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Thermal Shock Damage and Microstructure Evolution of Thermal Barrier Coatings on Mar-M247 Superalloy in a Combustion Gas Environment

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Abstract

The effect of preoxidation on the thermal shock of air plasma sprayed thermal barrier coatings (TBCs) was completely investigated in a combustion gas environment by burning jet fuel with high speed air. Results show that with increasing cycles, the as-oxidized TBCs lost more weight and enlarged larger spallation area than the as-sprayed ones. Thermally grown oxide (TGO) growth and thermal mismatch stress were proven to play critical roles on the as-oxidized TBC failure. Two types of significant cracks were identified: the type I crack was vertical to the TGO interface and the type II crack was parallel to the TGO interface. The former accelerated the TGO growth to develop the latter as long as the oxidizing gas continuously diffused inward and then oxidized the more bond coat (BC). The preoxidation treatment directly increased the TGO thickness, formed the parallel cracks earlier in the TGO during the thermal shocks, and eventually resulted in the worse thermal shock resistance.

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Acknowledgments

This work was financially supported by the Natural Science Foundation of China (Grant No. 50902112), Honeywell International Inc., Northwestern Polytechnical University (NPU) Foundation for Fundamental Research (Grant No. JC201135), and NPU Foundation for Flying Star. The preparation of the BC and top ceramic coat on the superalloy from Xi’an Jiaotong University is greatly appreciated.

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Authors and Affiliations

  1. National Key Laboratory of Thermostructure Composite Materials, School of Materials Science, Northwestern Polytechnical University, Xi’an, Shaanxi, 710072, P.R. China

    Hui Mei (Associate Professor)

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  1. Hui Mei
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Correspondence to Hui Mei.

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Manuscript submitted July 27, 2011.

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Mei, H. Thermal Shock Damage and Microstructure Evolution of Thermal Barrier Coatings on Mar-M247 Superalloy in a Combustion Gas Environment. Metall Mater Trans A 43, 1781–1790 (2012). https://doi.org/10.1007/s11661-011-1055-7

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