Self Diagnostic EB-PVD Thermal Barrier Coatings

Abstract

Thermal barrier coatings (TBCs) are an enabling materials technology to improve the efficiency and durability of gas turbines and thus through such efficiency improvements offer reduce fuel usage and an associated reduction in CO2 emission. This commercial drive is pushing both aero- and industrial turbines to be lifetime dependent on TBC performance – the TBC must be “prime reliant”. However, the prediction of the durability of the TBC system has proved difficult, with lifetimes varying from sample to sample and component to component. One factor controlling this is the inability to measure accurately the bondcoat/ceramic interface temperature when buried under a TBC. In operating engines this is further exacerbated by the fact that such TBC systems operate in strong temperature gradients due to the need to cool aerofoil components. This research examines the design and manufacture of self diagnostic thermal barrier coatings capable of accurately measuring the interface temperature under the TBC, whilst providing the requisite thermal protection. Data on the temperature sensing capability of various rare earth doped EB-PVD thermal barrier coatings will be reported. It will be shown that systems exist capable of measuring temperatures in excess of 1300oC. Details of the measurement method, the compositions and the thermal stability of such systems will be discussed in this paper. The ability to produce a sensing TBC capable of measuring interface temperature, surface temperature and heat flux will further be discussed permitting the design of thermal barrier protected components capable of in-situ performance monitoring.