Characterization of mechanical properties of aluminized coatings in advanced gas turbine blades using a small punch method

Abstract

Advanced technologies of superalloy casting and coatings enable one to enhance the performance of combined cycle gas turbines for electric power generation by increasing the firing temperature. This paper describes examination of the microstructure/composition and mechanical properties (22--950 C) in aluminized CoCrAlY coatings of advanced gas turbine blades using scanning Auger microprobe and a small punch (SP) testing method. Aluminized coatings consisted of layered structure divided into four regimes: (1) Al enriched and Cr depleted region, (2) Al and Cr graded region, (3) fine grained microstructure with a mixture of Al and Cr enriched phases and (4) Ni/Co interdiffusion zone adjacent to the interface. SP specimens were prepared in order that the specimen surface would be located in the various coating regions. SP tests indicated strong dependence of the fracture properties on the various coatings regimes. Coatings 1 and 2 with very high microhardness showed much easier formation of brittle cracks in a wide temperature range, compared to coatings 3 and 4 although the coating 2 had ductility improvement at 950 C. The coating 3 had lower room temperature ductility than the coating 4. However, the ductility in the coating 3 exceeded that in the region 4 above 730 Cmore » due to a precipitous ductility increase. The integrity of aluminized coatings while in-service is discussed in light of the variation of the low cycle fatigue life as well as the ductility in the layered structure.« less