Performance and Steady State Heat Transfer Analysis of Functionally Graded Thermal Barrier Coatings Systems

Abstract

Thermal barrier coatings (TBC’s), typically 8 wt.% Yttria Stabilized Zirconia (8YSZ), in single layered configuration have been traditionally used in aerospace components to protect them from degradation at high temperatures and to improve the thermal efficiency of the system. This paper compares the performance of two types of TBC configurations: single layered and multilayered functionally graded materials (FGM). Aerospace alloy, Inconel 718 substrates, NiCrAlY bond coat (BC) and 8YPSZ top coat (TC) were the materials used. FGM configuration was used to improve the durability and life of the conventional TBC system by reducing the coefficient of thermal expansion (CTE) mismatch. The TBCs were subjected to thermal fatigue (thermal shock and thermal barrier test) in laboratory scale burner rig test and oxidation stability test in high temperature furnace upto 1000°C. The as-sprayed and thermal fatigue tested specimen were characterized by X-ray diffraction (XRD) analysis and Scanning Electron Microscope (micro-structure). Results are discussed in the light of suitability of coating configuration, thermal fatigue and spalling characteristics with reference to aerospace applications at temperatures in the 900°C to 1500°C range. Computational work was carried out comprising a simulation model involving the developed TBCs..