Abstract
Thermal barrier coatings (TBC) have been used in both aero engines and industrial gas turbines for a few decades. However, the most commonly used MCrAlY bond coats which largely determine air plasma sprayed (APS) TBC lifetime are still deposited by the powders developed in 1980s. APS TBC has been found predominate failure within top coat near interface/or at interface with thermally grown oxides (TGO). TBC lifetime can be increased by either increasing top coat fracture strength (strain tolerance) or reducing the tensile stress in the top coat or both. By focusing on the reduction of tensile stress in the top coats, three new bond coat alloys have been designed and developed. More than doubled TBC lifetime has been achieved by using the new alloys as bond coat. Extended thermal cycle lifetime is attributed to the unique properties of the new alloys, such as remarkably lower coefficient of thermal expansion (CTE), lower weight fraction of β phase, lower aluminum migration rate and the absence of mixed/spinel TGO oxides.
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