Abstract
To protect the superalloy blades in industrial gas turbine engines from failure Atmospheric plasma-sprayed YSZ (yttria-stabilized zirconia) thermal barrier coatings (TBCs) are widely used. The spalling of YSZ coating is the main failure of TBCs. This failure usually occurs within the YSZ coating near the YSZ/bond coat interface. In the present feasibility study, a novel durable multilayer TBC was fabricated using atmospheric plasma spray (APS) on Ni718 superalloy substrate consisting of a NiCrAlY-20%YSZ- MoSi2 top coat. The developed system introduces a protective top layer of MoSi2 for preventing diffusion of oxygen, oxidation of the bond coating, provides thermal insulation and protection against corrosion and high temperature erosion. The results of hot gas flow exposure test (H2+O2) to the triple layered coating, a kinetic heating study, showed that a decreased temperature 400 °C for heating of 145 second achieved without any visible damage or delamination in such drastic combustion condition exposure even after 27 cycles of such repeated exposure.
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