Abstract
An increase in the efficiency of gas turbines results in higher thermal loads. Open porous metallic foams coated with a thermal barrier coating (TBC) and a dense array of laser drilled cooling holes are very promising for the realization of effusion cooling. Application of TBCs on such substrates has not been reported so far. Here, the application of TBCs using air plasma spraying (APS) and high velocity oxygen fuel (HVOF) on such substrates is researched. A TBC consisting of a metallic bond coat and a ceramic top coat is deposited. The results show that the application of TBCs on open porous foams is possible. However, a uniform coating growth is primarily linked to the pore sizes. In the case of large pores, the required coating thickness for a closed surface is leading to coating delamination caused by extensive tensile residual stresses.
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