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Author:

Wu, Yang (Wu, Yang.) | Guo, Xingye (Guo, Xingye.) | He, Dingyong (He, Dingyong.) (Scholars:贺定勇)

Indexed by:

EI Scopus

Abstract:

Thermal barrier coatings (TBCs) are widely used in the hot-section components of gas-turbine engines to allow operation at higher temperatures (> 1 200 degrees C), which has created some new issues. One issue is the spallation and premature failure of TBCs caused by calcium-magnesium-alumino-silicate (CMAS) deposits, which arise from entry of siliceous debris such as fly ash, sand, dust, and volcanic ash into engines. Since 1953, over 130 jet aircraft have encountered volcanic ash clouds, with varying degrees of damage and endangering the lives of many passengers. The 2010 eruption of Eyjafjallajokull volcano in Iceland led to the most severe air-traffic disruption since World War II. The operational response produced economic losses approaching 1.7 billion. When these debris enter the hot-section airfoil, they melt and are accelerated from low speed (similar to 15 m / s) to near supersonic speed (similar to 300 m / s), impacting and adhering to the TBC surface. Even with only a few molten silicate ash droplets adhering to the surface of hot-section airfoils, an initial deposit layer can form and large melt pockets (several cubic centimeters in volume) can accumulate. Such deposits can 1) block cooling holes and air flow paths, and 2) react with the top coating of hot-section airfoils. Furthermore, adhering droplets infiltrate the interior of TBCs under capillary forces. Due to the thermal gradient and thermal cycling, the infiltrated CMAS solidifies and fills in the microcracks, pores, and grain boundaries, resulting in loss of strain tolerance and increased coating stiffness. For traditional 7-8 wt.% yttria-stabilized zirconia (YSZ) material, chemical reaction with CMAS destroys the phase and structure stability. YSZ grains dissolve and Y-depleted ZrO2 grains precipitate due to the relatively low solubility of Zr4+ compared with Y3+ in melted CMAS. Upon cooling, the newly formed grains transform from tetragonal (t) to monoclinic (m) phases, accompanied by a 3%-4% volume expansion. As turbine inlet temperatures improve and industry production grows, TBCs are suffering from severe CMAS corrosion. This issue limits further application and development of TBCs; enhancing anti-corrosion performance of TBCs has become a concern. Herein, we compare the room-temperature and high-temperature properties of different CMAS and study the failure mechanism of TBCs exposed to CMAS. We also determine the most effective CMAS protection method. The results show that the chemical compositions, especially the Ca:Si ratio, of CMAS such as volcanic ash, dust and sand are different, further affecting their high-temperature viscosities and melting behaviors. With infiltration of molten CMAS toward the coating interior, chemical reaction occurs between them, resulting in instability of the coating microstructure and properties, and failure. Significant methods including inert-layer, rare-earth doping and novel materials have been proposed to improve the CMAS corrosion resistance of TBCs. The research and future development directions of CMAS corrosion and protection are proposed, providing a reference for design of novel TBCs.

Keyword:

advanced aero-engines thermal barrier coatings(TBCs) corrosion protection calcium-magnesium-alumino-silicate(CMAS)

Author Community:

  • [ 1 ] [Wu, Yang]Beijing Univ Technol, Fac Mat & Mfg, Beijing 100124, Peoples R China
  • [ 2 ] [Guo, Xingye]Beijing Univ Technol, Fac Mat & Mfg, Beijing 100124, Peoples R China
  • [ 3 ] [He, Dingyong]Beijing Univ Technol, Fac Mat & Mfg, Beijing 100124, Peoples R China

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Source :

CHINA SURFACE ENGINEERING

ISSN: 1007-9289

Year: 2023

Issue: 5

Volume: 36

Page: 1-13

Cited Count:

WoS CC Cited Count: 0

SCOPUS Cited Count: 5

ESI Highly Cited Papers on the List: 0 Unfold All

WanFang Cited Count:

Chinese Cited Count:

30 Days PV: 1

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