PERFORMANCE EVALUATION AND MODELING OF EROSION RESISTANT TURBINE ENGINE THERMAL BARRIER COATINGS
Dr. Robert A. Miller, Dr. Dongming Zhu, and Dr. Maria Kuczmarski
NASA Glenn Research Center Cleveland, Ohio 44135
Abstract The erosion resistant turbine thermal barrier coating system is critical to the rotorcraft engine performance and durability. The objective of this work was to determine erosion resistance of advanced thermal barrier coating systems under simulated engine erosion and thermal gradient environments, thus validating a new thermal barrier coating turbine blade technology for future rotorcraft applications. A high velocity burner rig based erosion test approach was established and a new series of rare earth oxide- and TiO2/Ta2O5-alloyed, ZrO2-based low conductivity thermal barrier coatings were designed and processed. The low conductivity thermal barrier coating systems demonstrated significant improvements in the erosion resistance. A comprehensive model based on accumulated strain damage low cycle fatigue is formulated for blade erosion life prediction. The work is currently aiming at the simulated engine erosion testing of advanced thermal barrier coated turbine blades to establish and validate the coating life prediction models.
https://ntrs.nasa.gov/search.jsp?R=20130013140 2020-06-08T03:17:43+00:00Z
1Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Performance Evaluation and Modeling of Erosion Resistant Turbine Engine Thermal Barrier Coatings
Dr. Robert A. Miller, Dr. Dongming Zhu *, Dr. Maria Kuczmarski
Structures and Materials DivisionNASA Glenn Research Center
Cleveland, Ohio
* Army Research Laboratory at NASA Glenn Research Center; Presenter
NASA Fundamental Aeronautics Program Annual Meeting, Atlanta, Georgia,October 7 - 9, 2008
2Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Motivation
— Innovative turbine coating and component materials are enabling technologies for advanced rotorcraft engine development
— Durable thermal barrier coating (TBC) technology is especially crucial for improving rotorcraft engine performance and reliability
Combustors and shrouds
Turbine vanes and
blades
Component technologies for reduced engine specific fuel consumption, increased power density, and reduced
maintenance cost
Ceramic coating
Ceramic coating
SubstrateSubstrateBond coat
Bond coat
Tgas
Tsurface
Tgas
Tsurface
TbackTback
Ceramic coating
Ceramic coating
SubstrateSubstrateBond coat
Bond coat
Tgas
Tsurface
Tgas
Tsurface
TbackTback
Ceramic coating
Ceramic coating
SubstrateSubstrateBond coat
Bond coat
Tgas
Tsurface
Tgas
Tsurface
TbackTback
(a) Current TBCs (b) Advanced TBCs
Advanced TBCs can significantly increase turbine inlet temperature and
thus efficiency
3Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Erosion Resistant Thermal Barrier Coatings for Improved Turbine Blade Life
• Objective─ Develop erosion resistant turbine blade thermal barrier coatings─ Develop physics-based life model and design tools for predicting blade coating erosion and degradation under simulated engine environments
• Approach─ Establish advanced erosion high-heat-flux test rigs for turbine TBC evaluations─ Develop advanced thermal barrier coatings based on nano-tetragonal t’ phase toughening approaches─ Advanced mechanism- and physics-based modeling
• Benefits─ Facilitate turbine thermal barrier coating design and applications─ Improve erosion resistance and durability─ Increase turbine temperature capability by 300˚F leading to higher fuel efficiency─ Establish advanced modeling methodologies Typical turbine airfoil
thermal barrier coating
25 µm
Ceramic coating
Bond coat
4Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Outline
• High temperature erosion testing development─ High velocity burner erosion rig simulating engine environments─ Computational Fluid Dynamics (CFD) modeling ─ Experimental validation of high temperature erosion testing
• Low conductivity turbine thermal barrier coating developments─ Low conductivity TBC design approach─ High toughness erosion resistant turbine airfoil TBC development─ Calcium-magnesium-alumino-silicate (CMAS) interaction testing
• Coating Performance and Life Prediction─ High toughness turbine erosion coating modeling─ Sintering-creep, oxidation and thermo-mechanical fatigue mechanisms
• Future Plans• Summary
5Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
High Velocity Burner Erosion Rig
─ Burner capable of up to Mach 1 velocity with erodent particulate injection
─ 0.75” to 1” diameter exhaust nozzle─ Temperature up to 2200˚F ─ Thermal gradient erosion testing─ Flexible test configurations
- 1” and 2” diameter disk specimens- Coated turbine blades
Mach 0.3-1.0 burner erosion rigSpecimens in testing
6Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Computational Fluid Dynamics (CFD) Modeling
─ Computational Fluid Dynamics (CFD) modeling predicting burner flow and particle velocities in conjunction with experiment validation
0
100
200
300
400
500
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Mach 0.4, 50 micron particlesMach 0.4, 560 micron particlesMach 0.9, 50 micron particlesMach 0.9, 560 micron particles
Parti
cle
velo
city
, m/s
Distance from injector, m
nozzle exit
specimen location
Gas velocity m/s
Mach 0.9
Mach 0.4
Maximum velocity 754 m/s
Maximum velocity 344 m/s
High speed camera image for particle trajectories
7Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Modeling of Erodent Particle Trajectories and Coating Erosion Test Approach
─ Erosion particulate trajectories modeled to understand high temperature erosion test configuration
─ The test rig demonstrated in coating erosion screening tests
- Examples of eroded 1” diameter disk specimens- Erosion crater profiles similar to those in erosion
standard G76-05 for coating downselect An erosion crater profile after testing
Modeled for 27 micron erodent
8Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Erosion Resistant Low Conductivity Thermal Barrier Coatings
─ Multi-component oxide defect clustering approach (Zhu and Miller, US Patents No. 6,812,176, No.7,001,859, and 7,186,466; US patent application 11/510,574 )
─ Lower thermal conductivity and improved thermal stability
EELS elemental maps of EB-PVD ZrO2-(Y, Gd,Yb)2O3
TEM Moiré fringes of EB-PVD ZrO2-(Y, Nd,Yb)2O3
e.g.: ZrO2-Y2O3-Nd2O3(Gd2O3,Sm2O3)-Yb2O3(Sc2O3) – TiO2-Ta2O5 systemsPrimary stabilizer
Oxide cluster dopants with distinctive ionic sizesToughening dopants
Advanced turbine WDS composition maps
O Yb
Zr
9Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Thermal Conductivity of Advanced Turbine Thermal Barrier Coatings
10Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Impact Resistant Low Conductivity Thermal Barrier Coatings
– Tetragonal t’ phase toughened low conductivity coatings showed improved impact resistance compared to the cubic-phase coatings in impact tests
11Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Erosion Resistance of Low Conductivity Thermal Barrier Coatings
– Tetragonal t’ phase toughened low conductivity coatings showed improved 50 micron size particulate erosion resistance compared to the cubic-phase coatings in erosion tests
12Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Erosion Resistance of Low Conductivity Thermal Barrier Coatings
– Advanced processing showed promise in improving 27 micron particle erosion resistance of low conductivity TBCs
13Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Physics-Based Erosion Model Development
– Physics-based erosion models being developed to predict turbine TBC erosion and degradation behavior
– Multiple physics-base processes and mechanisms considered
- Turbine TBC sintering and creep - Erosion (erosion fatigue mechanism) - Low cycle fatigue- Molten Calcium Magnesium Alumino-Silicate (CMAS) interactions
Variable erosion rates during the erosion process under high-heat-flux and thermal gradient cyclic conditions
14Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Sintering Cracks and Delaminations of Thermal Barrier Coatings
— Baseline ZrO2-7wt%Y2O3 turbine coating tested under laser simulated engine heat flux conditions
— Sintering strain corresponding to the thermal gradient across the coating (Tsurface=1280˚C , Tinterface=1095˚C )
— Coating delamination under high-heat-flux cyclic environments
0.00
0.50
1.00
1.50
2.00
0 50 100 150 200 250
0 hr46 hr200 hrmean strain
Surf
ace
open
ing
stra
in, %
Time, hours
strain (in%) = 0.40757 + 0.41 · t (in hr) 0.2
100 µm
15Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Modeled Sintering-Creep Strains as a Function of Temperature and Time
0.5
0.5
0.5
1
1
1
1.5
1.5
1.5
2
22
2.5
2.5
3
3
3.5
3.5
4
4
4.5
4.5
5
5
5.5
5.5
6
6
6.5
6.5
7
7
7.5
7.5
8
8
8.5
8.5
9
9
9.5
9.5
10 10.5 11 11.5
00
01000
1100
1200
1300
1400
1500
0 60 120
180
240
300
360
420
480
540
600
660
720
780
840
900
960
1020
1080
1140
1200
1260
1320
1380
1440
1500
TBC
surf
ace
tem
pera
ture
, °C
Time, hours
Sintering/creep cyclic fatigue dominant failure
Erosion dominant failure
— Erosion dominant region vs. sintering-creep dominant region— Strong interactions in accelerated damage accumulation
16Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Impact Failure of Advanced Multi-Component Low Conductivity Thermal Barrier Coatings
30 um30 um
Surface sintering and impact densification zone
SEM micrographs of advanced thermal barrier coating after impact/erosion damage
Backscattered electron imageSecondary electron image
― Surface sintering and impact densification zone interaction, with subsequent spallation
17Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Erosion Damage Accumulations
― Multi-level delaminations under combined erosion impact loading and thermal gradients
18Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Erosion Rates
Erosion rate (mg/g erodent) in erosion dominant regime – dynamic impact effect will be incorporated
─ Fatigue strain based models incorporate multiple mechanisms
2/32
32/1
Hv
Kec
erodentTBCTBC
⋅
⋅⋅⋅=
⋅
ερρ
cfoxidationpLCFpfluxheatpcreepperosionp N εεεεεε =⋅∆∆∆∆∆Σ −−−−−2/1
_ ),, ,,(
The erosion model development and validation: Emphasizing more realistic testing condition
and mechanisms interactions
KerodentTBC ρρ ,
cε
H
- Constant
- Densities of coating and erodent, respectively
- Critical strain to failure
- Dynamic hardness
cferosionp N εε =⋅∆ −2/1
19Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Additional Failure Driving Forces
─ Fatigue strain based models incorporate multiple mechanisms─ Elastic modulus and activation energies determined from experiments
( )( )211 1 0
1
116 1 SG E h T Tν α
ν +
= − −
2
2
/ 2[ (1 ) /(1 )]( ) / 2
G h EEh Tσ
ν ν α
=
= + − ∆ ∆
- Thermal expansion mismatch
- High heat-flux effect
- Creep and oxidation
( ) ssvolumep tx
RTQQ
A −⋅⋅
+−⋅= σε exp&
+−⋅= −−
− RTQQ
B oxGBoxVolumeoxp expε&
1 1,E ν
2 2,E ν
hP∆
M∆
interfacedelamination crack
σ
coating
substrate
20Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Laser High Heat Flux Rig for Molten Sand Erosion and CMAS Interactions
─ CMAS effect taken into account for coating development ─ Accelerated failure observed with CMAS interactions─ Modeling emphasis on coating densification and resulting delamination
failure
Specimen under the rig test
(a) Upon initial heating
(b) After testing
Combustor TBC
(c) Baseline coating
Turbine TBCs
(d) Advanced coating50 hrs
Erosion jet
21Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Plans
• Emphasize burner erosion resistance and coating life models
- Optimize high toughness erosion resistant turbine coatings
- Investigate and model erosion, creep, fatigue, and CMAS interactions
- Develop methodologies and key experiments for model validation
- Develop turbine blade TBC erosion-oriented life prediction models and design tools
22Fundamental Aeronautics Program Annual Meeting, October 7-9, 2008 Subsonic Rotary Wing Project
Summary
• High temperature erosion testing capability developed under the Subsonic Rotary Wing project
• CFD models established to understand gas and erodent flows
• Advanced turbine thermal barrier coatings developed for rotorcraft engines with combined low conductivity and high toughness
• Models formulated addressing the erosion, sintering and fatigue interactions – strain damage accumulations
• Physics-based turbine blade coating erosion lifing models and model validation emphasized in the current efforts