A reliable lifetime prediction rule for bondcoat/thermal barrier coating (BC/TBC) coated parts in gas turbine operation is necessary to determine remnant service life. The specimens investigated were coated with MCrAlY plus yttria partially stabilized zirconia applied by vacuum plasma spraying and atmospheric plasma spraying processes, respectively. The performances of these laboratory specimens were statistically assessed, combining long term oxidation testing with thermal cycling, thus superimposing thermomechanical loading on the laboratory specimens to more accurately represent engine conditions. A design of experiment (DOE) approach was used for manufacturing optimization of the BC/TBC system. The life of the coating system is influenced by several manufacturing parameters such as BC thickness, BC roughness, TBC thickness, TBC porosity, and TBC stiffness. Specimens with a suitable variation in these parameters were produced to ensure a balanced test matrix of fractional factorial DOE. Based on results derived from laboratory testing the specifically tailored parts, first and second order effects of manufacturing parameters on lifetime were quantified. The findings revealed that the second order effects (the interaction of manufacturing parameters) were more important on the lifetime of the BC/TBC system than the corresponding first order effect (single parameter). For instance, the variation in BC thickness or BC roughness led to a scatter of lifetimes of 10% and 60%, respectively, whereas their interaction resulted in a scatter of lifetime of 150% for the same range of coating parameters. Further examples of such pairings are also demonstrated. Finally, a lifetime prediction for three quality classes (high, medium, and low qualities) has been demonstrated. The difference in achievable lifetime highlights the importance of manufacturing parameters in determining the life of the BC/TBC system.
Skip Nav Destination
e-mail: hans-peter.bossmann@power.alstom.com
Article navigation
February 2010
Research Papers
Manufacturing Optimization for Bondcoat/Thermal Barrier Coating Systems
Hans-Peter Bossmann,
e-mail: hans-peter.bossmann@power.alstom.com
Hans-Peter Bossmann
ALSTOM
, Brown Boveri Strasse 7, CH-5401 Baden, Switzerland
Search for other works by this author on:
Sharath Bachegowda,
Sharath Bachegowda
ALSTOM
, Brown Boveri Strasse 7, CH-5401 Baden, Switzerland
Search for other works by this author on:
Alexander Schnell
Alexander Schnell
ALSTOM
, Brown Boveri Strasse 7, CH-5401 Baden, Switzerland
Search for other works by this author on:
Hans-Peter Bossmann
ALSTOM
, Brown Boveri Strasse 7, CH-5401 Baden, Switzerlande-mail: hans-peter.bossmann@power.alstom.com
Sharath Bachegowda
ALSTOM
, Brown Boveri Strasse 7, CH-5401 Baden, Switzerland
Alexander Schnell
ALSTOM
, Brown Boveri Strasse 7, CH-5401 Baden, SwitzerlandJ. Eng. Gas Turbines Power. Feb 2010, 132(2): 022101 (7 pages)
Published Online: October 30, 2009
Article history
Received:
April 16, 2008
Revised:
August 15, 2008
Published:
October 30, 2009
Citation
Bossmann, H., Bachegowda, S., and Schnell, A. (October 30, 2009). "Manufacturing Optimization for Bondcoat/Thermal Barrier Coating Systems." ASME. J. Eng. Gas Turbines Power. February 2010; 132(2): 022101. https://doi.org/10.1115/1.3155398
Download citation file:
Get Email Alerts
Cited By
Image-based flashback detection in a hydrogen-fired gas turbine using a convolutional autoencoder
J. Eng. Gas Turbines Power
Fuel Thermal Management and Injector Part Design for LPBF Manufacturing
J. Eng. Gas Turbines Power
An investigation of a multi-injector, premix/micromix burner burning pure methane to pure hydrogen
J. Eng. Gas Turbines Power
Related Articles
Evolution of Surface Deposits on a High-Pressure Turbine Blade—Part I: Physical Characteristics
J. Turbomach (April,2008)
Preliminary Testing of Metal-Based Thermal Barrier Coating in a Spark-Ignition Engine
J. Eng. Gas Turbines Power (July,2010)
Optical Nondestructive Condition Monitoring of Thermal Barrier Coatings
J. Eng. Gas Turbines Power (November,2008)
Development of Operating Temperature Prediction Method Using Thermophysical Properties Change of Thermal Barrier Coatings
J. Eng. Gas Turbines Power (January,2004)
Related Chapters
Thermo-mechanical Creep-Fatigue of Coated Systems
Thermomechanical Fatigue Behavior of Materials: 4th Volume
Gas-Fluidized Beds
Two-Phase Heat Transfer
Chitosan-Based Drug Delivery Systems
Chitosan and Its Derivatives as Promising Drug Delivery Carriers