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Title: EFFECTS OF BOND COAT SURFACE PREPARATION ON THERMAL CYCLING LIFETIME AND FAILURE CHARACTERISTICS OF THERMAL BARRIER COATINGS.
Creator: Liu, Jing, Sohn, Yong-ho, University of Central Florida
Abstract / Description: Thermal barrier coatings (TBCs) have been widely used in gas turbine engines to protect the underlying metal from high operating temperature so as to improve the durability of the components and enhance the engine efficiency. However, since the TBCs always operate in a demanding high-temperature environment of aircraft and industrial gas-turbine engines, a better understanding of this complex system is required to improve the durability and reliability.The objective of this study is to...
Show moreThermal barrier coatings (TBCs) have been widely used in gas turbine engines to protect the underlying metal from high operating temperature so as to improve the durability of the components and enhance the engine efficiency. However, since the TBCs always operate in a demanding high-temperature environment of aircraft and industrial gas-turbine engines, a better understanding of this complex system is required to improve the durability and reliability.The objective of this study is to investigate the effects of surface modification for the NiCoCrAlY bond coats on the thermal cycling lifetime and failure characteristics of TBCs. Parameters of modification for the bond coats included as-sprayed, barrel-finished, hand-polished and pre-oxidation heat treatment at 1100 C in =10-8 atm up to 4 hours, carried out prior to the electron beam physical vapor deposition (EB-PVD) of ZrO2-7wt% Y2O3 (7YSZ) ceramic topcoat. The resulting characteristics of the bond coat and the thermally grown oxide (TGO) scale were initially documented by surface roughness, phase constituents of the TGO scale, and residual stress of the TGO scale. The thermal cycling test consisted of 10-minute heat-up to 1121 C, 40-minute hold at 1121 C, and 10-minute forced air-quench. As-coated and thermally-cycled TBCs were characterized by optical profilometry (OPM), photo-stimulated luminescence spectroscopy (PSLS), optical microscopy, scanning electron microscopy (SEM) equipped with energy dispersive spectroscopy (EDS), and scanning/transmission electron microscopy (TEM/STEM) equipped with high angle annular dark field (HAADF) and X-ray energy dispersive spectroscopy (XEDS). TBC specimens for TEM/STEM analysis were prepared by focused ion beam (FIB) in-situ lift-out (INLO) technique.Superior thermal cycling lifetime was observed for TBCs with as-sprayed bond coats regardless of pre-oxidation heat treatment, and TBCs with hand-polished bond coats only after pre-oxidation heat treatment. With pre-oxidation heat treatment, relative photostimulated luminescence intensity of the equilibrium ¦Á-Al2O3 increased. Thus, the improvement in TBC lifetime can be correlated with an increase in the amount of ¦Á-Al2O3 in the TGO scale, given a specific surface modification/roughness. The lifetime improvement due to pre-oxidation was particularly significant to TBCs with smooth hand-polished bond coats and negligible for TBCs with rough as-sprayed bond coats.Spallation-fracture paths depended on the lifetime of TBCs. Premature spallation of TBCs occurred at the interface between the YSZ and TGO. Longer durability can be achieved by restricting the fracture paths to the TGO/bond coat interface. Small particulate phase observed through the TGO scale was identified as Y2O3 (cubic) by diffraction analysis on TEM. While small addition of Y in the NiCoCrAlY bond coat helps the adhesion of the TGO scale, excessive alloying can lead to deleterious effects.
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Date Issued: 2004
Identifier: CFE0000097, ucf:46083
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0000097

Title: PHENOMENOLOGY AND EXPERIMENTAL OBSERVATIONS IN HIGH TEMPERATURE TERNARY INTERDIFFUSION.
Creator: Elliott, Abby Lee, Sohn, Yongho, University of Central Florida
Abstract / Description: A new method to extract composition dependent ternary interdiffusion coefficients from a single diffusion couple experiment is presented. The calculations involve direct determination of interdiffusion fluxes from experimental concentration profiles and local integration and differentiation of Onsager's formalism. This new technique was applied to concentration profiles obtained from selected semi-infinite, single-phase diffusion couple experiments in the Cu-Ni-Zn, Fe-Ni-Al, and Ni-Cr-Al...
Show moreA new method to extract composition dependent ternary interdiffusion coefficients from a single diffusion couple experiment is presented. The calculations involve direct determination of interdiffusion fluxes from experimental concentration profiles and local integration and differentiation of Onsager's formalism. This new technique was applied to concentration profiles obtained from selected semi-infinite, single-phase diffusion couple experiments in the Cu-Ni-Zn, Fe-Ni-Al, and Ni-Cr-Al systems. These couples exhibit features such as uphill diffusion and zero flux planes. The interdiffusion coefficients from the new technique along with coefficients reported from other methods are graphed as functions of composition. The coefficients calculated from the new technique are consistent with those determined from Boltzmann-Matano analysis and an alternate analysis based on the concept of average ternary interdiffusion coefficients. The concentration profiles generated from the error function solutions using the calculated interdiffusion coefficients are in good agreement with the experimental profiles including those exhibiting uphill diffusion. The new technique is checked for accuracy and consistency by back-calculating known interdiffusion coefficients; in this exercise, the new method accurately predicts constant diffusivity.After rigorous verification, the new technique is applied to previously unexamined couples in the Ni-Pt-Al system. With Ni as the dependent component, the main coefficients are shown to be relatively constant and the cross coefficients are negative. The interdiffusion coefficient representing the contribution of the concentration gradient of Pt to the interdiffusion flux of Al is relatively large for couples whose Al content is low, indicating that Pt has a significant effect on Al when Al concentration is low.Another important aspect of analyzing diffusional interactions is the movement of single and multi-phase boundaries within a diffusion couple. Phase boundaries for an n-component system are newly classified and boundary movement is analyzed in terms of degrees of freedom. Experimental evidence of a category 2:1 boundary is presented with a solid-to-solid semi-infinite diffusion couple in the Fe-Ni-Al system with two single-phase terminal alloys. The diffusion path for this couple surprisingly passes through the vertex of the equilibrium tie triangle on the phase diagram to exhibit three phase equilibria in a ternary system. Here is shown for the first time experimental verification of this phenomenon.
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Date Issued: 2004
Identifier: CFE0000016, ucf:46101
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0000016

Title: PREVENTION OF ENVIRONMENTALLY INDUCED DEGRADATION IN CARBON/EPOXY COMPOSITE MATERIAL VIA IMPLEMENTATION OF A POLYMER BASED COATING SYSTEM.
Creator: Tipton, Bradford, Sohn, Yongho, University of Central Florida
Abstract / Description: As the use of fiber reinforced plastics increases in such industries as aerospace, wind energy, and sporting goods, factors effecting long-term durability, such as environmental exposure, are of increasing interest. The primary objectives of this study were to examine the effects of extensive environmental exposure (specifically UV radiation and moisture) on carbon/epoxy composite laminate structures and to determine the relative effectiveness of polymer-based coatings at mitigating...
Show moreAs the use of fiber reinforced plastics increases in such industries as aerospace, wind energy, and sporting goods, factors effecting long-term durability, such as environmental exposure, are of increasing interest. The primary objectives of this study were to examine the effects of extensive environmental exposure (specifically UV radiation and moisture) on carbon/epoxy composite laminate structures and to determine the relative effectiveness of polymer-based coatings at mitigating degradation incurred due to such exposure. Carbon/epoxy composite specimens, both coated and uncoated, were subjected to accelerated weathering in which prolonged outdoor exposure was simulated by controlling the radiation wavelength (in the UV region), temperature, and humidity. Mechanical test data obtained for the uncoated specimens indicated a reduction in strength of approximately 6% after an environmental exposure duration of 750 hours. Test data revealed that no further degradation occurred with increased exposure duration. This reduction resulted from the erosion of the epoxy matrix in additional to the formation of matrix microcracks. The protective coatings evaluated were all epoxy based and included two different surfacing films applied during initial cure of the carbon/epoxy composite laminate and a chromate containing epoxy based paint primer applied after the cure was complete. Although the chromate primer performed well initially, degradation of the underlying substrate was detected with extended exposure durations. In contrast, the surfacing films provided superior protection against environmentally induced degradation. Although similar degradation attributes were identified in the surfacing film as observed in the uncoated composite, it is likely that this degradation was either confined within the surfacing film layer or only penetrated the very near surface of the carbon/epoxy substrate, as it did not result in a substantial reduction in mechanical strength.
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Date Issued: 2008
Identifier: CFE0002406, ucf:47731
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0002406

Title: PHASE-FIELD SIMULATION OF MICROSTRUCTURALDEVELOPMENT INDUCED BY INTERDIFFUSIONFLUXES UNDER MULTIPLE GRADIENTS.
Creator: Mohanty, Rashmi, Sohn, Yongho, University of Central Florida
Abstract / Description: The diffuse-interface phase-field model is a powerful method to simulate and predict mesoscale microstructure evolution in materials using fundamental properties of thermodynamics and kinetics. The objective of this dissertation is to develop phase-field model for simulation and prediction of interdiffusion behavior and evolution of microstructure in multi-phase binary and ternary systems under composition and/or temperature gradients. Simulations were carried out with emphasis on...
Show moreThe diffuse-interface phase-field model is a powerful method to simulate and predict mesoscale microstructure evolution in materials using fundamental properties of thermodynamics and kinetics. The objective of this dissertation is to develop phase-field model for simulation and prediction of interdiffusion behavior and evolution of microstructure in multi-phase binary and ternary systems under composition and/or temperature gradients. Simulations were carried out with emphasis on multicomponent diffusional interactions in single-phase system, and microstructure evolution in multiphase systems using thermodynamics and kinetics of real systems such as Ni-Al and Ni-Cr-Al. In addition, selected experimental studies were carried out to examine interdiffusion and microstructure evolution in Ni-Cr-Al and Fe-Ni-Al alloys at 1000C. Based on Onsager's formalism, a phase-field model was developed for the first time to simulate the diffusion process under an applied temperature gradient (i.e., thermotransport) in single- and two-phase binary alloys. Development of concentration profiles with uphill diffusion and the occurrence of zero-flux planes were studied in single-phase diffusion couples using a regular solution model for a hypothetical ternary system. Zero-flux plane for a component was observed to develop for diffusion couples at the composition that corresponds to the activity of that component in one of the terminal alloys. Morphological evolution of interphase boundary in solid-to-solid two-phase diffusion couples (fcc- vs. B2-) was examined in Ni-Cr-Al system with actual thermodynamic data and concentration dependent chemical mobility. With the instability introduced as a small initial compositional fluctuation at the interphase boundary, the evolution of the interface morphology was found to vary largely as a function of terminal alloys and related composition-dependent chemical mobility. In a binary Ni-Al system, multiphase diffusion couples of fcc- vs. L12-,  vs. and  vs.  were simulated with alloys of varying compositions and volume fractions of second phase (i.e., ). Chemical mobility as a function of composition was employed in the study with constant gradient energy coefficient, and their effects on the final interdiffusion microstructure was examined. Interdiffusion microstructure was characterized by the type of boundaries formed, i.e. Type 0, Type I, and Type II boundaries, following various experimental observations in literature and thermodynamic considerations. Volume fraction profiles of alloy phases present in the diffusion couples were measured to quantitatively analyze the formation or dissolution of phases across the boundaries. Kinetics of dissolution of  phase was found to be a function of interdiffusion coefficients that can vary with composition and temperature. The evolution of interdiffusion microstructures in ternary Ni-Cr-Al solid-to-solid diffusion couples containing fcc- and + (fcc+B2) alloys was studied using a 2D phase-field model. Alloys of varying compositions and volume fractions of the second phase () were used to simulate the dissolution kinetics of the  phase. Semi-implicit Fourier-spectral method was used to solve the governing equations with chemical mobility as a function of compositions. The simulation results showed that the rate of dissolution of the  phase (i.e., recession of  two-phase region) was dependent on the composition of the single-phase  alloy and the volume fraction of the  phase in the two-phase alloy of the couple. Higher Cr and Al content in the  alloy and higher volume fraction of  in the  alloy lower the rate of dissolution. Simulated results were found to be in good agreement with the experimental observations in ternary Ni-Cr-Al solid-to-solid diffusion couples containing  and  alloys. For the first time, a phase-field model was developed to simulate the diffusion process under an applied temperature gradient (i.e., thermotransport) in multiphase binary alloys. Starting from the phenomenological description of Onsager's formalism, the field kinetic equations are derived and applied to single-phase and two-phase binary system. Simulation results show that a concentration gradient develops due to preferential movement of atoms towards the cold and hot end of an initially homogeneous single-phase binary alloy subjected to a temperature gradient. The temperature gradient causes the redistribution of both constituents and phases in the two-phase binary alloy. The direction of movement of elements depends on their atomic mobility and heat of transport values.
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Date Issued: 2009
Identifier: CFE0002515, ucf:47658
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0002515

Title: MULTICOMPONENT INTERDIFFUSION IN AUSTENITIC NI-, FE-NI-BASE ALLOYS AND L12-NI3AL INTERMETALLIC FOR HIGH-TEMPERATURE APPLICATIONS.
Creator: Garimella, Narayana, Sohn, Yong-ho, University of Central Florida
Abstract / Description: Interdiffusion in multicomponent-multiphase alloys is commonly encountered in many materials systems. The developments of multicomponent-multiphase alloys require control of microstructure through appropriate heat treatment, involving solid-state transformations, precipitation processes, and surface modification, where the interdiffusion processes play a major role. In addition, interdiffusion processes often control degradation and failure of these materials systems. Enhanced performance and...
Show moreInterdiffusion in multicomponent-multiphase alloys is commonly encountered in many materials systems. The developments of multicomponent-multiphase alloys require control of microstructure through appropriate heat treatment, involving solid-state transformations, precipitation processes, and surface modification, where the interdiffusion processes play a major role. In addition, interdiffusion processes often control degradation and failure of these materials systems. Enhanced performance and reliable durability always requires a detailed understanding of interdiffusion. In this study, ternary and quaternary interdiffusion in Ni-Cr-X (X = Al, Si, Ge, Pd) at 900C and 700C, Fe-Ni-Cr-X (X = Si, Ge) at 900C, and Ni3Al alloyed with Ir, Ta and Re at 1200C were examined using solid-to-solid diffusion couples. Interdiffusion fluxes of individual components were calculated directly from experimental concentration profiles determined by electron probe microanalysis. Moments of interdiffusion fluxes were examined to calculate main and cross interdiffusion coefficients averaged over selected composition ranges from single diffusion couple experiments. Consistency in the magnitude and sign of ternary and quaternary interdiffusion coefficient were verified with interdiffusion coefficients determined by Boltzmann-Matano analysis that requires multiple diffusion couples with intersecting compositions. Effects of alloying additions, Al, Si, Ge and Pd, on the interdiffusion in Ni-Cr-X and Fe-Ni-Cr-X alloys were examined with respect to Cr2O3-forming ability at high temperature. Effects of Ir, Ta and Re additions on interdiffusion in Ni3Al were examined with respect to phase stability and site-preference. In addition, a numerically refined approach to determine average ternary interdiffusion coefficients were developed. Concentrations and moments of interdiffusion fluxes are employed to generate multiple combinations of multicomponent interdiffusion coefficient as a function of moments. The matrix of multicomponent interdiffusion coefficients corresponds to the lowest order of the moment. It yields real and positive eigen values which provides reliable average interdiffusion coefficients for the selected composition range.
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Date Issued: 2009
Identifier: CFE0002521, ucf:47639
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0002521

Title: INTERDIFFUSION ANALYSIS FOR NICOCRALY AND NIAL VS. VARIOUS SUPERALLOYS.
Creator: Perez, Emmanuel, Sohn, Yong-Ho, University of Central Florida
Abstract / Description: Hot section components in gas turbines can be NiCoCrAlY-coated to provide the component with an Al reservoir that maintains a protective oxide layer on its surface. Over the service life of the component, the coatings degrade by composition and phase changes due to oxidation/hot-corrosion, and multicomponent interdiffusion from and into the superalloy substrate. In this study, the rate of Al interdiffusion into selected Ni-base superalloys using various diffusion couples of two-phase...
Show moreHot section components in gas turbines can be NiCoCrAlY-coated to provide the component with an Al reservoir that maintains a protective oxide layer on its surface. Over the service life of the component, the coatings degrade by composition and phase changes due to oxidation/hot-corrosion, and multicomponent interdiffusion from and into the superalloy substrate. In this study, the rate of Al interdiffusion into selected Ni-base superalloys using various diffusion couples of two-phase NiCoCrAlY (beta + gamma) and single beta-phase NiAl with the selected alloys is measured. The diffusion couples were examined with an emphasis on the composition-dependence of Al interdiffusion. Microstructural analysis of the NiCoCrAlY vs. superalloys couples is performed to examine the dependence of coatings lifetime on the superalloy composition. The beta-NiAl diffusion couples were analyzed to determine the integrated, apparent and average effective interdiffusion coefficient as a function of superalloy's composition. Concentration profiles were obtained by EPMA of the NiAl vs. superalloy diffusion couples. Findings of this study show that the lifetimes of NiCoCrAlY are heavily dependent on superalloy compositions. The rate of interdiffusion in the diffusion couples is affected by the refractory precipitate phase microstructure structures in the interdiffusion zones as well as by component interactions. The results of the beta-NiAl diffusion couples show that increasing concentrations of Cr, Mo and Ti in the superalloy increase the Al effective interdiffusion coefficient into the superalloy, while increasing concentrations of Al, Ta and W reduce it. Thus NiCoCrAlY-superalloy systems may be designed to produce optimal microstructures in the interdiffusion zone and minimize Al interdiffusion by consideration of these diffusional interactions.
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Date Issued: 2005
Identifier: CFE0000681, ucf:46486
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0000681

Title: NONDESTRUCTIVE EVALUATION OF THERMAL BARRIER COATINGS WITH THERMAL WAVE IMAGING AND PHOTOSTIMULATED LUMINESCENCE SPECTROSCOPY.
Creator: Franke, Barbara, Sohn, Yong-ho, University of Central Florida
Abstract / Description: Gas Turbine manufacturers strive for increased operating temperatures of gas turbine engines to improve efficiency and performance. One method of increasing the temperature beyond material limits is by applying thermal barrier coatings (TBCs) to hot section components. TBCs provide a thermal gradient between the hot gases and metallic substrate, and allow an increase in turbine inlet temperatures of 100-150ºC. However, spallation of TBCs can cause catastrophic failure of turbine engines...
Show moreGas Turbine manufacturers strive for increased operating temperatures of gas turbine engines to improve efficiency and performance. One method of increasing the temperature beyond material limits is by applying thermal barrier coatings (TBCs) to hot section components. TBCs provide a thermal gradient between the hot gases and metallic substrate, and allow an increase in turbine inlet temperatures of 100-150ºC. However, spallation of TBCs can cause catastrophic failure of turbine engines by incipient melting of the substrate. To prevent such an occurrence, non-destructive evaluation (NDE) techniques are critical for quality control, health monitoring, and life assessment of TBCs. Two techniques in development for this purpose are thermal wave imaging (TWI) and photostimulated luminescence (PL) spectroscopy. TWI is a promising NDE technique with the ability to detect integrity and thickness of TBCs. In this study, TWI was employed as an NDE technique to examine as-coated TBCs with varying thicknesses, and thermally-cycled TBCs for initiation and progression of subcritical-subsurface damage as a function of thermal cycling. TWI and thermal response amplitude were correlated to the microstructural characteristics and damage progression of TBCs based on phenomenological expressions of thermal diffusion. The TBC specimens examined consisted of air plasma sprayed ZrO2 - 7wt.% Y2O3 on NiCoCrAlY bond coats with Haynes 230 superalloy substrate. As-coated specimens of varying thicknesses were evaluated by TWI to examine its applicability as a thickness measurement tool. It was found that heat dissipation through the TBC following pulsed excitation by xenon flash lamps initially followed the 1-D law of conduction and deviated from it as a function of thickness and time. The deviation resulted from quick dissipation of heat into the conductive metallic substrate. Therefore, with calibration, TWI can be used as a tool for YSZ thickness measurements of APS TBCs in the as-coated condition for quality control measures. Specimens of uniform thickness were evaluated as a function of thermal cyclic oxidation for subcritical-subsurface damage detection. Thermal cycling was carried out in air with 30-minute heat-up, 10-hour dwell at 1150°C, 30-minute air-quench and 1-hour hold at room temperature. During thermal cycling, TBC specimens were evaluated non-destructively by TWI at room temperature every 10 to 20 thermal cycles, and selected specimens were removed from thermal cycling for microstructural analysis by scanning electron microscopy (SEM). Higher thermal response amplitude associated with disrupted heat transfer was observed where localized spallation at or near the YSZ/TGO interface occurred. The health of the TBC was monitored by a rise in thermal response amplitude which may indicate a coalescence of microcracks to a detectable level. PL has been developed to measure stress, and detect subsurface damage and polymorphic transformation within the thermally grown oxide (TGO) of TBCs. PL was employed in this study as an NDE technique for TBCs to correlate subsurface damage as a function of thermal cyclic oxidation. The TBCs consisted of ZrO2 – 7 wt.% Y2O3 applied by electron beam physical vapor deposition with an as-coated (Ni,Pt)Al bond coat on a CMSX-4 superalloy substrate. Specimens were thermally cycled with a 10 minute ramp to a peak temperature of 1121°C, 40 minute hold at peak temperature, and 10 minute forced air quench. The TBCs were periodically removed from thermal cycling for NDE using PL until failure. Two specimens were removed from thermal oxidation after 10% and 70% of the average lifetime for microstructural analysis by SEM. During initial thermal cycling, metastable phases and polymorphic transformations of the Al2O3 scale were examined by PL. The polymorphic transformation from a metastable phase to equilibrium a-Al2O3 was detected. Since metastable phases are thought to be detrimental to coating lifetime, detection of these phases by PL can be used as a quality control tool. Nearing end-of-life, relief of the TGO from the compressive residual stress arising from thermal expansion mismatch was detected with PL and confirmed with microstructural analysis that revealed damage initiation (e.g. microcracking within the TGO scale parallel to the interfaces.) Rise in luminescence near the R-line frequency for polycrystalline a-Al2O3 without any residual stress (i.e. n = 14402 cm-1 and n = 14432 cm-1) corresponded to regions where cracked TGO was adhered to YSZ and not exposed to compressive stresses from thermal expansion mismatch upon cooling.
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Date Issued: 2005
Identifier: CFE0000717, ucf:46613
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0000717

Title: EFFECTS OF INTERNAL OXIDATION ON THERMO-MECHANICAL PROPERTIES OF ATMOSPHERIC PLASMA SPRAYED CONICRALY COATINGS.
Creator: Patterson, Travis, Sohn, Yong-ho, University of Central Florida
Abstract / Description: Thermal barrier coatings (TBC) with MCrAlY (M=Co and/or Ni) bond coats have been widely used in hot sections of gas turbines to protect underlying superalloys from high temperatures, oxidation, and hot corrosion. Deposition of MCrAlY bond coats using atmospheric plasma spray (APS), as oppose to conventionally employed vacuum/low-pressure plasma spray and high velocity oxy-fuel deposition, allows greater flexibility in ability to coat economically and rapidly for parts with complex geometry...
Show moreThermal barrier coatings (TBC) with MCrAlY (M=Co and/or Ni) bond coats have been widely used in hot sections of gas turbines to protect underlying superalloys from high temperatures, oxidation, and hot corrosion. Deposition of MCrAlY bond coats using atmospheric plasma spray (APS), as oppose to conventionally employed vacuum/low-pressure plasma spray and high velocity oxy-fuel deposition, allows greater flexibility in ability to coat economically and rapidly for parts with complex geometry including internal surfaces. There were three objectives of this study. First, relationships between APS spray parameters and coating microstructure was examined to determine optimum spray parameters to deposit APS CoNiCrAlY bond coats. Second, free-standing APS CoNiCrAlY coatings were isothermally oxidized at 1124C for various periods to examine the evolving microstructure of internal oxidation. Third, as a function of time of isothermal oxidation (i.e., internal oxidation), thermal conductivity and coefficient of thermal expansion were measured for free-standing APS CoNiCrAlY bond coats. Thirteen CoNiCrAlY coatings were deposited on steel substrates by APS using the F4-MB plasma torch. APS CoNiCrAlY bond coats were produced by incremental variation in the flow rate of primary (argon) gas from 85 to 165 SCFH and the flow rate of secondary (hydrogen) gas from 9 to 29 SCFH. Optimum coating microstructure was produced by simultaneously increasing the flow rate of both primary and secondary gas, so that the particle temperature is high enough for sufficient melting and the particle velocity is rapid enough for minimum in-flight oxidation. Optimum spray parameters found in this study were employed to deposit free-standing APS CoNiCrAlY coatings that were isothermally oxidized at 1124ºC for 1, 6, 50,100, and 300 hours. Extent of internal oxidation was examined by scanning electron microscopy and image analysis. Internal oxidation occurred by a thickening of oxide scales segregated at the splat boundaries oriented parallel to the coating surfaces. Thermal conductivity and coefficient of thermal expansion (CTE) of the free-standing APS CoNiCrAlY coatings were measured as a function of internal oxidation (i.e., time of oxidation or extent of internal oxidation). Thermal conductivity of free-standing APS CoNiCrAlY was found to decrease with increasing internal oxidation from 28 to 25 W/m-K. This decrease is due to an increase in the amount of internal oxides with lower thermal conductivity (e.g., Al2O3). CTE of free-standing APS CoNiCrAlY, measured in temperature range of 100~500C, was also found to decrease with increasing internal oxidation. Internal oxides have lower CTE than metallic CoNiCrAlY coatings. These evolving properties of APS CoNiCrAlY should be beneficial to the overall performance of TBCs in gas turbine applications.
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Date Issued: 2008
Identifier: CFE0002400, ucf:47757
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0002400

Title: NON-DESTRUCTIVE MICROSTRUCTURAL EVALUATION OF YTTRIA STABILIZED ZIRCONIA, NICKEL ALUMINIDES AND THERMAL BARRIER COATINGS USING ELECTROCHEMICAL IMPEDANCE SPECTROSCOPY.
Creator: Vishweswaraiah, Srinivas, Sohn, Yongho, University of Central Florida
Abstract / Description: There has been an urge for increasing the efficiency in advanced gas turbine engines. To fulfill these needs the inlet gas temperatures should be increased in the gas turbine engines, thermal barrier coatings (TBCs) have gained significant applications in increasing the gas inlet temperatures. Insulating characteristics of ceramic TBCs allow the operation at up to 150~250 ˚C higher gas temperatures. Because of the severe turbine engine operating conditions that include high...
Show moreThere has been an urge for increasing the efficiency in advanced gas turbine engines. To fulfill these needs the inlet gas temperatures should be increased in the gas turbine engines, thermal barrier coatings (TBCs) have gained significant applications in increasing the gas inlet temperatures. Insulating characteristics of ceramic TBCs allow the operation at up to 150~250 ˚C higher gas temperatures. Because of the severe turbine engine operating conditions that include high temperature, steep temperature gradient, thermal cycling, oxidation and hot-corrosion, TBCs can fail by spallation at the interface between the metal and ceramic. The lack of understanding in failure mechanisms and their prediction warrant a development of non-destructive evaluation technique that can monitor the quality and degradation of TBCs. In addition, the development of NDE technique must be based on a robust correlation to the characteristics of TBC failure.The objective of this study is to develop electrochemical impedance spectroscopy (EIS) as a Non-destructive evaluation (NDE) technology for application to TBCs. To have a better understanding of the multilayer TBCs using EIS they were divided into individual layers and EIS were performed on them. The individual layers included polycrystalline ZrO2-7~8 wt.%Y2O3 (YSZ) (topcoat) of two different densities were subjected to sintering by varying the sintering temperature and holding time for three different thickness and hot extruded NiAl alloy buttons which were subjected to isothermal oxidation with varying temperature and time. NiAl is as similar to the available commercial bondcoats used in TBCs. Then degradation monitoring with electrolyte penetration was carried out on electron beam physical vapor deposited (EB-PVD) TBCs as a function of isothermal exposure. Quality control for air plasma sprayed TBCs were carried out as a function of density, thickness and microstructure. Dense vertically cracked TBCs were tested as a function of vertical crack density and thickness.Electrochemical impedance response was acquired from all specimens at room temperature and analyzed with an AC equivalent circuit based on the impedance response as well as multi-layered structure and micro-constituents of specimens. Physical and microstructural features of these specimens were also examined by optical and electron microscopy. The EIS measurement was carried out in a three-electrode system using a standard Flat Cell (K0235) from Princeton Applied Research and IM6e BAS ZAHNER frequency response analyzer. The electrolyte employed in this investigation was 0.01M (molar) potassium Ferri/Ferro Cyanide {(K3Fe(CN)6/K4Fe(CN)6•3H2O)}.The thickness and density were directly related to the resistance and capacitance of the polycrystalline YSZ with varying thickness and open pores. As the effective thickness of the YSZ increased with sintering time and temperature, the resistance of the YSZ (RYSZ) increased proportionally. The variation in capacitance of YSZ (CYSZ) with respect to the change in porosity/density and thickness was clearly detected by EIS. The samples with high porosity (less dense) exhibited large capacitance, CYSZ, compared to those with less porosity (high density), given similar thickness. Cracking in the YSZ monoliths resulted in decrease of resistance and increase in capacitance and this was related to the electrolyte penetration.Growth and spallation of TGO scale on NiAl alloys during isothermal oxidation at various temperatures and holding time was also correlated with resistance and capacitance of the TGO scale. With an increase in the TGO thickness, the resistance of the TGO (RTGO) increased and capacitance of the TGO (CTGO) decreased. This trend in the resistance and capacitance of the TGO changed after prolonged heat treatment. This is because of the spallation of the TGO scale from the metal surface. The parabolic growth of TGO
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Date Issued: 2004
Identifier: CFE0000041, ucf:52855
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0000041

Title: IMPURITY AND INTERDIFFUSION IN THE MAGNESIUM-ALUMINUM SYSTEM.
Creator: Brennan, Sarah, Sohn, Yongho, University of Central Florida
Abstract / Description: Magnesium alloys offer a base of lightweight engineering materials for electronic, military and transportation applications where weight reduction is crucial for higher efficiency. Understanding fundamental diffusion behavior in Mg alloys elicits better materials properties through the optimization of processing techniques and heat treatments, whose material responses are affected by diffusion. The main objective of this study is to provide a clear, comprehensive description of the diffusion...
Show moreMagnesium alloys offer a base of lightweight engineering materials for electronic, military and transportation applications where weight reduction is crucial for higher efficiency. Understanding fundamental diffusion behavior in Mg alloys elicits better materials properties through the optimization of processing techniques and heat treatments, whose material responses are affected by diffusion. The main objective of this study is to provide a clear, comprehensive description of the diffusion behavior in the technically important magnesium-aluminum binary metallic system. In this study, diffusion in the Mg-Al system was observed through solid diffusion couples and thin film specimens in the temperature range of 673-523K. The formation and growth of the intermetallic phases, [two]-Mg2Al3 and [three]-Mg17Al12, and the absence of the [micro]-Mg23Al30 phase was observed. The [two]-Mg2Al3 phase grew thicker, had higher parabolic growth constants and lower activation energy for growth. Concentration-dependent interdiffusion coefficients were determined using the Boltzmann-Matano method. Interdiffusion in the [two]-Mg2Al3 phase was the highest, followed by the [three]-Mg17Al12 phase, the Al solid solution and the Mg solid solution. Intrinsic diffusion coefficients at the marker plane composition of 38 at.% Mg in the [two]-Mg2Al3 were determined from Heumann's method for Mg and Al, for which Al was higher. Extrapolations of the impurity diffusion coefficients in both terminal solid solutions were made and compared to available literature data. The thermodynamic factor, tracer diffusivity and atomic mobility of Mg and Al at the marker plane concentration were estimated using Mg activities in the [two]-Mg2Al3 available from literature. The impurity diffusion of Al and self-diffusion of the stable isotope, 25Mg, in polycrystalline Mg was measured from thin film specimens via depth profiling using secondary ion mass spectrometry. The Al impurity diffusion observed is compared to the extrapolations from the parallel interdiffusion study. The self-diffusion measurements are compared to reported literature values and were observed to be significantly higher. Several reasons for the observed difference in the magnitude of diffusivities are discussed.
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Date Issued: 2011
Identifier: CFE0003984, ucf:48678
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0003984

Title: CORRELATING MICROSTRUCTURAL DEVELOPMENT AND FAILURE MECHANISMS TO PHOTOSTIMULATED LUMINESCENCE SPECTROSCOPY AND ELECTROCHEMICAL IMPEDANCE SPECTROSCOPY IN THERMAL BARRIER COATINGS.
Creator: Jayaraj, Balaji, Sohn, Yongho, University of Central Florida
Abstract / Description: Thermal barrier coatings (TBCs) are widely used for thermal protection of hot section components in turbines for propulsion and power generation. Applications of TBCs based on a clearer understanding of failure mechanisms can help increase the performance and life-cycle cost of advanced gas turbine engines. Development and refinement of robust non-destructive evaluation techniques can also enhance the reliability, availability and maintainability of hot section components in gas turbines...
Show moreThermal barrier coatings (TBCs) are widely used for thermal protection of hot section components in turbines for propulsion and power generation. Applications of TBCs based on a clearer understanding of failure mechanisms can help increase the performance and life-cycle cost of advanced gas turbine engines. Development and refinement of robust non-destructive evaluation techniques can also enhance the reliability, availability and maintainability of hot section components in gas turbines engines. In this work, degradation of TBCs was non-destructively examined by photostimulated luminescence spectroscopy (PSLS) and electrochemical impedance spectroscopy (EIS) as a function of furnace thermal cycling carried out in air with 10-minute heat-up, 0.67, 9.6 and 49.6 -hour dwell duration at 1121°C (2050°F), and 10-minute forced-air quench. TBCs examined in this study consisted of either electron beam physical vapor deposited and air plasma sprayed yttria-stabilized zirconia (YSZ) on a variety of bond coat / superalloy substrates including bond coats of NiCoCrAlY and (Ni,Pt)Al, and superalloys of CMSX-4, Rene'N5, Haynes 230 and MAR-M-509. Detailed microstructural characterization by scanning electron microscopy and energy dispersive spectroscopy was carried out to document the degradation and failure characteristics of TBC failure, and correlate results of PSLS and EIS. Mechanisms of microstructural damage initiation and progression varied as a function of TBC architecture and thermal cycling dwell time, and included undulation of the interface between the thermally grown oxide (TGO) and bond coats, internal oxidation of the bond coats, and formation of Ni/Co-rich TGO. These microstructural observations were correlated to the evolution in compressive residual stress in the TGO scale determined by PSLS shift. Correlations include stress-relief and corresponding luminescence shift towards stress-free luminescence associated with subcritical cracking of the TGO scale and stress-relaxation associated with gradual shift in the luminescence towards stress-free luminescence is related to the undulation of TGO/bondcoat interface (e.g., rumpling and ratcheting). Microstructural changes in TBCs such as YSZ sintering, TGO growth, and subcritical damages within the YSZ and TGO scale were also correlated to the changes in electrochemical resistance and capacitance of the YSZ and TGO, respectively. With thermal exposure the YSZ/TGO resistance and capacitance increased and decreased as result of sintering and TGO growth. With progressive thermal cycling damages in the TGO was related to the TGO capacitance showing a continuous increase and at failure TGO capacitance abruptly increased with the exposure of bondcoat. Further correlations among the microstructural development, PSLS and EIS are documented and discussed, particularly as a function of dwell time used during furnace thermal cycling test, with due respect for changes in failure characteristics and mechanisms for various types of TBCs.
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Date Issued: 2011
Identifier: CFE0003635, ucf:48882
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0003635

Title: CHARACTERIZATION AND AQUEOUS COLLOIDAL PROCESSING OF TUNGSTEN NANO-POWDERS.
Creator: Yang, Zhengtao, Sohn, Yongho, University of Central Florida
Abstract / Description: Extensive attention has been paid to consolidate nanoparticles into nanocrystalline components that possess better properties than their coarse-grained counterparts. Nanocrystalline monolithic tungsten (W) has been envisaged to possess better properties than coarse-grained tungsten and to improve the performance of many military components. Commercially available nano-W powders were characterized via X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy...
Show moreExtensive attention has been paid to consolidate nanoparticles into nanocrystalline components that possess better properties than their coarse-grained counterparts. Nanocrystalline monolithic tungsten (W) has been envisaged to possess better properties than coarse-grained tungsten and to improve the performance of many military components. Commercially available nano-W powders were characterized via X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray photoelectron spectroscopy (XPS), Auger electron spectroscopy (AES) and Brunauer, Emmett, and Teller (BET) measurement. While the bulk of nano-W powders consisted of bcc-W as confirmed by XRD and TEM, much of their surface consisted of WO3 with traces of WO2 and WC. Despite the irregular morphology and agglomerates greater than 1 m in size, the diameter of individual nano-W powders ranged from 30 to 100 nm with a surface area of 10.4 m2/g. To obtain green bodies of higher densities and more homogeneous microstructures after consolidation, W nanopowders were de-agglomerated in water and slip cast in plaster molds. De-agglomeration in water was conducted by repeated ultrasonication, washing, centrifuge and pH adjustment. The change in particle size and morphology was examined via SEM. After the initial surface oxide was removed by repeated washing, the reactivity of W nanoparticles to water was somewhat inhibited. Increasing the number of cycles for ultrasonication and washing increased the pH, the degree of de-agglomeration and the stability of W suspension. The zeta potential was more negative with increasing pH and most negative at pH values close to 5. Viscosity also decreased with increasing pH and reached a minimum at a pH 5. To obtain the highest solid loading with the lowest viscosity, the pH value of W suspension was adjusted to 5 using aqueous tetramethylammonium hydroxide solutions. The relative density of the slip cast increased with longer ultrasonic time, increasing slurry pH up to 5, and consequent increase in solids loading. Smaller particles were separated from larger ones by ultrasonication, washing with water and centrifugation. At a 27.8 vol.% solids loading, the size-separated fine W slurry was slip cast into pellets with relative green densities up to 41.3 % and approximate particle sizes of 100 nm. W powders were also ultrasonicated in aqueous poly (ethyleneimine) (PEI) solutions with various concentrations. SEM examinations of particle sizes showed that 1 wt.% PEI led to the optimum dispersion and ultrasonication for longer time with a low power resulted in better dispersion. 0.5 g of W powders were ultrasonicated in 10 ml aqueous poly (allylamine hydrochloride) (PAH) solutions with molar concentrations ranging from 0.01 to 0.05 M. W suspensions with 0.03 M and 0.04 M PAH after two washing cycles showed improved dispersion. Cold isostatic pressing can further increase the green density following slip casting. Sintered slip casts made from de-agglomerated nanoparticle W showed a lower density, more uniform microstructure, smaller grains and smaller pores than the sintered dry pressed pellets.
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Date Issued: 2009
Identifier: CFE0002706, ucf:48144
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0002706

Title: ENVIRONMENTAL DEGRADATION OF OXIDATION RESISTANT AND THERMAL BARRIER COATINGS FOR FUEL-FLEXIBLE GAS TURBINE APPLICATIONS.
Creator: Mohan, Prabhakar, Sohn, Yongho, University of Central Florida
Abstract / Description: The development of thermal barrier coatings (TBCs) has been undoubtedly the most critical advancement in materials technology for modern gas turbine engines. TBCs are widely used in gas turbine engines for both power-generation and propulsion applications. Metallic oxidation-resistant coatings (ORCs) are also widely employed as a stand-alone protective coating or bond coat for TBCs in many high-temperature applications. Among the widely studied durability issues in these high-temperature...
Show moreThe development of thermal barrier coatings (TBCs) has been undoubtedly the most critical advancement in materials technology for modern gas turbine engines. TBCs are widely used in gas turbine engines for both power-generation and propulsion applications. Metallic oxidation-resistant coatings (ORCs) are also widely employed as a stand-alone protective coating or bond coat for TBCs in many high-temperature applications. Among the widely studied durability issues in these high-temperature protective coatings, one critical challenge that received greater attention in recent years is their resistance to high-temperature degradation due to corrosive deposits arising from fuel impurities and CMAS (calcium-magnesium-alumino-silicate) sand deposits from air ingestion. The presence of vanadium, sulfur, phosphorus, sodium and calcium impurities in alternative fuels warrants a clear understanding of high-temperature materials degradation for the development of fuel-flexible gas turbine engines. Degradation due to CMAS is a critical problem for gas turbine components operating in a dust-laden environment. In this study, high-temperature degradation due to aggressive deposits such as V2O5, P2O5, Na2SO4, NaVO3, CaSO4 and a laboratory-synthesized CMAS sand for free-standing air plasma sprayed (APS) yttria stabilized zirconia (YSZ), the topcoat of the TBC system, and APS CoNiCrAlY, the bond coat of the TBC system or a stand-alone ORC, is examined. Phase transformations and microstructural development were examined by using x-ray diffraction, scanning electron microscopy, and transmission electron microscopy. This study demonstrated that the V2O5 melt degrades the APS YSZ through the formation of ZrV2O7 and YVO4 at temperatures below 747Ã‚Â°C and above 747Ã‚Â°C, respectively. Formation of YVO4 leads to the depletion of the Y2O3 stabilizer and the deleterious transformation of the YSZ to the monoclinic ZrO2 phase. The investigation on the YSZ degradation by Na2SO4 and a Na2SO4 + V2O5 mixture (50-50 mol. %) demonstrated that Na2SO4 itself did not degrade the YSZ, however, in the presence of V2O5, Na2SO4 formed vanadates such as NaVO3 that degraded the YSZ through YVO4 formation at temperature as low as 700Ã‚Â°C. The APS YSZ was found to react with the P2O5 melt by forming ZrP2O7 at all temperatures. This interaction led to the depletion of ZrO2 in the YSZ (i.e., enrichment of Y2O3 in tÃ‚Â'-YSZ) and promoted the formation of the fluorite-cubic ZrO2 phase. Above 1250Ã‚Â°C, CMAS deposits were observed to readily infiltrate and significantly dissolve the YSZ coating via thermochemical interactions. Upon cooling, zirconia reprecipitated with a spherical morphology and a composition that depended on the local melt chemistry. The molten CMAS attack destabilized the YSZ through the detrimental phase transformation (tÃ‚Â' -> t -> f + m). Free standing APS CoNiCrAlY was also prone to degradation by corrosive molten deposits. The V2O5 melt degraded the APS CoNiCrAlY through various reactions involving acidic dissolution of the protective oxide scale, which yielded substitutional-solid solution vanadates such as (Co,Ni)3(VO4)2 and (Cr,Al)VO4. The molten P2O5, on the other hand, was found to consume the bond coat constituents significantly via reactions that formed both Ni/Co rich phosphates and Cr/Al rich phosphates. Sulfate deposits such as Na2SO4, when tested in encapsulation, damaged the CoNiCrAlY by Type I acidic fluxing hot corrosion mechanisms at 1000Ã‚Â°C that resulted in accelerated oxidation and sulfidation. The formation of a protective continuous Al2O3 oxide scale by preoxidation treatment significantly delayed the hot corrosion of CoNiCrAlY by sulfates. However, CoNiCrAlY in both as-sprayed and preoxidized condition suffered a significant damage by CaSO4 deposits via a basic fluxing mechanism that yielded CaCrO4 and CaAl2O4. The CMAS melt also dissolved the protective Al2O3 oxide scale developed on CoNiCrAlY by forming anorthite platelets and spinel oxides. Based on the detailed investigation on degradation of the APS YSZ and CoNiCrAlY by various corrosive deposits, an experimental attempt was carried out to mitigate the melt-induced deposit attack. Experimental results from this study demonstrate, for the first time, that an oxide overlay produced by electrophoretic deposition (EPD) can effectively perform as an environmental barrier overlay for APS TBCs. The EPD protective overlay has a uniform and easily-controllable thickness, uniformly distributed closed pores and tailored chemistry. The EPD Al2O3 and MgO overlays were successful in protecting the APS YSZ TBCs against CMAS attack and hot corrosion attack (e.g., sulfate and vanadate), respectively. Furnace thermal cyclic oxidation testing of overlay-modified TBCs on bond-coated superalloy also demonstrated the good adhesive durability of the EPD Al2O3 overlay.
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Date Issued: 2010
Identifier: CFE0003099, ucf:48315
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0003099

Title: STRENGTHENING POTENTIAL OF SINGLE-WALLED CARBON NANOTUBES IN PHENOLIC RESIN COMPOSITES.
Creator: Kerr, Brittany, Sohn, Yongho, University of Central Florida
Abstract / Description: Strengthening potential of single-walled carbon nanotubes (SWCNTs) in a phenolic resin composite was evaluated by characterization of purified and phenyl sulfonated SWCNTs, investigation of the load transfer capability of the purified SWCNTs, and characterization of the composites. Purified and phenyl sulfonated SWCNTs, as well as their composites, were examined by Raman spectroscopy, thermogravimetric analysis, scanning electron microscopy equipped with energy dispersive spectroscopy,...
Show moreStrengthening potential of single-walled carbon nanotubes (SWCNTs) in a phenolic resin composite was evaluated by characterization of purified and phenyl sulfonated SWCNTs, investigation of the load transfer capability of the purified SWCNTs, and characterization of the composites. Purified and phenyl sulfonated SWCNTs, as well as their composites, were examined by Raman spectroscopy, thermogravimetric analysis, scanning electron microscopy equipped with energy dispersive spectroscopy, transmission electron microscopy, X-ray photoelectron spectroscopy and ultra violet-visible spectrometry. Fabrication of the SWCNT/phenolic resin composite was performed by first dispersing the SWCNTs in ethylene glycol and then homogenizing the mixture with phenolic resin. The ethylene glycol was then evaporated from the mixture and the SWCNT/phenolic resin composite was cured at 200Ã‚Â°C for 1 hour. The dispersion of SWCNTs in the phenolic resin was reduced with higher SWCNT concentrations. Load was transferred from the phenolic resin to the purified SWCNTs. This demonstrated the potential to strengthen phenolic resin composite with SWCNT reinforcement. The load transfer efficiency in total tension (0.8%) decreased with an increase in SWCNT concentration, while in total compression (-0.8%), the load transfer efficiency remained constant. At very low strain (Ã‚Â± 0.2%), the load transfer efficiency remained constant regardless of SWCNT concentration in both tension and compression. Characterization of the phenyl sulfonated SWCNTs indicated that calcium was introduced as a contaminant that interfered with functionalization of the SWCNTs. The use of contaminated phenyl sulfonated SWCNTs resulted in macroscopic inhomogeneity within the composite.
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Date Issued: 2010
Identifier: CFE0003070, ucf:48317
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0003070

Title: EVOLUTION OF MICROSTRUCTURE AND RESIDUAL STRESS IN DISC-SHAPE EB-PVD THERMAL BARRIER COATINGS AND TEMPERATURE PROFILE OF HIGH PRESSURE TURBINE BLADE.
Creator: Mukherjee, Sriparna, Sohn, Yongho, University of Central Florida
Abstract / Description: A detailed understanding of failure mechanisms in thermal barrier coatings (TBCs) can help develop reliable and durable TBCs for advanced gas turbine engines. One of the characteristics of failure in electron beam physical vapor deposited (EB-PVD) TBCs is the development of instability, named rumpling, at the interface between (Ni, Pt)Al bond coat and thermally grown oxide (TGO). In this study, thermal cycling at 1100[degrees]C with 1 hr dwell time was carried out on 25.4mm disc specimens of...
Show moreA detailed understanding of failure mechanisms in thermal barrier coatings (TBCs) can help develop reliable and durable TBCs for advanced gas turbine engines. One of the characteristics of failure in electron beam physical vapor deposited (EB-PVD) TBCs is the development of instability, named rumpling, at the interface between (Ni, Pt)Al bond coat and thermally grown oxide (TGO). In this study, thermal cycling at 1100[degrees]C with 1 hr dwell time was carried out on 25.4mm disc specimens of TBCs that consisted of EB-PVD coated ZrO2-7wt.%Y2O3, (Pt,Ni)Al bond coat, and CMSX-4 Ni-based superalloy. At specific fraction of lifetime,TBCs were examined by electron microscopy and photostimulated luminescence (PL). Changes in the average compressive residual stress of the TGO determined by PL and the magnitude of rumpling, determined by tortuosity from quantitative microstructural analyses, were examined with respect to the furnace thermal cyclic lifetime and microstructural evolution of TBCs. The combination of elastic strain energy within the TGO and interfacial energy at the interface between the TGO and the bond coat was defined as the TGO energy, and its variation with cyclic oxidation time was found to remain approximately constant ~135J/m2 during thermal cycling from 10% to 80% thermal cyclic lifetime. Parametric study at ~135J/m2 was performed and variation in residual stress with rumpling for different oxide scale thicknesses was examined. This study showed that the contribution of rumpling in residual stress relaxation decreased with an increase in TGO thickness. High pressure turbine blades serviced for 2843 hours and in the as coated form were also examined using electron microscopy and photostimulated luminescence. The difference in residual stress values obtained using PL on the suction and pressure sides of as-coated turbine blade were discussed. The presence of a thick layer of deposit on the serviced blade gave signals from stress free alpha-Al2O3 in the deposit, not from the TGO. The TGO growth constant data from the disc-shape TBCs, thermally cycled at 1100[degrees]C, and studies by other authors at different temperatures but on similar EB-PVD coated TBCs with (Pt, Ni)Al bond coat and CMSX-4 Ni- based superalloy were used to determine the temperature profile at the YSZ/bond coat interface. The interfacial temperature profiles of the serviced blade and the YSZ thickness profile were compared to document the variable temperature exposure at the leading edge, trailing edge, suction and the pressure side.
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Date Issued: 2011
Identifier: CFE0003927, ucf:48700
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0003927

Title: INTERDIFFUSION BEHAVIOR OF U-MO ALLOYS IN CONTACT WITH AL AND AL-SI ALLOYS.
Creator: Perez, Emmanuel, Sohn, Yong-Ho, University of Central Florida
Abstract / Description: U-Mo dispersion and monolithic fuels embedded in Al-alloy matrix are under development to fulfill the requirements of research reactors to use low-enriched molybdenum stabilized uranium alloys as fuels. The system under consideration in this study consisted of body centered cubic (gamma) U-Mo alloys embedded in an Al structural matrix. Significant interaction has been observed to take place between the U-Mo fuel and the Al matrix during manufacturing of the fuel-plate system assembly and...
Show moreU-Mo dispersion and monolithic fuels embedded in Al-alloy matrix are under development to fulfill the requirements of research reactors to use low-enriched molybdenum stabilized uranium alloys as fuels. The system under consideration in this study consisted of body centered cubic (gamma) U-Mo alloys embedded in an Al structural matrix. Significant interaction has been observed to take place between the U-Mo fuel and the Al matrix during manufacturing of the fuel-plate system assembly and during irradiation in reactors. These interactions produce Al-rich phases with physical and thermal properties that adversely affect the performance of the fuel system and can lead to premature failure. In this study, interdiffusion and microstructural development in the U-Mo vs. Al system was examined using solid-to-solid diffusion couples consisting of U-7wt.%Mo, U-10wt.%Mo and U-12wt.%Mo vs. pure Al, annealed at 600°C for 24 hours. The influence of Si alloying addition (up to 5 wt.%) in Al on the interdiffusion microstructural development was also examined using solid-to-solid diffusion couples consisting of U-7wt.%Mo, U-10wt.%Mo and U-12wt.%Mo vs. pure Al, Al-2wt.%Si, and Al-5wt.%Si annealed at 550°C for 1, 5 and 20 hours. To further clarify the diffusional behavior in the U-Mo-Al and U-Mo-Al-Si systems, Al-rich 85.7Al-11.44U-2.86Mo, 87.5Al-10U-2.5Mo, 56.1Al-18.9Si-21.9U-3.1Mo and 69.3Al-11.9Si-18.8U (at.%) alloys were cast and homogenized at 500°C to determine the equilibrium phases of the system. Scanning electron microscopy (SEM), transmission electron microscopy (TEM) and electron probe microanalysis (EPMA) and X-ray diffraction (XRD) were employed to examine the phase development in the diffusion couples and the cast alloys. In ternary U-Mo-Al diffusion couples annealed at 600°C for 24 hours, the interdiffusion microstructure consisted of finely dispersed UAl3, UAl4, U6Mo4Al43, and UMo2Al20 phases while the average composition throughout the interdiffusion zone remained constant at approximately 80 at.% Al. The interdiffusion microstructures observed by EPMA, SEM and TEM analyses were correlated to explain the observed morphological development in the interdiffusion zones. The concept of thermodynamic degrees of freedom was used to justify that, although deviations are apparent, the interdiffusion zones did not significantly deviate from an equilibrium condition in order for the observed microstructures to develop. Selected diffusion couples developed periodic bands within the interdiffusion zone as sub-layers in the three-phase regions. Observation of periodic banding was utilized to augment the hypothesis that internal stresses play a significant role in the phase development and evolution of U-Mo vs. pure Al diffusion couples. The addition of Si (up to 5 wt.%) to the Al significantly reduced the growth rate of the interdiffusion zone. The constituent phases and composition within the interdiffusion zone were also modified. When Si was present in the Al terminal alloys, the interdiffusion zones developed layered morphologies with fine distributions of the (U,Mo)(Al,Si)3 and UMo2Al20 phases. The U6Mo4Al43 phase was observed scarcely in Si depleted regions within the interdiffusion zone. The phase development and evolution of the interdiffusion zone was described in terms of thermodynamic degrees of freedom with minimal deviations from equilibrium.
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Date Issued: 2011
Identifier: CFE0003747, ucf:48778
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0003747

Title: Multiphase Flow Modeling of Molten Metal Atomization at High Gas Pressure.
Creator: Hanthanan Arachchilage, Kalpana, Kumar, Ranganathan, Sohn, Yongho, Kassab, Alain, Shivamoggi, Bhimsen, University of Central Florida
Abstract / Description: The high-pressure gas atomization is well known as one of the best powder manufacturing processes due to its controllability over powder size distribution. However, with the continuous improvement of new alloys, optimizing the operating parameters to maximize the yield is costly and time-consuming. Therefore, it is essential to understand the high-pressure gas atomization process and the effects of different operational parameters on the powder size distribution.Two-phase numerical...
Show moreThe high-pressure gas atomization is well known as one of the best powder manufacturing processes due to its controllability over powder size distribution. However, with the continuous improvement of new alloys, optimizing the operating parameters to maximize the yield is costly and time-consuming. Therefore, it is essential to understand the high-pressure gas atomization process and the effects of different operational parameters on the powder size distribution.Two-phase numerical simulations are performed to capture the interfacial dynamic during the atomization process and to obtain the effects of gas pressure, melt flow rate, and thermophysical properties of atomizing gas and the molten metal. The Volume of Fluid (VOF) model is used to capture the melt-gas interface, and in-house post-processing code is developed to obtain the droplet size distributions. Three-dimensional geometry of an annular-slit close-coupled gas atomizer is utilized to investigate the primary atomization process. The current grid resolution is sufficient forcapturing primary atomization and some characteristics of the secondary atomization, but it is not adequate to capture all the length scales in secondary atomization. Qualitative comparisons of the cumulative volume graphs indicate that this numerical approach is capable of capturing the trends in the atomization process as in the experiments. It is found that a combination of several interfacial instabilities governs the atomization process. Simulations corresponding to different gas pressures show that the atomizationcharacteristics remain unchanged irrespective of the gas pressure. However, it is found that the rate of the evolution and the effectiveness of the atomization process increases with the gas pressure. Three melts (aluminum, steel, and an artificial material with intermediate thermophysical properties) are used to investigate the effects of the molten metal properties and found that the rate of the atomization process decreases with increasing melt density, and the yield of the atomized powder is seen to increase. The flow characteristics remain unchanged for all three melts. The melt flow is strongly correlated with flow characteristics and interfacial instability.
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Date Issued: 2019
Identifier: CFE0007814, ucf:52342
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0007814

Title: Analysis of residual stress and damage mechanisms of thermal barrier coatings deposited via PS-PVD and EB-PVD.
Creator: Rossmann, Linda, Raghavan, Seetha, Sohn, Yongho, Vaidyanathan, Raj, Ghosh, Ranajay, University of Central Florida
Abstract / Description: Thermal barrier coatings (TBCs) are critical to gas turbine engines, as they protect the components in the hot section from the extreme temperatures of operation. The current industry standard method of applying TBCs for turbine blades in jet engines is electron-beam physical vapor deposition (EB-PVD), which results in a columnar structure that is valued for its high degree of strain tolerance. An emerging deposition method is plasma-spray physical vapor deposition (PS-PVD), capable of...
Show moreThermal barrier coatings (TBCs) are critical to gas turbine engines, as they protect the components in the hot section from the extreme temperatures of operation. The current industry standard method of applying TBCs for turbine blades in jet engines is electron-beam physical vapor deposition (EB-PVD), which results in a columnar structure that is valued for its high degree of strain tolerance. An emerging deposition method is plasma-spray physical vapor deposition (PS-PVD), capable of producing a variety of customizable microstructures as well as non-line-of-sight deposition, which allows more complex geometries to be coated, or even multiple parts at once. The pseudo-columnar microstructure that can be produced with PS-PVD is a possible alternative to EB-PVD. However, before PS-PVD can be used to its full potential, its mechanical properties and behavior must be understood. This work contributes to this understanding by characterizing PS-PVD TBCs that have been thermally cycled to simulate multiple lifetimes (0, 300, and 600 thermal cycles). Residual stress in the thermally grown oxide (TGO) layer is characterized by photoluminescence piezospectroscopy as TGO residual stress is correlated with the lifetime of the coating. Residual stress in the top coat is characterized by Raman spectroscopy, because this stress drives cracking in the top coat that can lead to failure. Scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) are performed to observe microstructural and phase evolution to provide context and possible explanations for the stress results. In addition, EB-PVD samples of the same thermal cycling history are characterized in the same way so that PS-PVD can be benchmarked against the industry standard. The compressive residual stress in the TGO in both coatings was relieved with thermal cycling due to the TGO lengthening as well as microcracking. The PS-PVD samples had slightly lower TGO stress than the EB-PVD, which is attributed to the greater extent of cracking within the TGO, whereas cracking in the EB-PVD samples was at the TGO/topcoat interface. The PS-PVD cycled samples had significant cracking within the topcoat near the TGO due to both greater porosity than EB-PVD samples and regions of unmelted particles that provide little resistance to cracking. The greater convolution of the TGO in the PS-PVD samples results in greater out-of-plane tensile stresses that cause crack initiation, as well as diverts cracks away from the difficult-to-follow interface. The TGO stress results agree with existing literature and extend the thermal cycling beyond what has previously been reported for PS-PVD coatings, revealing a trend of stress relief and stress values similar to that of EB-PVD coatings in this study and in the literature. Residual stress in the topcoat for both coating types became increasingly compressive with thermal cycling, indicating loss of strain tolerance by sintering. The trend of the YSZ stress for both coating types to become more compressive with cycling and with depth agrees with the literature, and the thermal cycling is longer than has been previously reported for PS-PVD. The two coating types had quite different microstructures and crack modes as well as different as-deposited residual stresses, but after thermal cycling had similar stresses in both the TGO and top coat. No samples experienced spallation. These results indicate that, while PS-PVD coatings have different properties and behavior from EB-PVD coatings, they had comparable levels of damage to EB-PVD coatings of the same lifetime and are a viable alternative to EB-PVD. Further tuning of the processing parameters may result in PS-PVD coatings with even more similar behavior to EB-PVD coatings.
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Date Issued: 2019
Identifier: CFE0007717, ucf:52429
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0007717

Title: Fatigue Lifetime Approximation based on Quantitative Microstructural Analysis for Air Plasma Sprayed Thermal Barrier Coatings.
Creator: Bargraser, Carmen, Sohn, Yongho, An, Linan, Heinrich, Helge, University of Central Florida
Abstract / Description: The durability of thermal barrier coatings (TBCs) affects the life of the hot section engine components on which they are applied. Fatigue is the general failure mechanism for such components and is responsible for most unexpected failures; therefore it is desirable to develop lifetime approximation models to ensure reliability and durability.In this study, we first examined the microstructural degradation of air plasma sprayed ZrO2-8wt.%Y2O3 TBCs with a low-pressure plasma sprayed CoNiCrAlY...
Show moreThe durability of thermal barrier coatings (TBCs) affects the life of the hot section engine components on which they are applied. Fatigue is the general failure mechanism for such components and is responsible for most unexpected failures; therefore it is desirable to develop lifetime approximation models to ensure reliability and durability.In this study, we first examined the microstructural degradation of air plasma sprayed ZrO2-8wt.%Y2O3 TBCs with a low-pressure plasma sprayed CoNiCrAlY bond coat on an IN 738LC superalloy substrate. The durability of TBCs were assessed through furnace thermal cyclic tests carried out in air at 1100(&)deg;C with a 1-, 10-, and 50-hour dwell period, preceded by a 10-minute heat-up and followed by a 10-minute forced-air-quench. Failure mechanisms of the TBCs were thoroughly investigated through materials characterization techniques including: X-Ray Diffraction, Scanning Electron Microscopy, and Energy Dispersive X-Ray Spectroscopy.Quantitative microstructural analyses were then carried out to document the growth of the thermally grown oxide (TGO) scale, the depletion of the Al-rich ?-NiAl phase in the bond coat, and the population and growth of micro-cracks near the YSZ/bond coat interface. Trends in the TGO growth and the ?-phase depletion in the bond coat followed those of diffusion-controlled processes(-)parabolic growth of the TGO and exponential depletion of the ?-phase. Formation and propagation of cracks within the YSZ resulted in complete spallation of the YSZ topcoat from the bond-coated superalloy substrate.Evolution in these microstructural features was correlated to the lifetime of TBCs, which showed cracking within the YSZ to be the cause of failure; thus a lifetime approximation model was developed, via modification of Paris Law, based on the experimental data. The model predicted the TBC lifetime within 10% of the experimental lifetime.
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Date Issued: 2011
Identifier: CFE0004087, ucf:49145
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0004087

Title: Process-Dependent Microstructure And Severe Plastic Deformation In SiCp Reinforced Aluminum Metal Matrix Composites.
Creator: Uribe Restrepo, Catalina, Sohn, Yongho, Coffey, Kevin, Orlovskaya, Nina, University of Central Florida
Abstract / Description: Discontinuously reinforced MMCs with optimized microstructure are sought after for exceptional high strain rate behavior. The microstructure evolution of a stir-cast A359 aluminum composite reinforced with 30 vol.% SiCp after isothermal anneal, successive hot-rolling, and high strain rate deformation has been investigated. Quantitative microstructural analysis was carried out for the as-cast, annealed (470(&)deg;C, 538(&)deg;C and 570(&)deg;C) and successively hot rolled specimens (64, 75, 88...
Show moreDiscontinuously reinforced MMCs with optimized microstructure are sought after for exceptional high strain rate behavior. The microstructure evolution of a stir-cast A359 aluminum composite reinforced with 30 vol.% SiCp after isothermal anneal, successive hot-rolling, and high strain rate deformation has been investigated. Quantitative microstructural analysis was carried out for the as-cast, annealed (470(&)deg;C, 538(&)deg;C and 570(&)deg;C) and successively hot rolled specimens (64, 75, 88, and 96% rolling reductions). Selected composites were also examined after high strain rate deformation. X-ray diffraction, optical microscopy, scanning electron microscopy and transmission electron microscopy were employed for microstructural characterization. The strength and ductility of the A359 Al alloys, and the composite, were greatly influenced by the brittle eutectic silicon phase and its morphology. Lamellar eutectic silicon spheroidized with isothermal anneal and successive hot rolling with a corresponding decrease in hardness. The hot rolling process also considerably decreased the SiC particle size (approximately 20% after 96% reduction) by breaking-up the hard SiC particles. However, this break-up of particles increased the homogeneity of SiCp size distribution. Successive hot rolling also healed voids due to solidification shrinkage, incomplete infiltration of molten Al and defects originating from fractured particles. Four selected specimens of composites were examined after high strain rate deformation. Fractography and metallographic analysis for the craters, voids, and relevant regions affected by the high velocity impact were carried out. The deposition of impact residuals was frequently observed on the exposed fracture surfaces. These residuals were typically observed as (")molten-and-solidified(") as a consequence of excessive heat generated during and after the damage. Particularly in regions of entry and exit of impact, intermixing of residuals and composite constituents were observed, demonstrating that the Al matrix of the composite also had melted.In all samples examined, cracks were observed to propagate through the eutectic Si network while a small number of broken reinforcement particles were observed. A slight variation in failure mechanisms was observed (e.g., radial, fragmentation, petalling) corresponding to the variation in ductility against high strain rate deformation. In selected specimens, parallel sub-cracks at the exit were observed at 45(&)deg; and 30(&)deg;. These sub-cracks were again filled with intermixed constituents from projectile residuals and composites. This observation suggests that the melting of composite constituents that leads to intermixing occured after the crack propagation and other damage.
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Date Issued: 2011
Identifier: CFE0004172, ucf:49056
Format: Document (PDF)
PURL: http://purl.flvc.org/ucf/fd/CFE0004172

Diffusion (6)	+ -
interdiffusion (6)	+ -
Interdiffusion (4)	+ -
TEM (4)	+ -
diffusion (4)	+ -

Aluminum (3)	+ -
MMC (3)	+ -
Magnesium (3)	+ -
thermal barrier coatings (3)	+ -
Characterization (2)	+ -
Direct Metal Laser Sintering (2)	+ -
Intermetallics (2)	+ -
Nanoindentation (2)	+ -
Raman (2)	+ -
Residual stress (2)	+ -
Thermal Barrier Coatings (2)	+ -
Uranium (2)	+ -
aluminum (2)	+ -
composite (2)	+ -
diffusion coefficient (2)	+ -
impurity diffusion (2)	+ -
kinetics (2)	+ -
metal matrix composite (2)	+ -
microstructure (2)	+ -
molybdenum (2)	+ -
residual stress (2)	+ -
stress (2)	+ -
uranium (2)	+ -
zirconium (2)	+ -
(Pt (1)	+ -

University of Central Florida (53)	+ -
Sohn, Yongho (46)	+ -
Coffey, Kevin (23)	+ -
Heinrich, Helge (6)	+ -
Suryanarayana, Challapalli (6)	+ -

An, Linan (5)	+ -
Fang, Jiyu (5)	+ -
Challapalli, Suryanarayana (4)	+ -
Gaume, Romain (4)	+ -
Gordon, Ali (4)	+ -
Orlovskaya, Nina (4)	+ -
Raghavan, Seetha (4)	+ -
Sohn, Yong-ho (4)	+ -
Sohn, Yong-Ho (3)	+ -
Bai, Yuanli (2)	+ -
Florczyk, Stephen (2)	+ -
Hofmeister, Clara (2)	+ -
Kammerer, Catherine (2)	+ -
Kapat, Jayanta (2)	+ -
Park, Young Joo (2)	+ -
Perez, Emmanuel (2)	+ -
Richardson, Kathleen (2)	+ -
Roldan Cuenya, Beatriz (2)	+ -
Schelling, Patrick (2)	+ -
Shoulders, William (2)	+ -
Ahmed, Omar (1)	+ -
Bargraser, Carmen (1)	+ -
Barmak, Katayun (1)	+ -
Brennan, Sarah (1)	+ -
Britt, Daniel (1)	+ -

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