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The aim of this research project was to investigate the microstructural changes of MCrAlY coated Ni-based superalloys that are routinely used in industrial gas turbine engines for power generation. One of the main aims of the characterisation was to understand ageing time and temperature effects on the microstructural evolution so that a methodology could be developed where the characterisation of a thermally exposed microstructure can be used to estimate unknown service exposure conditions.

Conventional yttria stabilized zirconia (YSZ) are widely used in the gas turbine to protect the substrate material from high temperature. But the common YSZ top coatings have limitations at higher temperature (above 1200 ℃) due to significant phase transformation and intensified sintering effect. Among the list of pyrochlores, gadolinium zirconate offer very attractive properties like low thermal conductivity, high thermal expansion coefficient and CMAS resistance. However, a lower fracture toughness than YSZ and tendency to react with alumina (thermal grown oxide) can lead to lower lifetime. Therefore, multi-layered thermal barrier coating approach was attempted and compared with single layer system. Single layer (YSZ) was processed by suspension plasma spraying (SPS). Double layer coating system comprising of YSZ as the bottom ceramic layer and gadolinium zir-conate as the top ceramic coat was processed by SPS. Also, a triple layer coating system with denser gadolinium zirconate on top of double layer system, was sprayed. Denser gado-linium zirchonate acts as the sealing layer and arrest the CMAS penetration. Isothermal oxidation performance of the sprayed coating systems including bare substrate and sub-strate with bond coat were investigated for a time period of 10hr, 50hr and 100hr at 1150℃ in air environment. Weight gain was observed in all the systems investigated. Microstruc-tural analysis was carried out using optical microscopy, SEM/EDS. Phase analysis was done using X-ray diffraction (XRD). Porosity measurement was made by water impregna-tion method. It was observed that multi-layered thermal barrier coating systems of YSZ/GZ and YSZ/GZ/GZ(dense) showed lower weight gain and TGO thickness than the single layer YSZ for all exposure time (10hr, 50hr & 100hr). The triple layer system had lower weight gain and TGO thickness compared to double layer system due to lower po-rosity content. Also, from the porosity measurement data, it could be seen that sintering effect is more dominant at 10 hr. of oxidation for all the coatings systems.

The aim of this thesis is to investigate the effects of additives, reactive elements and impurities, on the lifetime of thermal barrier coatings. The thesis consists of a number of studies on interface adhesion, impurity diffusion, grain boundary sliding and cleavage processes and their impact on the mechanical behaviour of grain boundaries. The effects of additives and impurity on interface adhesion were elaborated by using total energy calculations, electron localization and density of states, and by looking into the atomic separations. The results of these calculations allow the assessment of atomic level contributions to changes in the adhesive trend. Formation of new bonds across the interface is determined to improve the adhesion in reactive element(RE)-doped structures. Breaking of the cross interface bonds and sulfur(S)-oxygen(O) repulsion is found responsible for the decreased adhesion after S segregation. Interstitial and vacancy mediated S diffusion and the effects of Hf and Pt on the diffusion rate of S in bulk NiAl are studied. Hf is shown to reduce the diffusion rate, and the preferred diffusion mechanism of S and the influence of Pt are revealed to be temperature dependent. Finally, the effects of reactive elements on alumina grain boundary strength are studied. Reactive elements are shown to improve both the sliding and cleavage resistance, and the analysis of atomic separations suggest an increased ductility after the addition of quadrivalent Hf and Zr to the alumina grain boundaries.

<p><a>Zirconium oxide (zirconia, ZrO₂) is one of the essential structural ceramics for industrial applications due to its superb strength and fracture toughness. ZrO₂ has three main polymorphs: cubic, tetragonal, and monoclinic phase, depending on temperature, type, and concentration of dopants. Stabilized zirconia with metastable tetragonal phase can transform into monoclinic phase with ~ 4% volume expansion under an applied external stress. The tetragonal-to-monoclinic transformation can hinder crack propagations by generating a compressive stress field near crack field, thereby enhancing fracture toughness. In addition, other deformation mechanisms such as dislocation activities, crack deflection, and ferroelastic domain switching can further enhance its deformability. Bulk ZrO₂ is typically prepared by sintering at high temperatures over a long period of time. Recently, field-assisted sintering techniques such as flash sintering and spark plasma sintering have been applied to effectively sinter ZrO₂. These techniques can significantly decrease sintering temperature and time, and more importantly introduce a large number of defects in the sintered fine grains.</a></p> <p>The miniaturization of sample dimension can alter the mechanical properties of materials by increasing the surface-to-volume ratio and decreasing the likelihood of retaining process-induced flaws. The knowledge of mechanical properties of ZrO₂ at micro and nanoscale is critical in that superelasticity and shape memory effect of ZrO₂ can be utilized for applications of actuation, energy-damping, and energy-harvesting at small scale. Here, we performed <i>in-situ</i> microcompression tests at various temperatures inside a scanning electron microscope to examine and compare the mechanical properties of ZrO₂ prepared by flash sintering, spark plasma sintering, plasma spray, and thermal spray. Detailed microstructural analyses were conducted by transmission electron microscopy. The unique microstructures in ZrO₂ prepared by field-assisted sintering largely improved their plasticity. Temperature and processing technique-dependent underlying deformation mechanisms and fracture behavior of ZrO₂ are discussed.</p>

Thermal Barrier Coatings have been used for decades to impose a thermal gradient between the hot combustion gases and the underlying superalloy substrate in engine turbine blades. Yttria Stabilized Zirconia (YSZ) is an industry standard high temperature ceramic for turbine applications. The protective coating is adhered to the substrate using a nickel based alloy bond coat. Through exposure to high temperature, a Thermally Grown Oxide (TGO) layer develops at the bond coat-YSZ interface. Large residual stresses develop in these layers due to thermal expansion mismatch that occurs during cool down from high temperature spraying and cyclic operating conditions. Despite their standard use, much is to be determined as to how these residual stresses are linked to the various failure modes. This study developed techniques to monitor the strain and stress in these internal layers during thermal gradient and mechanical conditions representing operating conditions. The thermal gradient is applied across the coating thickness of the tubular samples from infrared heating of the outer coating and forced air internal cooling of the substrate. While thermal and mechanical loading conditions are applied, 2-dimensional diffraction measurements are taken using the high-energy Synchrotron X-Rays and analyzed to provide high-resolution depth-resolved strain. This study will include fatigue comparisons through use of samples, which are both 'as-coated' as well as aged to various stages in a TBC lifespan. Studies reveal that variations in thermal gradients and mechanical loads create corresponding trends in depth resolved strains with the largest effects displayed at or near the bond coat/TBC interface. Single cycles as well as experiments targeting thermal gradient and mechanical effects were conducted to capture these trends. Inelastic behavior such as creep was observed and quantified for the different layers at high temperatures. From these studies more accurate lifespan predictions, material behaviors, and causes of failure modes can be determined. The work further develops measurement and analysis techniques for diffraction measurements in internal layers on a coated tubular sample which can be used by various industries to analyze similar geometries with different applications.

The continued focus to include high hydrogen fuels such as Syngas in aircraft operation to reduce emissions and increase engine efficiency has led to an ongoing investigation into bond coat materials capable of withstanding unfavourable oxidation in high temperature humid environments. The increased presence of water in the engine exhaust leads to increased oxygen activity in the hot section of the engine. In this work, four commercially available MCrAlY bond coat materials were oxidized in high temperature environments with various humidities to understand the behaviours of different reactive element inclusions in resisting high temperature oxidation. Oxidation tests were done at 0%, 18%, and 33% water by volume at 1100C in a 1atm environment to simulate conditions expected in engines using high hydrogen fuels. Oxidation was done for 2h and 20h to observe transient oxide formation behaviour. The surfaces and cross sections of the specimens were examined using SEM and EDS analysis, along with XRD analysis. The progression of surface oxides, TGO thickness, and element depletion zones were observed. Two opposing mechanisms are observed: the upward diffusion of metal cations to the free surface and the inward diffusion of oxygen to the alloy. The presence of water is shown to increase internal oxidation of the bond coat alloy and delay the formation of a protective alumina TGO. Tantalum inclusion in the alloy composition is shown to produce the most stable alumina TGO with the least internal oxidation after 20h exposure in 33% H2O (%vol); the most hostile oxidation environment tested.

No description available.

No description available.