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Long-Term Failure Mechanisms of Thermal Barrier Coatings in Heavy-Duty Gas Turbines

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Long-Term Failure Mechanisms of Thermal Barrier Coatings in Heavy-Duty Gas Turbines coatings Review Long-Term Failure Mechanisms of Thermal Barrier Coatings in Heavy-Duty Gas Turbines Feng Xie 1 , Dingjun Li 2 and Weixu Zhang 1,* 1 State Key Laboratory for Strength and Vibration of Mechanical Structures, Department of Engineering Mechanics, School of Aerospace Engineering, Xi’an Jiaotong University, Xi’an 710049, China; [email protected] 2 State Key Laboratory of Long-Life High Temperature Materials, Dongfang Electric Corporation Dongfang Turbine Co., LTD, Deyang 618000, China; [email protected] * Correspondence: [email protected] Received: 26 September 2020; Accepted: 19 October 2020; Published: 23 October 2020 Abstract: Thermal barrier coatings serve as thermal insulation and antioxidants on the surfaces of hot components. Different from the frequent thermal cycles of aero-engines, a heavy-duty gas turbine experiences few thermal cycles and continuously operates with high-temperature gas over 8000 h. Correspondingly, their failure mechanisms are different. The long-term failure mechanisms of the thermal barrier coatings in heavy-duty gas turbines are much more important. In this work, two long-term failure mechanisms are reviewed, i.e., oxidation and diffusion. It is illustrated that the growth of a uniform mixed oxide layer and element diffusion in thermal barrier coatings are responsible for the changes in mechanical performance and failures. Moreover, the oxidation of bond coat and the interdiffusion of alloy elements can affect the distribution of elements in thermal barrier coatings and then change the phase component. In addition, according to the results, it is suggested that suppressing the growth rate of uniform mixed oxide and oxygen diffusion can further prolong the service life of thermal barrier coatings. Keywords: heavy-duty gas turbine; thermal barrier coatings; oxidation; diffusion; failure 1. Introduction A heavy-duty gas turbine is an important device for power generation. Thermal barrier coatings (TBCs) serve as a thermal protection structure and protect the hot components in heavy-duty gas turbines [1]. TBCs are made up of a top ceramic coat (TC), intermediate metal bond coat (BC) and the underlying superalloy substrate. A layer of thermally grown oxide (TGO) forms between the TC and BC during the oxidation of TBCs [2,3]. Different from the frequent thermal cycling of aero-engines, a heavy-duty gas turbine continuously operates at high temperature over 8000 h [4,5], as shown in Figure1, and the thermal stress, which mainly originates from the start and stop, is almost released by material creep in the long-term service [6,7]. Moreover, the inlet air of a heavy-duty gas turbine is filtrated and clean. Thus, the attack of calcium-magnesium-aluminum-silicate (CMAS) also almost cannot occur. Accordingly, the spalling of TBCs is mainly induced by oxidation and element diffusion during its long-term service. Coatings 2020, 10, 1022; doi:10.3390/coatings10111022 www.mdpi.com/journal/coatings Coatings 2020, 10, x FOR PEER REVIEW 2 of 19 CoatingsCoatings 20202020,,10 10,, 1022x FOR PEER REVIEW 22 ofof 1919 Figure 1. Schematic diagram of the typical service conditions of aero-engines and heavy-duty gas Figureturbines. 1. T is the initial temperature. Figure 1. SchematicSchematic0 diagramdiagram of thethe typicaltypical serviceservice conditionsconditions ofof aero-enginesaero-engines andand heavy-dutyheavy-duty gasgas turbines. T0 is the initial temperature. turbines. T0 is the initial temperature. Both oxidation and element diffusion involve long-term atomic exchange processes and exhibit Both oxidation and element diffusion involve long-term atomic exchange processes and exhibit the slow evolution behaviors of material. A typical BC composition is MCrAlY (M = Ni, Co, NiCo) the slowBoth evolution oxidation behaviors and element of material. diffusion A involve typical BClong-term composition atomic is MCrAlYexchange (M processes= Ni, Co, and NiCo) exhibit [8]. [8]. During the long-term oxidation of TBCs, firstly, Al in the BC reacts with the inward O and then Duringthe slow the evolution long-term behaviors oxidation of of material. TBCs, firstly, A typica Al inl theBC BCcomposition reacts with isthe MCrAlY inward (M O and= Ni, then Co, slowlyNiCo) slowly forms a dense α-Al2O3. Then, with the continuous proceeding of oxidation, Al near the forms[8]. During a dense theα -Allong-termO . Then, oxidation with the of continuous TBCs, firstly, proceeding Al in the of BC oxidation, reacts with Al nearthe inward the reaction O and region then reaction region is2 almost3 depleted. While other alloy elements, e.g., Ni and Co, continue to be isslowly almost forms depleted. a dense While α-Al other2O3. Then, alloy elements,with the e.g.,continuous Ni and proceeding Co, continue of tooxidation, be oxidized, Al near and thethe reactionoxidized, region and the is formedalmost depletα-Al2Oed.3 is While consumed other throughalloy elements, the reaction e.g., NiNi +and O +Co, α-Al continue2O3 = NiAl to2 Obe4, formed α-Al2O3 is consumed through the reaction Ni + O + α-Al2O3 = NiAl2O4, accordingly the porous accordingly the porous mixed oxide (MO), which comprises NiO, Cr2O3 and (Ni, Co)(Cr, Al)2O4 [9], mixedoxidized, oxide and (MO), the formed which comprisesα-Al2O3 is NiO,consumed Cr O throughand (Ni, the Co)(Cr, reaction Al) ONi [+9 ],O forms+ α-Al rapidly2O3 = NiAl [10,211O].4, forms rapidly [10,11]. As a result, the mechanical2 3 performance of the2 4 BC changes significantly, Asaccordingly a result, the the mechanical porous mixed performance oxide (MO), of thewhich BC changescomprises significantly, NiO, Cr2O3 which and (Ni, is detrimental Co)(Cr, Al)2 forO4 the[9], which is detrimental for the reliability and durability of TBCs [12–14]. Thus, clarifying the reliabilityforms rapidly anddurability [10,11]. As of TBCsa result, [12 –the14]. mechanical Thus, clarifying performance the long-term of the failure BC changes mechanism significantly, is helpful long-term failure mechanism is helpful for us to evaluate the service performance and predict the forwhich us to is evaluate detrimental the service for the performance reliability and and predict durability the lifetime of TBCs of TBCs [12–14]. in heavy-duty Thus, clarifying gas turbines. the lifetime of TBCs in heavy-duty gas turbines. long-termGenerally, failure oxidation mechanis andm elementis helpful di ffforusion us to are evaluate a continuous the service and related performance process and [2]. Afterpredict TBCs the Generally, oxidation and element diffusion are a continuous and related process [2]. After operatelifetime atofthe TBCs elevated in heavy-duty temperature, gas turbines. under the driving of the difference in chemical potential between TBCsGenerally, operate at oxidation the elevated and temperature, element diffusion under tharee drivinga continuous of the differenceand related in chemicalprocess [2]. potential After the external reservoir, e.g., O2 and coating, the guest atoms, e.g., O, leave the external reservoir and between the external reservoir, e.g., O2 and coating, the guest atoms, e.g., O, leave the external insertTBCs intooperate coating at the at theelevated boundary. temperature, Subsequently, under thethe guestdriving atoms of the continue difference to di inffuse chemical forwards potential in the reservoir and insert into coating at the boundary. Subsequently, the guest atoms continue to diffuse coatingbetween until the theyexternal reach reservoir, the reaction e.g., region, O2 and as coating, shown inthe Figure guest2. atoms, When thee.g., guest O, leave atoms the encounter external forwards in the coating until they reach the reaction region, as shown in Figure 2. When the guest thereservoir outward and alloy insert elements, into coating e.g., at Al the and boundary. Ni, new Subsequently, oxides form and the significantguest atoms stress continue occurs to diffuse due to atoms encounter the outward alloy elements, e.g., Al and Ni, new oxides form and significant stress theforwards surrounding in the coating constraint. until The they induced reach the stress reacti noton only region, causes as theshown failures in Figure of TBCs 2. When but also the a ffguestects occurs due to the surrounding constraint. The induced stress not only causes the failures of TBCs theatoms diff encounterusion and the oxidation outward processes. alloy elements, Thus, oxidation e.g., Al and and Ni, di ffnewusion, oxides as a form whole, and are significant responsible stress for but also affects the diffusion and oxidation processes. Thus, oxidation and diffusion, as a whole, are long-termoccurs due failure to the mechanisms surrounding of cons TBCstraint. in heavy-duty The induced gas stress turbines. not only causes the failures of TBCs butresponsible also affects for thelong-term diffusion failure and mechanismsoxidation processes. of TBCs Thus,in heavy-duty oxidation gas and turbines. diffusion, as a whole, are responsible for long-term failure mechanisms of TBCs in heavy-duty gas turbines. FigureFigure 2.2. SchematicSchematic diagramdiagram ofof oxidationoxidation andand thethe didiffusiffusionon ofof guestguest atomsatoms inin thethe long-timelong-time serviceservice process of thermal barrier coatings (TBCs) in heavy-duty gas turbines. Figureprocess 2. of Schematic thermal barrier diagram coatings of oxidation (TBCs) andin heavy-duty the diffusi gason ofturbines. guest atoms in the long-time service process of thermal barrier coatings (TBCs) in heavy-duty gas turbines. Coatings 2020, 10, 1022 3 of 19 Coatings 2020, 10, x FOR PEER
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