding
amorphous YAG [25] phase occurs which will be prone to crystallization of YAG agglomerate (Alfa Aesar, Ward Hill, MA) and then siev-ing using a
during service and thus cracking. Also, an APS YAG is devoid of stress
relieving vertical cracks that are found in SPPS coatings thus will have a 50 μm wire mesh. YAG and 8YSZ (Metco 204 NS) powders were then mixed
much larger ther-mal expansion mismatch with the bottom TBC layers. A with 9-CMAS powder (composition listed in Table 1) in a 1:1 ratio by weight.
5 wt% of PVA (low molecular weight, Alfa Aesar, Ward Hill, MA) was added
head to head comparison with the APS industrial standard is not done here.
to the mixture to provide strength to the green body. The mixture was ball
The aim of the study is to look at the application of a new TBC material
milled, dried and compressed to form powder pellets. The pellets were heat
processed by a relatively young SPPS process and show that it is a candidate treated in a box furnace (CM Furnaces Inc., Bloomfield, N.J.) for 24 h at
to re-place the current industry standard APS YSZ in the presence of CMAS. different temperatures ranging from 1100 °C–1500 °C. Then the pellets were
At the same time, we are looking for the first time at the nature of YAG in- analyzed for reac-tion using X-ray Diffractometer (D2 Phaser, Bruker AXS,
teraction with CMAS. We have also explored the theory of Optical Basic-ity Madison, WI). For SEM, a small piece of the heat-treated pellets was
which has been recently used to predict the reactivity between the top coat embedded in epoxy resin, polished and finally sputtered with Au/Pd coatings.
materials with CMAS [26,27]. This theory will be shown to be consistent with Field emission scanning electron microscopes (JSM-6350/5F, JEOL USA,
the current results. In the following, the CMAS behavior of YAG TBCs will be Pea-body, MA) and energy dispersive X-ray spectrometer (Noran system six
studied. In each case YSZ samples are tested in the same experiment to EDS, Thermo, Waltham, MA) were used to further analyze the reac-tions
provide a comparison basis using identical conditions. between ceramics and 9-CMAS.
Table 1
Chemical compositions of 4 and 9 component CMAS used in paste and spritz testing.
Constituents 4-CMAS 4-CMAS 9-CMAS 9-CMAS 9-CMAS after sulfate decomposition 9-CMAS after sulfate decomposition
(wt%) (mol%) (wt%) (mol%) (wt%) (mol%)
Table 2 Table 3
CMAS viscosity calculated using Giordano and Fluegel model. Spraying parameters for SPPS YAG samples.
Temperature (°C) Giordano Fluegel Giordano Fluegel Plasma gun Metco 9 MB, GP gun nozzle
Gun power 45.5 kW
1180 376.6 33.2 11.9 4.4
Primary gas/secondary Ar/H 2
1200 252.9 21.5 8.4 1.9
gas
Gas flow rate Ar: 52–57 l/min, H 2 :8–10 l/min
Precursor injection mode Atomization using BETE FC4 spray nozzles, 15 psi
baseline samples were provided to us by the same industrial partner and were pressure
tested in ‘as received’ condition. These samples had a 250 μm top coat of APS Precursor feed rate 18–20 ml/min
8YSZ and same bondcoat and substrate as the SPPS YAG, allowing a fair Standoff distances 35–37 mm
comparison of coatings. For all the tests half of a sample was used which Gun scan speed 550 mm/s
initially had a diameter of 25.4 mm. Raster scan step size 2 mm
Pellet testing was done using 9 component CMAS only. The cylindri-cal
shaped pellets after a 24-h exposure changed their shape depending upon the
temperature and the material. This change, captured in Fig. 3 was
exacerbated in the case of 8YSZ + CMAS pellets which melted completely
whereas the YAG + CMAS pellet only became rounded. Such a macroscopic
behavior indicates reaction between CMAS and 8YSZ which led to dissolution
and re-precipitation of 8YSZ particles thus forming a ‘puddle’ of reaction
products. The minimal change in the shape of YAG based pellets establish the
lack of interaction between YAG and CMAS and the deformation resulted
from preferential or local-ized melting of CMAS in the pellets but held intact
due to YAG matrix. This theory can be further confirmed by Fig. 4 which
shows the SEM im-ages and EDS of the reaction zone in both 8YSZ and YAG
during the heat treatment at 1500 °C. While edge dissolution of ceramic
particles can be observed in both cases, the YAG particles are still rounded
and discrete. 8YSZ particles have changed their shape from rounded to
Fig. 1. Temperature profile of elevator furnace during CMAS paste and spritz testing.
irregular,
R. Kumar et al. / Surface & Coatings Technology 327 (2017) 126–138 129
primarily due to dissolution in CMAS and re-precipitation. Some CMAS is Interestingly, at 1100 °C–1300 °C some anorthite (CaAl 2 Si 2 O 8 ) phase can
also trapped within the particles in the process. X-ray diffraction re-sults for also be seen with maximum intensity at 1300 °C. At higher temper-atures,
both YAG and YSZ based pellets are shown side by side for com-parison in anorthite phase is absent and the same anorthite observation holds true in
Fig. 5. YSZ based pellets showed primarily tetragonal phase at 1100 °C and YAG + CMAS pellets. With an increase in temperature for YSZ, the
1200 °C with small peaks of monoclinic phase. tetragonal to monoclinic phase transformation increases, as indicated by an
increase in monoclinic peak intensity. At 1400 °C and 1500 °C most of the
tetragonal phase has converted to a combina-tion of cubic and monoclinic.
YAG based pellets show almost no reactiv-ity with CMAS at all temperatures.
Crystallization of anorthite is observed between 1100 °C–1300 °C which
disappears at higher temper-atures. At 1400 °C peaks of Ca 4 Y 6 O(SiO 4 ) 6 is
observed which does indi-cate some reactions between CMAS and YAG but
the phase seems to disappear at 1500 °C.
Fig. 4. SEM images of mixed powder pellets post sintering at 1500 °C for 24 h with chemical analysis data acquired at the ceramic-CMAS interface. (a) 8YSZ + 9-CMAS (1:1 by wt), (b) EDS
spectrum at 8YSZ − 9-CMAS interface, (c) YAG + 9-CMAS (1:1 by wt) and (d) EDS spectrum at YAG − 9-CMAS interface.
layer, deposited via APS process, is of 8YSZ and has a thickness of ~250 μm, precursor is pyrolyzed on the sample which causes shrinkage and for-mation
of horizontal pores [24] while the over spray which results in isolated splats
followed by a 100 μm layer of bondcoat and finally the su-peralloy substrate.
adds additional porosity in that layer.
Fig. 6b shows the magnified image of APS 8YSZ coating which has a typical
microstructure obtained through APS process with uniformly distributed splat
boundaries and porosity (~15%, calculated using ImageJ software). 3.4. Thermal cycling without CMAS and failure modes
Fig. 7a is a cross section SEM image of “in house” deposited SPPS YAG Fig. 8 shows the average thermal cycling lives of SPPS YAG and APS
with a thickness of ~225 μm on superalloy substrates pre-coated with 25 μm of 8YSZ baseline samples with standard deviation indicated through bars. SPPS
YAG samples lasted 22% longer than the baseline 8YSZ sam-ples. To analyze
APS 8YSZ and a 100 μm bondcoat layer. The SPPS YAG coating has
the failure modes, BSE images of the failed coatings were taken. Fig. 9a
approximately uniform vertical cracks which extend through the entire
coating thickness and offers stress relieving during thermal cy-cling shows the failed baseline sample with spallation at YSZ-TGO interface. Fig.
experiments. Fig. 7b shows a magnified SEM image of YAG coat-ings which 9b shows a magnified image of the failure inter-face with elemental mapping.
depicts the aforementioned vertical cracks and also reveals horizontal pores The failure is a mixture of failure in the top coat and through the TGO. A
that form between the subsequent gun passes by trap-ping of semi-pyrolyzed distinct TGO layer (10–15 μm) can be observed. The relatively large TGO
precursor an overspray. The under pyrolyzed thickness enables a failure
Fig. 5. X-ray diffraction of mixed powder pellets after heat treatments at temperatures from 1100 °C to 1500 °C. (a) 8YSZ + 9-CMAS (1:1 by wt) (b) YAG + 9-CMAS (1:1 by wt)
R. Kumar et al. / Surface & Coatings Technology 327 (2017) 126–138 131
Fig. 8. Thermal cyclic performance of SPPS YAG and APS 8YSZ TBCs.
CMAS paste tests were done with both 4 component and 9 compo-nent
CMAS and the general failure modes were the same for the two CMAs
compositions however the chemical interactions were different. The lives of
Fig. 6. (a) SEM image of as received APS 8YSZ TBC showing topcoat, bondcoat and substrate both YAG and 8YSZ coatings decreased drastically with CMAS application
layers. (b) Magnified image of the 8YSZ topcoat showing typical microstructure generated by but the reduction in life of 8YSZ sample was more dramatic. 8 YSZ samples
an APS process with horizontal splats and pores. showed a 147 times reduction due to CMAS ex-posure where SPPS YAG
samples showed ~20 times reduction. Fig. 11 shows the cyclic lives of the two
mechanism than includes shape change imposed on the ceramic associ-ated coatings. SPPS YAG coatings performed much better than APS 8YSZ
with TGO growth [7,34]. coatings, with a cycling life greater by at least a factor of 8. The mode of
In the case of SPPS YAG the failure occurs in YSZ interlayer-TGO in- failure was quite different in the two coatings. APS 8YSZ coatings failed in
terface and failure at YAG-YSZ interface is also observed as shown in Fig. the form of flakes, where layer after layer of the coating came off until no
10a. A magnified image of the failed region is shown in Fig. 10b with the coating remained on the sub-strate. On the other hand, SPPS YAG coatings
elemental analysis. Failure at the YSZ TGO interface probably has a failed in one piece at the SPPS YAG to APS YSZ interface (shown in Fig. 12).
contribution to stress in the coating due to shape change due to On further examina-tion, as shown in Fig. 13, it appears that delamination of
flakes happens in relatively larger horizontal pores in the APS 8YSZ coatings.
This is
Fig. 7. SEM image of SPPS YAG TBC showing “in house” deposited YAG topcoat with vertical
cracks, a thin APS 8YSZ inner layer, bondcoat and substrate layers. (b) Magnified image of the
SPPS YAG topcoat showing typical microstructure generated by SPPS process with vertical Fig. 9. (a) Cross section of a failed APS 8YSZ coating in thermal cycling test showing
cracks for strain tolerance and horizontal pores called inter pass boundaries. spallation at YSZ-TGO interface. (b) Magnified cross section of the spallation region with
elemental mapping showing growth of TGO and separation at YSZ-TGO interface.