THERMAL SPRAY OF STUHSPEERMALNSIONS S& PSORLAUYTIONS OF SUSPESYMPOSIUMNSIONS & S O(TS4)LUTIONS SYMPOSIUM (TS4) DECEMBER 2-3 , 2 0 1 5 MONTDECEMBERR E A L, 2- C3A,NAD 2 0 1A5 MONTR E A L, CA NADA E E D D C C B B A A Organzied by: TS415_InsidePages.indd 1 11/24/2015 10:33:16 AM ABOUT THE EVENT This special symposium is a chance for scientists and engineers interested in the emerging S&STS technologies to address both research challenges and development of industrial applications. The symposium will comprise a bal- anced group of speakers from industry, academia and national laboratories. Attendees will be coming from all over the world: Canada, United States, Japan, France, Germany, South Korea, Sweden, and Finland. GENERAL INFORMATION REGISTRATION SCHEDULE Day/Date Hours Location Tuesday, December 1, 2015 4:00–6:00 p.m. Soprano Foyer, 4th Floor Wednesday, December 2, 2015 7:00 a.m.–5:00 p.m. Soprano Foyer Thursday, December 3, 2015 7:00 a.m.–4:00 p.m. Soprano Foyer EXHIBIT DATES AND TIMES Soprano Foyer, 4th Floor Wednesday, December 2 Refreshment Break: 10:00–10:30 a.m. Lunch: 12:00–1:00 p.m. 2 Refreshment Break: 3:00–3:30 p.m. Networking Reception and Dinner: 6:00–8:00 p.m. Thursday, December 3 Refreshment Break: 10:00–10:30 a.m. Lunch: 12:00–1:00 p.m. Refreshment Break: 2:30–3:00 p.m. ORGANIZING COMMITTEE Brian Callen, Oerlikon Metco, Canada Ali Dolatabadi, Concordia University, Canada Brian Hazel, Pratt & Whitney, United States Luc Leblanc, GE-Fuel Cells, United States Rogerio Lima, National Research Council of Canada Christian Moreau, Concordia University, Canada Filofteia-Laura Toma, Fraunhofer Institute for Material and Beam Technology IWS, Germany TS415_InsidePages.indd 2 11/24/2015 10:33:26 AM TECHNICAL PROGRAM SCHEDULE WEDNESDAY, DECEMBER 2, 2015 Time Activity Presenter Institution Room Soprano AB, 8:00–8:15 a.m. Welcoming Remarks: Rogerio Lima/Christian Moreau 4th Floor Keynote Presentation: Suspension Plasma Spraying of TBCs for Industrial Gas Turbines Ramesh Soprano AB, 8:15–9:00 a.m. Siemens Energy Inc. Chair: Rogerio Lima, National Research Subramanian 4th Floor Council of Canada SESSION 1: TBCs Engineered via Suspensions & Solutions Chair: Brian Hazel, Pratt & Whitney Influence of Coating Morphology on Thermal Properties and Thermal Cyclic Lifetime Nicolaie 9:00–9:30 a.m. University West Soprano AB of Axial Suspension Plasma Sprayed Markocsan Thermal Barrier Coatings Low Conductivity GdZr/YSZr Bilayer Thermal 9:30– University of Barrier Coating Made by the Solution Eric Jordan Soprano AB 10:00 a.m. Connecticut Precursor Plasma Spray Process 10:00– Refreshment Break with Exhibitors Soprano Foyer 10:30 a.m. SESSION 2: Suspension Thermal Spraying—Process Control & Reliability Chair: Luc Leblanc, GE-Fuel Cells 10:30– Engineering Coating Structure By Suspension Christian Moreau Concordia University Soprano AB 11:00 a.m. Plasma Spray 11:00– Rapid Formation of Fine Ceramic Layers 3 Soshu Kirihara Osaka University Soprano AB 11:30 a.m. by Thermal Nanoparticle Spraying 11:30 a.m.– Numerical Simulation of Suspension Ali Dolatabadi Concordia University Soprano AB 12:00 p.m. Thermal Spray Processes Soprano C 12:00–1:00 p.m. Lunch with Exhibitors and Foyer SESSION 3: Suspensions & Solutions—Opportunities and Steps to Industrial Commercialization Chair: Brian Callen, Oerlikon Metco Industry Considerations in Spraying of 1:00–1:30 p.m. Brian Hazel Pratt & Whitney Soprano AB Suspensions 1:30–2:00 p.m. Is Suspension Plasma Spray a Solution? Luc Leblanc GE-Fuel Cells Soprano AB Lessons for Commercializing Suspension and 2:00–2:30 p.m. Kent VanEvery Progressive Surface Soprano AB Solution Plasma Spraying From Columnar Thermal Barriers to Dense 2:30–3:00 p.m. Coatings-Suspensions for Thermal Spray Nicholas Curry Treibacher Industrie AG Soprano AB Coating Applications 3:00–3:30 p.m. Refreshment Break with Exhibitors Soprano Foyer SESSION 4: Suspension Spraying Processing—Economical & Technical Challenges Chair: Christian Moreau, Concordia University Fraunhofer Institute Demands, Potentials and Economic Aspects of Filofteia-Laura 3:30–4:00 p.m. for Material and Beam Soprano AB Thermal Spraying with Aqueous Suspensions Toma Technology Development of Suspension Plasma Spray Processes Ghislain Univ. Bourgogne 4:00–4:30 p.m. Soprano AB at Atmosphere and at Low Pressure (100 Pa) Montavon Franche-Comté Axial Suspension Plasma Spraying: Northwest Mettech 4:30–5:00 p.m. Zhaolin Tang Soprano AB Its Development and Application Corporation Soprano C 6:00–8:00 p.m. Networking Reception and Dinner with Exhibitors and Foyer TS415_InsidePages.indd 3 11/24/2015 10:33:30 AM THURSDAY, DECEMBER 3, 2015 Time Activity Presenter Institution Room 8:00–8:15 a.m. Opening Remarks Soprano AB Keynote Presentation: High Velocity Flame Spraying of Nano-structured Materials and University of 8:15–9:00 a.m. Rainer Gadow Soprano AB Related Industrial Applications Stuttgart Chair: Laura Toma (Fraunhofer IWS) SESSION 5: Suspension Engineered TBCs—Processing & Properties Chair: Brian Hazel, Pratt & Whitney National Suspension Plasma Spray (SPS) as an Emerging Institute for 9:00–09:30 a.m. Seiji Kuroda Soprano AB Process for Thermal Barrier Coatings Materials Science Columnar & Porous SPS YSZ Thermal Barrier National 9:30– Coatings Deposited at Traditional Air Plasma Research Dina Goldbaum Soprano AB 10:00 a.m. Spray Distances—A Study on Microstructural Council of Evolution and Thermal Conductivity Canada 10:00– Refreshment Break with Exhibitors Soprano Foyer 10:30 a.m. SESSION 6: Suspension Engineered TBCs—Performance & Evaluation Chair: Ali Dolatabadi, Concordia University Comparison of APS, SPS and EB-PVD YSZ 10:30– Coating Characteristics for Advanced Brian Callen Oerlikon Metco Soprano AB 11:00 a.m. Thermal Barrier Coatings 11:00– Evaluation of SPS YSZ Coating Performance Progressive 4 Kent VanEvery Soprano AB 11:30 a.m. in Thermal Barrier Applications Surface 11:30 a.m.– Performance of Columnar 7–8wt% YSZ SPS Christopher Praxair Surface Soprano AB 12:00 p.m. Coatings as a Function of Heat-Treatment Petorak Technologies 12:00–1:00 p.m. Lunch with Exhibitors Soprano C and Foyer SESSION 7: Suspension/Solution Applications & System Development Chair: Luc Leblanc, GE-Fuel Cells Use of Suspension and Solution Precursor University of 1:00–1:30 p.m. Plasma Spraying for Solid Oxide Fuel Cell Olivera Kesler Soprano AB Toronto Applications Effects of SPPS Deposition Conditions on University of 1:30–2:00 p.m. the Structure and Wetting Behaviour of a Thomas Coyle Soprano AB Toronto Superhydrophobic Ceramic Coating National Institute of Advanced Microstructure Control of SPS Ceramic Coating 2:00–2:30 p.m. Masato Suzuki Industrial Soprano AB with an Axial Feed Plasma Spray Gun Science and Technology (AIST) 2:30–3:00 p.m. Refreshment Break with Exhibitors Soprano Foyer Round Table Discussion Moderators: Rogerio Lima, National 3:00–4:00 p.m. Soprano AB Research Council of Canada and Christian Moreau, Concordia University 4:00 p.m. Conclusion TS415_InsidePages.indd 4 11/24/2015 10:33:30 AM ABSTRACTS with time at high temperature. The results showed SUSPENSION PLASMA SPRAYING OF significant influence of coating morphology on ther- mal conductivity and thermal-cyclic performance of TBCS FOR INDUSTRIAL GAS TURBINES the coatings. Also, significant microstructural changes Siemens Energy Inc. Ramesh Subramanian, were noticed during the heat treatment such as pore- Siemens Industrial Turbomachinery Xin-Hai Li, rearrangement and sintering. The push to higher firing temperatures, increased efficiencies, reduced emissions and multiple fuel capa- bility continues to demand more out of gas turbine de- LOW CONDUCTIVITY GdZr/YsZr sign and materials systems capabilities. Thermal bar- BILAYER THERMAL BARRIER COATING rier coatings are an integral part of many hot section turbine components, contributing one of the key func- MADE BY THE SOLUTION PRECURSOR tions of thermal protection, especially with increas- ing firing temperatures. Strain tolerance is one of the PLASMA SPRAY PROCESS key TBC characteristics necessary for increasing high Eric H. Jordan, Chen Jiang, and Maurice Gell University of Connecticut temperature operations. Suspension plasma spray Storrs, CT, USA processes offer a unique path to manufacturing strain tolerant, low thermal conductivity TBCs. Thermal con- The, low thermal conductivity, high temperature ductivity and cyclic lives depend strongly on the micro- stability and good CMAS resistance of gadolinium structures, which are different from conventional plas- zirconate (GZO) are well-documented. Gadolinium zi- ma sprayed TBCs. Furthermore, it has been seen that conate is more expensive than yttria stabilized zirconia spallation life times depend on bond-coat type, chem- (YSZ) and has lower fracture toughness. The advan- istry, and surface roughness. Results from efforts in SPS tages of GZO can be achieved and the disadvantage TBCs, performed by Siemens Gas Turbines division in minimized by fabricating a bilayer TBC consisting of an Sweden, will be presented and future outlook will be inner layer of YSZ and outer layer of GSO. A low thermal discussed for this emerging manufacturing approach. conductivity (0.62 W/mK) YSZ coating with structured porosity was deposited using the solution precursor plasma spray process (SPPS) then an SPPS GZO layer 5 INFLUENCE OF COATING was put on top. Cyclic furnace tests, two types of CMAS MORPHOLOGY ON THERMAL resistance tests and steam environment tests were run. No failures were observed at the GZO to YSZ interface PROPERTIES AND THERMAL in any of the tests. It was also found that GZO top layer coatings had greatly superior CMAS resistance when CYCLIC LIFETIME OF AXIAL the CMAS was put on all at once at the start of a cyclic SUSPENSION PLASMA SPRAYED furnace testing but performed no better than YSZ in tests where CMAS precursor was applied every cycle.