Thermal Barrier Coatings
Thermal barrier coatings offer gas turbines one way to reach fuel flexibility and improved efficiency. Test/analytical results are encouraging for this young technology.
Grisaffe, S. J.↗
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Flexible pile thermal barrier insulator
A flexible pile thermal barrier insulator included a plurality of upstanding pile yarns. A generally planar backing section supported the upstanding pile yarns. The backing section included a plurality of filler yarns forming a mesh in a first direction. A plurality of warp yarns were looped around said filler yarns and pile yarns in the backing section and formed a mesh in a second direction. A binder prevented separation of the yarns in the backing section.
Anderson, G. E.↗
A computer program for full-coverage film-cooled blading analysis including the effects of a thermal barrier coating
The program input, coolant flow and heat transfer model, and the program output are discussed. As an example, sections of the suction and pressure sides of a high temperature, high pressure turbine vane are analyzed to show the effects of a thermal barrier coating. Compared to the uncoated design, the coating halves the required coolant flow, while simultaneously reducing metal outer temperatures by over 111 K.
Source record↗
Effects of compositional changes on the performance of a thermal barrier coating system
Currently proposed thermal barrier systems for aircraft gas turbine engines consist of NiCrAlY bond coating covered with an insulating oxide layer of yttria-stabilized zirconia. The effect of yttrium concentration (from 0.15 to 1.08 w/o) in the bond coating and the yttria concentration (4 to 24.4 w/o) in the oxide layer were evaluated. Furnace, natural gas-oxygen torch, and Mach 1.0 burner rig cyclic tests on solid specimens and air-cooled blades were used to identify trends in coating behavior. Results indicate that the combinations of yttrium levels between 0.15 - 0.35 w/o in the bond coating and the yttria concentration between 6 - 8 w/o in the zirconium oxide layer were the most adherent and resistant to high temperature cyclic exposure.
Stecura, S.↗
Tests of NASA ceramic thermal barrier coating for gas-turbine engines
A two-layer thermal barrier coating system with a bond coating of nickel-chromium-aluminum-yttrium and a ceramic coating of yttria-stabilized zirconia was tested for corrosion protection, thermal protection and durability. Full-scale gas-turbine engine tests demonstrated that this coating eliminated burning, melting, and warping of uncoated parts. During cyclic corrosion resistance tests made in marine diesel fuel products of combustion in a burner rig, the ceramic cracked on some specimens. Metallographic examination showed no base metal deterioration.
Liebert, C. H.↗
Industry tests of NASA ceramic thermal barrier coating
Ceramic thermal barrier coating (TBC) system was tested by industrial and governmental organizations for a variety of aeronautical, marine, and ground-based gas turbine engine applications. This TBC is a two-layer system with a bond coating of nickel-chromium-aluminum-yttrium (Ni-16Cr-6Al-0.6Y, in wt. percent) and a ceramic coating of yttria-stabilized zirconia (ZrO2-12Y2O3, in wt. percent). Seven tests evaluated the system's thermal protection and durability. Five other tests determined thermal conductivity, vibratory fatigue characteristics, and corrosion resistance of the system. The information presented includes test results and photographs of the coated parts. Recommendations are made for improving the coating procedures.
Liebert, C. H.↗
Photoinduced currents in metal-barrier-metal junctions
The fabrication and application of metal-barrier-metal tunneling junctions for radiative interactions are discussed. Particular attention is given to the photolithographic fabrication of small area devices and the coupling to such devices via surface plasmon waves which play an important role at infrared and optical frequencies. It has been shown that the junction electron tunneling currents can be strongly coupled to surface plasmon junction modes, and spontaneous and stimulated emission of the latter are possible as well as nonlinear interactions. Finally, results demonstrating the photo-excitation of electrons with subsequent tunneling induced by ultraviolet radiation are presented. It is estimated that quantum efficiencies of the order of 5% and higher are possible in the ultraviolet region.
Guedes, M. P.↗
NASA thermal barrier coatings - Summary and update
The work conducted at the NASA Lewis Research Center to evolve and evaluate a thermal-barrier coating system will be discussed. A durable, two-layer, plasma-sprayed coating consisting of a ceramic layer over a metallic layer was developed that has the potential of insulating hot engine parts and thereby reducing metal temperatures and coolant flow requirements and/or permitting use of less costly and complex cooling configurations and materials. The paper summarizes the results of analytical and experimental investigations of the coatings on flat metal specimens, turbine vanes and blades, and combustor liners. Discussed are results of investigations to determine coating adherence and durability, coating thermal, strength and fatigue properties, and chemical reactions of the coating with oxides and sulfates. Also presented are the effect of the coating on aerodynamic performance of a turbine vane, measured vane and combustor liner temperatures with and without the coating, and predicted turbine metal temperatures and coolant flow reductions potentially possible with the coating. Included also are summaries of some current research related to the coating and potential applications for the coating.
Stepka, F. S.↗
Effects of compositional changes on the performance of a thermal barrier coating system
Systems consisting of Ni-base bond coatings containing about 16Cr, 6Al, and from 0.15 to 1.08Y (all in wt %) and zirconium oxide layers containing from 4.0 to 24.4Y2O3 were evaluated for suitability as thermal barrier systems for advanced aircraft gas turbine engine components. The evaluations were performed in a cyclic furnace between 990 and 280 C as well as between 1095 and 280 C on solid specimens; in a natural gas-oxygen torch rig between about 1200 and 100 C on solid specimens and up to 1580 C surface temperatures on air-cooled blades; and in a Mach 1.0 burner rig up to 1570 C surface temperatures on air-cooled blades. The data indicate that the best systems consist of combinations involving the Ni-16.4Cr-5.1Al-0.15Y and Ni-17.0Cr-5.4Al-0.35Y bond coatings and the 6.2Y2O3- and 7.9Y2O3- (all in wt %) stabilized zirconium oxide layers.
Stecura, S.↗
Emittance and absorptance of the National Aeronautics and Space Administration ceramic thermal barrier coating
The spectral emittance of a NASA developed zirconia ceramic thermal barrier coating system, consisting of a metal substrate, a layer of Ni-Cr-Al-Y bond material and a layer of yttria-stabilized zirconia ceramic material, is analyzed. The emittance, needed for evaluation of radiant heat loads on cooled coated gas turbine components, was measured over a range of temperatures that would be typical of its use on such components. Emittance data were obtained with a spectrometer, a reflectometer and a radiation pyrometer at a single bond coating thickness of 0.010 cm and at a ceramic coating thickness of 0-0.076 cm. The data were transformed into the hemispherical total emittance and were correlated to the ceramic coating thickness and temperature using multiple-regression curve-fitting techniques. The system was found to be highly reflective, and, consequently, capable of significantly reducing radiation heat loads on cooled gas turbine engine components.
Liebert, C. H.↗
Transport of majority and minority carriers in 2-micron-diameter Pt-GaAs Schottky barriers
An experimental study of small area (2-micron diameter) Pt-GaAs Schottky barrier diodes has been made, by using a wafer chip with a matrix of these diodes lying within approximately a minority carrier diffusion length of one another. Using one diode as collector and another as emitter, transistor measurements indicated that the dominant contribution to the current is the majority-carrier thermionic field emission current for large forward-bias voltage of the emitter junction (V-EB no less than about 0.4 V), whereas the smaller forward-bias (V-EB no greater than about 0.4 V) recombination in the space-charge region was most important. The minority carrier injection ratio is measurable only for large forward-bias voltages, decreasing from about 0.02 to 0.00001 as VEB increases from 0.5 to 1.0 V. The minority carrier diffusion length was measured to be about 1.3 microns. These results are of considerable significance for the understanding and optimization of the performance of these devices as classical detectors and mixers.
Chan, E. Y.↗
Tests of NASA ceramic thermal barrier coating for gas-turbine engines
A NASA ceramic thermal barrier coating (TBC) system was tested by industrial and governmental organizations for a variety of aeronautical marine, and ground-based gas-turbine engine applications. This TBC is a two-layer system with a bond coating of nickel-chromium-aluminum-yttrium (Ni-16Cr-6Al-0.6Y, in wt %) and a ceramic coating of yttria stabilized zirconia (ZrO2-12Y2O3, in wt %). Tests (Liebert and Stenka, 1979) have been conducted to determine corrosion resistance, thermal protection, durability, thermal conductivity, and fatigue characteristics. The information presented covers some of the significant test results obtained on the first three items. The information also includes photographs of coated parts after tests, measurements of coating loss, amount of metal wall temperature reduction when the TBC is used, and extent of base metal corrosion.
Liebert, C. H.↗
Direct observation of voltage barriers in ZnO varistors
Voltage barriers in a ZnO varistor have been imaged by voltage-contrast scanning electron microscopy. They are due to grain boundaries and are capable of supporting voltage differences of up to about 4 V.
Krivanek, O. L.↗
Thermal barrier and gas seal
Resilient baglike seal tolerates thousand-degree temperatures and accommodates small changes in gap size without losing gas-barrier properties; at same time, it maintains smooth aerodynamic surface across gap. Seal includes alumina filler backed by metal plate. Alumina-filled envelope is easily handled and installed, and can be used in high-temperature industrial processes like coal gasification and liquefaction.
Kane, J. O.↗
Improved metallic and thermal barrier coatings
Low thermal conductivity two layer ceramic coatings are efficient thermal barriers between cooled matallic components and high temperature combustion gases. Potential components are combustors, blades, and vanes in aircraft engines of power-generating turbines. Presence of two layer coatings greatly reduces temperature and coolant requirements.
Stecura, S.↗
Analysis of the response of a thermal barrier coating to sodium and vanadium doped combustion gases
Published data on the behavior of zirconia-based thermal barrier coatings exposed to combustion gases doped with sodium and vanadium were analyzed with respect to calculated condensate dew points and melting points. Coating temperatures, failure locations, and depths were reasonably well correlated.
Miller, R. A.↗
Effect of thermal cycling on ZrO2-Y2O3 thermal barrier coatings
A study was made of the comparative life of plasma sprayed ZrO2-Y2O3 thermal barrier coatings on NiCrAlY bond coats on Rene 41 in short (4 min) and long (57 min) thermal cycles to 1040 C in a 0.3 Mach flame. Short cycles greatly reduced the life of the ceramic coating in terms of time at temperature as compared to longer cycles. Appearance of the failed coating indicated compressive failure. Failure occurred at the bond coat-ceramic coat junction. At heating rates greater than 550 kw/sq m, the calculated coating detachment stress was in the range of literature values of coating adhesive/cohesive strength. Methods are discussed for decreasing the effect of high heating rate by avoiding compressive stress.
Mcdonald, G.↗
Significance of thermal contact resistance in two-layer thermal-barrier-coated turbine vanes
The importance of thermal contact resistance between layers in heat transfer through two layer, plasma sprayed, thermal barrier coatings applied to turbine vanes was investigated. Results obtained with a system of NiCrAlY bond and yttria stabilized zirconia ceramic show that thermal contact resistance between layers is negligible. These results also verified other studies which showed that thermal contact resistance is negligible for a different coating system of NiCr bond calcia stabilized zirconia ceramic. The zirconia stabilized ceramic thermal conductivity data scatter presented in the literature is ?20 to -10 percent about a curve fit of the data. More accurate predictions of heat transfer and metal wall temperatures are obtained when the thermal conductivity values are used at the ?20 percent level.
Liebert, C. H.↗