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MECHANISMS OF LIFETIME IMPROVEMENT IN THERMAL BARRIER COATINGS WITH HF AND/OR Y MODIFICATION OF CMSX-4 SUPERALLOY SUBSTRATES
Title
MECHANISMS OF LIFETIME IMPROVEMENT IN THERMAL BARRIER COATINGS WITH HF AND/OR Y MODIFICATION OF CMSX-4 SUPERALLOY SUBSTRATES.
Creator
Liu, Jing, Sohn, Yong ho, University of Central Florida
Abstract / Description
In modern turbine engines for propulsion and energy generation, thermal barrier coating (TBCs) protect hot-section blades and vanes, and play a critical role in enhancing reliability, durability and operation efficiency. In this study, thermal cyclic lifetime and microstructural degradation of electron beam physical vapor deposited (EB-PVD) Yttria Stabilized Zirconia (YSZ) with (Ni,Pt)Al bond coat and Hf- and/or Y- modified CMSX-4 superalloy substrates were examined. Thermal cyclic lifetime...
Show moreIn modern turbine engines for propulsion and energy generation, thermal barrier coating (TBCs) protect hot-section blades and vanes, and play a critical role in enhancing reliability, durability and operation efficiency. In this study, thermal cyclic lifetime and microstructural degradation of electron beam physical vapor deposited (EB-PVD) Yttria Stabilized Zirconia (YSZ) with (Ni,Pt)Al bond coat and Hf- and/or Y- modified CMSX-4 superalloy substrates were examined. Thermal cyclic lifetime of TBCs was measured using a furnace thermal cycle test that consisted of 10-minute heat-up, 50-minute dwell at 1135C, and 10-minute forced-air-quench. TBC lifetime was observed to improve from 600 cycles to over 3200 cycles with appropriated Hf- and/or Y alloying of CMSX-4 superalloys. This significant improvement in TBC lifetime is the highest reported lifetime in literature with similar testing parameters. Beneficial role of reactive element (RE) on the durability of TBCS were systematically investigated in this study. Photostimulated luminescence spectroscopy (PL) was employed to non-destructively measure the residual stress within the TGO scale as a function of thermal cycling. Extensive microstructural analysis with emphasis on the YSZ/TGO interface, TGO scale, TGO/bond coat interface was carried out by scanning electron microscopy (SEM), transmission electron microscopy (TEM), and scanning electron microscopy (STEM) as a funcion of thermal cycling including after the spallation failure. Focused ion beam in-situ lift-out (FIB-INLO) technique was employed to prepare site-specific TEM specimens. X-ray diffraction (XRD) and secondary ion mass spectroscopy (SIMS) were also employed for phase identification and interfacial chemical analysis. While undulation of TGO/bond coat interface (e.g., rumpling and ratcheting) was observed to be the main mechanism of degradation for the TBCs on baseline CMSX-4, the same interface remained relatively flat (e.g., suppressed rumpling and ratcheting) for durable TBCs on Hf- and/or Y-modified CMSX-4. The fracture paths changed from the YSZ/TGO interface to the TGO/bond coat interface when rumpling was suppressed. The geometrical incompatibility between the undulated TGO and EB-PVD YSZ lead to the failure at the YSZ/TGO interface for TBCs with baseline CMSX-4. The magnitude of copressive residual stress within the TGO scale measured by PL gradually decreased as a function of thermal cycling for TBCs with baseline CMSX-4 superalloy substrates. This gradual decrease corrsponds well to the undulation of the TGO scale that may lead to relaxation of the compressive residual stress within the TGO scale. For TBCs with Hf- and/or Y-modified CMSX-4 superalloy substrates, the magnitude of compressive residual stress within the TGO scale remained relatively constant throughout the thermal cycling, although PL corresponding to the stress-relief caused by localized cracks at the TGO/bond coat interface and within the TGO scale was observed frequently starting 50% of lifetime. A slightly smaller parabolic growth constant and grain size of the TGO scale was observed for TBCs with Hf- and/or Y- modified CMSX-4. Small monoclinic HfO2 precipitates were observed to decorate grain boundaries and the triple pointes within the alpha-Al2O3 scale for TBCs with Hf- and/or Y-modified CMSX-4 substrates. Segregation of Hf/Hf4+ at the TGO/bond coat interfaces was also observed for TBCs with Hf- and/or Y-modified CMSX-4 superalloys substrates. Adherent and pore-free YSZ/TGO interface was observed for TBCs with Hf- and/or Y-modified CMSX-4, while a significant amount of decohesion at the YSZ/TGO interface was observed for TBCs with baseline CMSX-4. The beta-NiAl(B2) phase in the (Ni,Pt)Al bond coat was observed to partially transform into gama prime-Ni3Al (L12) phase due to depletion of Al in the bond coat during oxidation. More importantly, the remaining beta-NiAl phase transformed into L10 martensitic phase upon cooling even though there was no significant difference in these phase transformations for all TBCs. Results from these microstructural observations are documented to elucidate mechanisms that suppress the rumpling of the TGO/bond coat interface, which is responsible for superior performance of EB-PVD TBCs with (Ni,Pt)Al bond coat and Hf- and/or Y-modified CMXS-4 superalloy.
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Date Issued
2007
Identifier
CFE0001872, ucf:47382
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0001872
Study On Anisotropic Plasticity And Fracture Of Lightweight Metal Sheets
Title
Study On Anisotropic Plasticity And Fracture Of Lightweight Metal Sheets.
Creator
Jia, Yueqian, Bai, Yuanli, Kassab, Alain, Raghavan, Seetha, Gou, Jihua, Wu, Thomas, University of Central Florida
Abstract / Description
How to reduce weight and increase fuel efficiency is a critical challenge in transportation industries. One way to resolve the problem is to adopting lightweight alloys (i.e. advanced high strength steel, aluminum alloys, or magnesium alloy) in structure designs and manufacturing. Fully understanding the mechanical properties of these materials is a key step.In order to fully characterize the plasticity and fracture of magnesium AZ31B-H24 sheets, a set of mechanical experiments (170 in total)...
Show moreHow to reduce weight and increase fuel efficiency is a critical challenge in transportation industries. One way to resolve the problem is to adopting lightweight alloys (i.e. advanced high strength steel, aluminum alloys, or magnesium alloy) in structure designs and manufacturing. Fully understanding the mechanical properties of these materials is a key step.In order to fully characterize the plasticity and fracture of magnesium AZ31B-H24 sheets, a set of mechanical experiments (170 in total) were performed under both monotonic and non-proportional loading conditions, including monotonic uniaxial tension, notch tension, in-plane uniaxial compression, wide compression (or called biaxial compression), plane strain compression, through-thickness compression, in-plane shear, punch test, uniaxial compression-tension reverse loading, and two-step uniaxial tension (cross-loading).Both the plastic strain histories and stress responses were obtained under the above loading conditions, which give a comprehensive picture of mechanical behaviors of this material. No apparent cross-hardening effect was observed for this material.An extended orthotropic yield criterion involving two linear anisotropic transformation tensors, CPB06ex2, in conjunction with its associated flow rule was fully calibrated to describe both the anisotropy in plastic flow and tension-compression asymmetry in stress-strain behaviors.A fully modularized framework to combine isotropic, kinematic, and cross hardening behaviors was established under non-monotonic loading conditions. Three sets of state variables were defined and applied to consider the effects of, a) loading history, b) twinning and de-twinning and c) different pre-strain.In order to predict ductile fracture of metal sheets, the (")mixed(") stress/strain invariants based Modified-Mohr-Coulomb (MMC) fracture model was transferred into an all-strain based MMC (eMMC) model under plane stress condition, predicting the fracture strain dependent on strain ratio or ? angle, instead of stress triaxiality and Lode angle parameter. The strain ratio or ? angle could be directly measured by digital image correlation (DIC), while the latter required finite element analysis to be determined. This method makes it possible to study material fracture behavior while bypassing plasticity. The eMMC fracture locus can be fully calibrated by fracture strains directly measured from DIC. The fracture strain was also extended by a linear transformation operating to the plastic strain tensor to incorporate the fracture anisotropy. All models were implemented into Abaqus/Explicit as a user material subroutine (VUMAT). Good prediction capability has been demonstrated for magnesium AZ31B-H24 sheets by FE simulation using shell elements.The current framework was also applied for TRIP780, BH240, DP600, and EDDQ steel sheets with adjustment, under different loading conditions. The FE simulation results for TRIP780 correlated well with experimental data under different monotonic loading conditions. The analytical results for BH240, DP600, and EDDQ demonstrated good prediction capability for cross-hardening behavior, and validated by the non-proportional experimental data under two-stage uniaxial tension.
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Date Issued
2016
Identifier
CFE0006121, ucf:51165
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0006121