Sanjay Sampath, Gopal Dwivedi, Vaishak ViswanathanSanjay Sampath, Gopal Dwivedi, Vaishak Viswanathan...

Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015

Manufacturing Science of LayeredMultifunctional coatings

Sanjay Sampath, Gopal Dwivedi, Vaishak ViswanathanDOE UTSR Meeting, Nov 2015


Hot section coatings having been critical enablers in recent years

These are complex Dynamically Evolving Structures

Photo Courtesy – Dr. Ramesh Subramanian, Siemens


TBC Manufacturing Technologies

Plasma Sprayed TBCs

EBPVD TBCs

(a) (b)

SPS TBCs

PSPVD TBCs


Superalloy

Bondcoat

TopcoatEBPVD

APS

SPS

Ni/Pt-AlAPS

VPSHVOF

LPPS APS SPS High Through-put APS

Liquid Fuel HVOF Gas Fuel HVOF VPS

Thermal spray manufacturing variants


Layer-2

Layer-1

Layer-3

Layer-1

Layer-2

Evolution of TBC microstructures

Porous DVC

1960-1990 1990 - present 2007 & 2014 2014

Overhaul

& Repair

expands

Poun

ds/y

ear

Plas

ma

Spra

yed

TBC

s

~ 2 M

1960 1970 1980 1990 2000 2010

Space Program

7% YSZAero engine

Plasma spray process

Gas Turbine Engine

Vane

Transition duct

Blade

DOE

Advanced

Turbine

System.

Vertically Cracked

TBCs Invented

Pratt & Whitney

Siemens

Gadolinum

Zirconate

Pratt & Whitney

Implements

zirconate

coatings

GE’s DVC

in manufacturing

ZirconiaCaZr,MgZr 20%YSZ

Evolution of TBC Materials and Thermal Spray Manufacturing


FeedstockCharacteristics

ProcessVariables

Component Performance

CoatingStructure

Spray StreamCharacteristics

Substrate Conditions

Coating Property

Deposition Conditions

- Equipment related

(Gun, Gases, Power)- Particle Injection

- Feed rate- Raster / Rotation Rate- Angle of Deposition

- Chemistry- Adsorbates- Temperature- Roughness

- Plume Orientation- Plume Spread- Particle State

- Structural Adhesion, Residual Stress, Toughness, Stiffness, Elastic Modulus

- FunctionalElectrical / Thermal transport,Wear / Erosion / Corrosion Resistance

- Defect (Cracks & Pores)- Crystal (Phase & Composition)- Layering (Splat Characteristics)- Grain (Size)- Anisotropy

- Composition- Morphology- Size Distribution

APS TBC fabrication involves numerous variables

Plasma Spray Grey box

Multitude of spray devices

& parameters

Multitude of evaluation

Criteria and variants

Multitude of applicators

locations

Implications

Extreme variability – local and global

Infant mortality and poor reliability

Difficult to incorporate into life models


Requires ….- Robust scientific understanding of manufacturing process- Effective tool to assess coating quality and process/coating reliability (both from development and manufacturing point of view)

Quality

# of

coa

tings

Traditional Role of TBC ⇒ Life Extension

Extra protection on substrates

Higher operating temperature

German Aerospace CenterInstitute of Materials Research

Wu et al, NIMS, Japan

Coating Failures

Future Role of TBC ⇒ Prime Reliant

Must protect (super-alloy) substrates

Requires better control of quality variability

TBC Processing Reliability/Quality is becoming increasingly important

Plasma spray is a highly complex deposition process:Materials Synthesized from Extreme Conditions

NON-EQUILIBRIUM PROCESSINGUltra rapid heating and phase changeRapid cooling and solidificationImpact pressure induced transformations

MULTI-SCALE STRUCTURE AND PROPERTIESNano-, micro-, meso- and macro-scalesDefect-dominated attributes

HIGHLY ANISOTROPIC BEHAVIORProcess-induced residual stresses Anisotropic properties across length scalesNon-linear elastic behavior

Resolidified

Unmelted

TsTm D

d

Resolidified

Unmelted

TsTm D

d

-0.005 0 0.005 0.010 0.015 0.020-40

-20

0

20

40

60

Stre

ss (

MP

a)

Strain

Non-linear responsein YSZ

-0.005 0 0.005 0.010 0.015 0.020-40

-20

0

20

40

60

Stre

ss (

MP

a)

Strain

Non-linear responsein YSZ

Non-linear response ceramics Anisotropy

Impact induced changes

Multiscale microstructures

Microsecond time scales

Need to develop interdisciplinary Processing/Manufacturing Science


Linking Research to Practice

Center for Thermal Spray Research at Stony Brook University

Established as an NSF MRSEC in 1996Integrated InterdisciplinaryResearch Aimed at AdvancingScience, Technology and Outreach for Thermal Spray Technology


Particle injector

Substra

te

100 µm

1. Plume particle

interactions

2. Deposit formation dynamics

3. Advanced microstructural characterization

4. Multi-scale property

assessment

Stre

ss (M

Pa)

Strain (%)

LoadingNon-linear

Unloading

Hysteresis

A typical Ceramic

Tools, Technologies and Models are now available at each step

Industry has started to adopt these capabilities for manufacturing control,

Enhanced new processes, novel designs, models and applications Article in Integrating Materials and Manufacturing Innovation

PAINT: Partnership for Accelerated Insertion of New Technology:

Case Study for Thermal Spray

http://www.immijournal.com/content/pdf/2193-9772-2-1.pdf


A large portfolio of scientific information has been developed manufacturing science of TBCs

1999- Present


Demonstrated Industrial Benefits of Advanced Manufacturing Science through Joint Experiments: 32 Field Trips in the Last 7 Years

Stony Brook-Caterpillar Team

Volvo Sweden Field Trip

Post-docs and students facilitate effective knowledge transfer to industrial workforce through cooperative experimentation using advanced technologies and scientific methodologies developed in academia.

Simultaneously, they benefit from the industrial insight and priorities

Companies involved in field trips

http://www.cat.com/

http://www.cat.com/

http://www.praxair.com/praxair.nsf

http://www.praxair.com/praxair.nsf

http://www.sulzer.com/en/DesktopDefault.aspx/tabid-94/

http://www.sulzer.com/en/DesktopDefault.aspx/tabid-94/

http://www.alstom.com/

http://www.alstom.com/


Advanced science impacts both efficiency and reliability

E

σ

ε

σT

ε∗

σ∗

ε* = σ*/E + σ*n/EσNn-1

ε*= σ*/ELINEAR

NONLINEAR

E

σ

ε

σT

σ

ε

σT

ε∗

σ∗

ε* = σ*/E + σ*n/EσNn-1

ε*= σ*/ELINEAR

NONLINEAR

Observations of novel phenomena in thermal plasmas (injection sweet spot)

Proof of Concept Demo

2200

2400

2600

2800

3000

1 3 5 7 9180

220

260

300

Plume PositionCarrier Gas Flow (cf/hr)

Tem

pera

ture

(°C

)

Velo

city

(m/s

)

2200

2400

2600

2800

3000

1 3 5 7 9180

220

260

300


Tem

pera

ture

(°C

)

Velo

city

(m/s

)

Injection Sweetspot

2200

2400

2600

2800

3000

1 3 5 7 9180

220

260

300


Tem

pera

ture

(°C

)

Velo

city

(m/s

)

2200

2400

2600

2800

3000

1 3 5 7 9180

220

260

300


Tem

pera

ture

(°C

)

Velo

city

(m/s

)

Injection Sweetspot

Traditional Method New Method(Injection Optimization)

Coa

ting

Thic

knes

s (µ

m)

280

290

300

310

320


Coa

ting

Thic

knes

s ( µ

m)

280

290

300

310

320~ 10% improvement in process efficiency


Coa

ting

Thic

knes

s ( µ

m)

280

290

300

310

320


Coa

ting

Thic

knes

s (µ

m)

280

290

300

310

320~ 10% improvement in process efficiency

Fundamental Science

Tem

pera

ture

(°C

)

Velocity (m/s)

2750

2800

2850

2900

2950

200 210 220 230 240

Tem

pera

ture

(°C

)

Velocity (m/s)

2750

2800

2850

2900

2950

200 210 220 230 240

Traditional Method

New Method

Tem

pera

ture

(°C

)

Velocity (m/s)

2750

2800

2850

2900

2950

200 210 220 230 240

Tem

pera

ture

(°C

)

Velocity (m/s)

2750

2800

2850

2900

2950

200 210 220 230 240

Traditional Method

New Method

0

6

12

18

Evol

ving

Str

ess

( MPa

)


0

6

12

18

Evol

ving

Str

ess

(MPa

)


Observations and quantification of non-linear properties of ceramic coatings

Observation

Successful testing of hypothesis in field: Tinker AF Base & Plasma Technology Inc.

In situ & ex situ extraction of non-linear properties

In situ process diagnostics

OUTCOME:

Procedures for simultaneously enhancing process efficiencies

and reliability


The Past and Future

Industrial perception of APS manufacturing as a constraint- Lack of understanding of the scientific nuances

- Perception of poor Repeatability, Reproducibility and Reliability

- In effective control and metrology tools

- Lack of integrated understanding

- Disconnect between design, materials and processes

=> Implication: Manufacturing is a “burden”

With advanced science manufacturing can be an enabler- Implemention of Segmented or Dense Vertically Cracked Coatings

- (Directionally solidified, in-plane compliant coatings)

- Understanding the importance of toughness of metastable t” YSZ on durability

- Advanced process control through insitu sensor based feedback

- Predictive microstructures through maps, correlations and models

- Process-property guided layered engineering


Thermal spray as an additive and layered manufacturing technology

Bring Manufacturing Science and Novel Capabilities

to Expand Design and Materials Options


Ni based Superalloy Substrate

Mul

tilay

er T

opco

atB

ondc

oat

Oxidation protectionstrength/creep resistant

High fracture toughness layer

Sinter Resistant Low Thermal conductivity

Erosion and CMAS ResistantLow thermal conductivity

Phase stability

Teixeira et al., JTST, 9(2), 2000—191

Padture et al., vol. 296,Science, 280, 2002

E.g. Optimal Layer Design for Improved Durability

Critical microstructural parameters

- Intrinsic Material Toughness

- Manufactured Material Toughness

Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015 21

Superalloy Substrate

Overlay BC

Porous YSZLow K

Low E

Conventional TBCsEnhanced Durability

TBCs


Overlay BCenhanced roughness

Layer-1

Layer-2

High KIC TBC Layer

Porous YSZLow K

Low E

Toughness engineered multilayer TBCs

TBC

life

time

(hou

rs)

0

200

400

600

800

1000

1200

1400

Con

vent

iona

l

Single layer TBCs

Bi-layer TBCs


TBC

life

time

(hou

rs)

RT Thermal conductivity (W/m-K)0.6 0.8 1.0 1.2 1.4 1.6 1.8

400

600

800

1000

1200

1400

Single layer YSZ TBCs

bi-layer YSZ-TBCs with improveddurability

Inverse

bi-layer TBC

Simultaneous optimization of durability and functionality

DVC


Coatings experience multiple failure mechanisms

o Ceramic strength/toughnesso Ceramic coating compliance

and ceramic chemistry

o Bond coat chemistry, Roughnesso Ceramic coating toughness

o Ceramic coating composition

o Coating density o Coating porosity/cracks

o Bond coat roughnesso Coating thickness

o Pore architectureo Coating thickness


Multilayered architecture to combat multifunctional requirements

(Rene 80 or CMSX4)

Plasma spray is naturally suited for such layered manufacturing



High KIC YSZ Layer

Erosion ,CMAS ResistantLow K ,E GZO Layer

Multifunctional Multimaterial TBCs

Bond Coat

Low K

Low ELoca

tion

spec

ific

prop

erty

requ

irem

ents

Design consideration for YSZ- GDZ multilayer architectures

Possible Microstructural Variants

Porous YSZ / Porous GDZ

Dense GDZ / DVC GDZ

DVC / Thin interfacial layer of dense YSZ


Single Layer TBC

600 hrs

50 +coating conditions

40+ architectures

600+ FCT samples

Adequate erosion resistance

Significantly higher durability

CMAS resistance

Mechanisms and Methodology to incorporate andynew composition

The multilayer TBC architecture

Layer-2

Layer-1

Layer-3

1,200 hrs

Multilayer TBC

Validated through FCT testing both in house, ORNL and industry (Siemens, GE) during UTSR program


Successfully validated at industrial sites (GE, Siemens, Praxair)

Bond Coat

Porous Single layer

Bond Coat

Bi-layer YSZ

Bond Coat

Multilayer YSZ-GDZ

coating

Bond Coat

Dense Single layer 0

200

400

600

800

TBC

life

time

(cyc

les)

PorousYSZ

DenseYSZ

Bi layerYSZ

YSZ-GDZ

Porous YSZ Dense YSZ Bi layer YSZ YSZ-GDZ

All failed at BC/TC interface

FCT: 2000F (1093oC), 45 mins cyclingCourtesy: Ben Nagaraj

6 x 2000 cycles: No Failure yet

0 500 1000 1500 2000

1600

1800

2000

2200

2400

2600

δT ~ 506

0 500 1000 1500 2000

1600

1800

2000

2200

2400

2600

δT ~ 752 F

0 500 1000 1500 20001600

1700

1800

1900

2000

2100

2200

2300

δT ~ 396

0 500 1000 1500 20001600

1800

2000

2200

2400

2600

2800

Tem

pera

ture

(o F)

δT ~ 818 F

JETS test

Courtesy: Dr. Li Li

J. Mater. Engg. Perf.Ann Bolcavage

http://link.springer.com/journal/11665

http://link.springer.com/search?facet-creator=%22Ann+Bolcavage%22


Superalloy

Bondcoat

TopcoatEBPVDAPSSPS

Ni/Pt-AlAPSVPSHVOF

Increasing Turbine operation TemperatureY:1980 Y:2015

Ni based- Bond Coat

Conventional single layer TBC

Superalloy

Low-KYSZ

Ni based- Bond Coat

Multilayer Advanced TBC

Superalloy

High K1c- YSZ

Low E, K- YSZ

Low K, CMAS ResistantGd2Zr2O7

Si-bondcoat

Yb2SiO5Low water

volatalization

CMCs

Mullite-oxygen barrier

Multilayer Advanced EBCs

oP

hase

-sta

bilit

yo

CM

AS

oP

hase

-sta

bilit

yo

CM

AS

oS

ubst

rate

Tem

p lim

it.

CMCs

O2, H2O

Si

T~1400oC

SiO2(s) + 2H2O(g) = Si(OH)4(g)

TBCs + EBCs EBCs

Cur

rent

TBC

sAp

plic

atio

n ch

alle

nges

Cur

rent

bill

of T

BCs

Applying similar ideas to emergent TBCs, EBCs, T/EBCs


MesoPlasma™ 3D-Printing Technology

Printing onto Films

Provides new process capabilities not achieved with conventional plasma spray / cold spray

Precision, multi-layered metallic and ceramic dielectric patterns

Printed thermocouples and high watt density heaters onto parts

Stand-alone heat flux sensor and heater products

Printed patterns onto temperature-sensitive polymer films

Direct Write Technology

Temperature Sensing

Part Heating

Heat Flux Sensor Products

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Sanjay Sampath, Gopal Dwivedi, Vaishak ViswanathanSanjay Sampath, Gopal Dwivedi, Vaishak Viswanathan...

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