Research Papers

Preparation and Distribution Analysis of Thermal Barrier Coatings Deposited on Multiple Vanes by Plasma Spray-Physical Vapor Deposition Technology

[+] Author and Article Information
J. Mao

Guangdong Institute of New Materials,
National Engineering Laboratory for Modern
Materials Surface Engineering Technology,
The Key Lab of Guangdong for Modern Surface
Engineering Technology,
Guangzhou 510651, China
e-mail: jmao0901@163.com.cn

M. Liu, C. G. Deng, C. M. Deng, K. S. Zhou, Z. Q. Deng

Guangdong Institute of New Materials,
National Engineering Laboratory for Modern
Materials Surface Engineering Technology,
The Key Lab of Guangdong for Modern Surface
Engineering Technology,
Guangzhou 510651, China

1Corresponding author.

Contributed by the Materials Division of ASME for publication in the JOURNAL OF ENGINEERING MATERIALS AND TECHNOLOGY. Manuscript received August 31, 2016; final manuscript received February 28, 2017; published online May 16, 2017. Assoc. Editor: Tetsuya Ohashi.

J. Eng. Mater. Technol 139(4), 041003 (May 16, 2017) (7 pages) Paper No: MATS-16-1250; doi: 10.1115/1.4036584 History: Received August 31, 2016; Revised February 28, 2017

The multicomponent NiCoCrAlTaY coating as bond layer as well as the zirconia stabilized by yttrium oxide (YSZ) coating as top ceramic layer was deposited on duplex vane surface by plasma spray-physical vapor deposition (PS-PVD) system. The thickness and microstructure of thermal barrier coatings (TBCs) under the influence of duplex vane geometry were presented in this article. It has been proven that the entire surface of duplex vane was covered by NiCoCrAlTaY and YSZ coatings. The position with thickest coating was found close to the leading edge and trailing edge of the vane. In those places, the coating was approximately 80–100% thicker than in the other areas on duplex vane. The obtained results indicate that it is possible to manufacture the TBCs including metallic bond layer and top ceramic layer by PS-PVD process on multiple vanes for gas turbines.

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Fig. 1

MultiCoat hybrid plasma-coating system at GINM

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Fig. 2

Three-dimensional sketch of simplified duplex vane model with parallel platforms and solid airfoils made of DZ40M alloy

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Fig. 3

Measuring point distribution on the duplex vane model

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Fig. 4

Typical lamellar NiCoCrAlTaY coatings deposited at different positions

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Fig. 5

NiCoCrAlTaY coating thickness distribution of a PS-PVD-coated duplex vane model

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Fig. 6

Featherlike YSZ coatings deposited at different positions by PS-PVD

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Fig. 7

Representative featherlike structure and fine spherical particles in the gaps

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Fig. 8

YSZ coating thickness distribution of a PS-PVD-coated duplex vane model

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Fig. 9

Schematic graph of PS-PVD nonline-of-sight deposition characteristic



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