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High Temperature Material Processes: An International Quarterly of High-Technology Plasma Processes
OPTIMIZATION OF COATING THICKNESS FOR VARIOUS PROPERTIES OF COMPOSITE TYPE THERMAL BARRIER COATED WITH INCONEL 718 ALLOY
Department of Mechanical Engineering, Methodist College of Engineering,
Department of Mechanical Engineering, College of Engineering and Islamic
Architecture, Umm Al-Qura University, Makkah, Al-Abdiah, 24231, Kingdom
of Saudi Arabia
In the past, continuous improvements were made in the gas turbines field using several methods such as increasing the efficiency of reheating, regeneration, and intercooling stages. This required either high thermal resistant alloys or surface modification of conventional material. The latter method is inexpensive and effective. Thermal barrier coating is one surface modification methods for improving the performance of gas turbines. Various studies have been carried out either by taking different coating materials and their thicknesses, or by inmplementing different processes. In the current work, atmospheric plasma spray coating technique is used for depositing the ceramic material (8%YSZ−Cr2O3). The coating thickness is also varied by using different proportions of YSZ (yttria-stabilized zirconia) and Cr2O3 (chromium oxide) and analyzing various properties. The optimum thickness of coating is found from the experimental results for maximum temperature gradient across the material to increase the efficiency of a turbine by reducing the stress levels.
Aabid, A. and Khan, S.A., Optimization of Heat Transfer on Thermal Barrier Coated Gas Turbine Blade, Proc. of IOP Conf. Series: Materials Science and Engineering, vol. 370, May 2018.
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Bengtsson, P., Ericsson, T., and Wigren, J., Thermal Shock Testing of Burner Cans Coated with a Thick TBC, J. Therm. Spray Technol., vol. 7, no. 3, pp. 341-348, 1998.
Chraska, P., Dubsky, J., Neufuss, K., and Pisacka, J., Alumina-Base Plasma-Sprayed Materials. Part I: Phase Stability of Alumina and Alumina-Chromia, J. Therm. Spray Technol., vol. 6, no. 3, pp. 320-326, 1997.
Di, J., Liu, W., Xue, L., Zhou, Q., and Yan, Y., A Dense Cr2O3/Al2O3 Composite Ceramic Coating Prepared by Electrodeposition and Sealing with Al2O3, J. Coat. MDPI, vol. 9, no. 14, pp. 1-10, 2018.
Gleeson, B.M., Thermal Barrier Coatings for Aero Engine Applications, J. Propuls. Power, vol. 22, no. 2, pp. 375-383, 2006.
Guo, H.B., VaBen, R., and Stover, D., Atmospheric Plasma Sprayed Thick Thermal Barrier Coatings with High Segmentation Crack Density, J. Surf. Coat. Technol., vol. 186, no. 3, pp. 353-363, 2004.
Gupta, M., Curry, N., Nylen, P., Markocsan, N., and VaBen, R., Design of Next Generation Thermal Barrier Coatings-Experiments and Modeling, J. Surf. Coat. Technol., vol. 220, pp. 20-26, 2013.
Gurrappa, I. and Rao, A.S., Thermal Barrier Coatings for Enhanced Efficiency of Gas Turbine Engines, J. Surf. Coat. Technol., vol. 201, no. 6, pp. 3016-3029, 2006.
Kaspar, J. and Ambroz, O., Plasma Spray Coatings as Thermal Barriers Based on Zirconium Oxide with Yittrium Oxide, Proc. of 1st Plasma-Technik-Symposium, Lucerne, Switzerland, vol. 2, pp. 155-166, May 18-20, 1988.
Kim, Y., Lee, J., Song, H., Han, K., Koo, J., Lee, Y., and Seok, C., TBC Delamination Life Prediction by Stress-Based Delamination Map, J. Precis. Eng. Manufact.-Green Technol., vol. 4, no. 1, pp. 67-72, 2017.
Rahman, J.F. and Yunus, M., Benefits of TBC Coatings on Engine Applications, Proc. of Int. Conf., IN-CAM 2009, Kalsalingam University, Tamil Nadu, India, vol. 1, 2009.
Sohn, Y.H., Lee, E.Y., Nagaraj, B.A., Biederman, R.R., and Sisson, R.D., Jr., Microstructural Characterization of Thermal Barrier Coatings on High Pressure Turbine Blades, J. Surf. Coat. Technol., vols. 146-147, pp. 132-139, 2001.
Vassen, R., Tietz, F., Kerkhoff, G., and Stoever, D., New Materials for Advanced Thermal Barrier Coatings, Proc. of 6th Liege Conf. on Materials for Advanced Power Engineering, University de Liege, Belgium, November 1998.
Vorkottera, C., Macka, D.E., Guillonab, O., and VaBena, R., Superior Cyclic Life of Thermal Barrier Coat with Advanced Bond Coat on Single-Crystal Superalloy, J. Surf. Coat. Technol., vol. 361, no. 15, pp. 150-158, 2019.
Voyer, J., Gitzhofer, F., and Boulos, M.I., Study of the Performance of TBC under Thermal Cycling Conditions Using Acoustic Mission Rig, J. Therm. Spray Technol., vol. 7, no. 2, pp. 181-190, 1998.
Yang, K., Zhou, X., Zhao, H., and Tao, S., Microstructure and Mechanical Properties of Al2O3-Cr2O3 Composite Coatings Produced by Atmospheric Plasma Spraying, J. Surf. Coat. Technol., vol. 206, no. 6, pp. 1362-1371, 2011.
Yang, L., Liu, Q.X., Zhou, Y.C., Mao, W.G., and Lu, C., Finite Element Simulation on Thermal Fatigue of a Turbine Blade with Thermal Barrier Coatings, J. Mater. Sci. Technol., vol. 30, pp. 371-380, 2014.
Yunus, M., Alsoufi, M.S., and Irfan, M., Application of QC Tools for Continuous Improvement in an Expensive Seat Hardfacing Process Using TIG Welding, J. Quality Res., vol. 10, no. 3, pp. 143-154, 2016.
Yunus, M. and Alsoufi, M.S., Experimental Investigations into the Mechanical, Tribological, and Corrosion Properties of Hybrid Polymer Matrix Composites Comprising Ceramic Reinforcement for Biomedical Applications, J. Biomater., vol. 2018, pp. 1-8, 2018. DOI: 10.1155/2018/9283291.
Yunus, M. and Rahman, J.F., Optimization of Usage Parameters of Ceramic Coatings in High Temperature Applications Using Taguchi Design, J. Eng. Sci. Technol., vol. 3, no. 8, pp. 6364-6371, 2011.
Zamani, P. and Valefi, Z., Microstructure, Phase Composition and Mechanical Properties of Plasma Sprayed Al2O3, Cr2O3 and Cr2O3-Al2O3 Composite Coatings, J. Surf. Coat. Technol., vol. 316, pp. 138-145, 2017.
Ziaei-Asl, A. and Ramezanlou, M.T., Effect of TBC Thickness on Temperature Distribution of Gas Turbine Blade, Proc. of 3rd Conf. on Advances in Mechanical Engineering 2017, Yildiz Technical University, Istanbul, December 2017.
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