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EFFECTS OF BOND COAT SURFACE PREPARATION ON THERMAL CYCLING LIFETIME AND FAILURE CHARACTERISTICS OF THERMAL BARRIER COATINGS
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
Incorporating Remotely Sensed Data into Coastal Hydrodynamic Models: Parameterization of Surface Roughness and Spatio-Temporal Validation of Inundation Area
Title
Incorporating Remotely Sensed Data into Coastal Hydrodynamic Models: Parameterization of Surface Roughness and Spatio-Temporal Validation of Inundation Area.
Creator
Medeiros, Stephen, Hagen, Scott, Weishampel, John, Wang, Dingbao, Yeh, Gour-Tsyh, University of Central Florida
Abstract / Description
This dissertation investigates the use of remotely sensed data in coastal tide and inundation models, specifically how these data could be more effectively integrated into model construction and performance assessment techniques. It includes a review of numerical wetting and drying algorithms, a method for constructing a seamless digital terrain model including the handling of tidal datums, an investigation into the accuracy of land use / land cover (LULC) based surface roughness...
Show moreThis dissertation investigates the use of remotely sensed data in coastal tide and inundation models, specifically how these data could be more effectively integrated into model construction and performance assessment techniques. It includes a review of numerical wetting and drying algorithms, a method for constructing a seamless digital terrain model including the handling of tidal datums, an investigation into the accuracy of land use / land cover (LULC) based surface roughness parameterization schemes, an application of a cutting edge remotely sensed inundation detection method to assess the performance of a tidal model, and a preliminary investigation into using 3-dimensional airborne laser scanning data to parameterize surface roughness.A thorough academic review of wetting and drying algorithms employed by contemporary numerical tidal models was conducted. Since nearly all population centers and valuable property are located in the overland regions of the model domain, the coastal models must adequately describe the inundation physics here. This is accomplished by techniques that generally fall into four categories: Thin film, Element removal, Depth extrapolation, and Negative depth. While nearly all wetting and drying algorithms can be classified as one of the four types, each model is distinct and unique in its actual implementation.The use of spatial elevation data is essential to accurate coastal modeling. Remotely sensed LiDAR is the standard data source for constructing topographic digital terrain models (DTM). Hydrographic soundings provide bathymetric elevation information. These data are combined to form a seamless topobathy surface that is the foundation for distributed coastal models. A three-point inverse distance weighting method was developed in order to account for the spatial variability of bathymetry data referenced to tidal datums. This method was applied to the Tampa Bay region of Florida in order to produce a seamless topobathy DTM.Remotely sensed data also contribute to the parameterization of surface roughness. It is used to develop land use / land cover (LULC) data that is in turn used to specify spatially distributed bottom friction and aerodynamic roughness parameters across the model domain. However, these parameters are continuous variables that are a function of the size, shape and density of the terrain and above-ground obstacles. By using LULC data, much of the variation specific to local areas is generalized due to the categorical nature of the data. This was tested by comparing surface roughness parameters computed based on field measurements to those assigned by LULC data at 24 sites across Florida. Using a t-test to quantify the comparison, it was proven that the parameterizations are significantly different. Taking the field measured parameters as ground truth, it is evident that parameterizing surface roughness based on LULC data is deficient.In addition to providing input parameters, remotely sensed data can also be used to assess the performance of coastal models. Traditional methods of model performance testing include harmonic resynthesis of tidal constituents, water level time series analysis, and comparison to measured high water marks. A new performance assessment that measures a model's ability to predict the extent of inundation was applied to a northern Gulf of Mexico tidal model. The new method, termed the synergetic method, is based on detecting inundation area at specific points in time using satellite imagery. This detected inundation area is compared to that predicted by a time-synchronized tidal model to assess the performance of model in this respect. It was shown that the synergetic method produces performance metrics that corroborate the results of traditional methods and is useful in assessing the performance of tidal and storm surge models. It was also shown that the subject tidal model is capable of correctly classifying pixels as wet or dry on over 85% of the sample areas.Lastly, since it has been shown that parameterizing surface roughness using LULC data is deficient, progress toward a new parameterization scheme based on 3-dimensional LiDAR point cloud data is presented. By computing statistics for the entire point cloud along with the implementation of moving window and polynomial fit approaches, empirical relationships were determined that allow the point cloud to estimate surface roughness parameters. A multi-variate regression approach was chosen to investigate the relationship(s) between the predictor variables (LiDAR statistics) and the response variables (surface roughness parameters). It was shown that the empirical fit is weak when comparing the surface roughness parameters to the LiDAR data. The fit was improved by comparing the LiDAR to the more directly measured source terms of the equations used to compute the surface roughness parameters. Future work will involve using these empirical relationships to parameterize a model in the northern Gulf of Mexico and comparing the hydrodynamic results to those of the same model parameterized using contemporary methods. In conclusion, through the work presented herein, it was demonstrated that incorporating remotely sensed data into coastal models provides many benefits including more accurate topobathy descriptions, the potential to provide more accurate surface roughness parameterizations, and more insightful performance assessments. All of these conclusions were achieved using data that is readily available to the scientific community and, with the exception of the Synthetic Aperture Radar (SAR) from the Radarsat-1 project used in the inundation detection method, are available free of charge. Airborne LiDAR data are extremely rich sources of information about the terrain that can be exploited in the context of coastal modeling. The data can be used to construct digital terrain models (DTMs), assist in the analysis of satellite remote sensing data, and describe the roughness of the landscape thereby maximizing the cost effectiveness of the data acquisition.
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Date Issued
2012
Identifier
CFE0004271, ucf:49506
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0004271
THE EFFECTS OF PHOSPHATE AND SILICATE INHIBITORS ON SURFACE ROUGHNESS AND COPPER RELEASE IN WATER DISTRIBUTION SYSTEMS
Title
THE EFFECTS OF PHOSPHATE AND SILICATE INHIBITORS ON SURFACE ROUGHNESS AND COPPER RELEASE IN WATER DISTRIBUTION SYSTEMS.
Creator
MacNevin, David, Taylor, James, University of Central Florida
Abstract / Description
The effects of corrosion inhibitors on water quality and the distribution system were studied. This dissertation investigates the effect of inhibitors on iron surface roughness, copper surface roughness, and copper release. Corrosion inhibitors included blended poly/ortho phosphate, sodium orthophosphate, zinc orthophosphate, and sodium silicate. These inhibitors were added to a blend of surface water, groundwater, and desalinated brackish water. Surface roughness of galvanized iron, unlined...
Show moreThe effects of corrosion inhibitors on water quality and the distribution system were studied. This dissertation investigates the effect of inhibitors on iron surface roughness, copper surface roughness, and copper release. Corrosion inhibitors included blended poly/ortho phosphate, sodium orthophosphate, zinc orthophosphate, and sodium silicate. These inhibitors were added to a blend of surface water, groundwater, and desalinated brackish water. Surface roughness of galvanized iron, unlined cast iron, lined cast iron, and polyvinyl chloride was measured using pipe coupons exposed for three months. Roughness of each pipe coupon was measured with an optical surface profiler before and after exposure to inhibitors. For most materials, inhibitor did not have a significant effect on surface roughness; instead, the most significant factor determining the final surface roughness was the initial surface roughness. Coupons with low initial surface roughness tended to have an increase in surface roughness during exposure, and vice versa, implying that surface roughness tended to regress towards an average or equilibrium value. For unlined cast iron, increased alkalinity and increased temperature tended to correspond with increases in surface roughness. Unlined cast iron coupons receiving phosphate inhibitors were more likely to have a significant change in surface roughness, suggesting that phosphate inhibitors affect stability of iron pipe scales. Similar roughness data collected with new copper coupons showed that elevated orthophosphate, alkalinity, and temperature were all factors associated with increased copper surface roughness. The greatest increases in surface roughness were observed with copper coupons receiving phosphate inhibitors. Smaller increases were observed with copper coupons receiving silicate inhibitor or no inhibitor. With phosphate inhibitors, elevated temperature and alkalinity were associated with larger increases in surface roughness and blue-green copper (II) scales.. Otherwise a compact, dull red copper (I) scale was observed. These data suggest that phosphate inhibitor addition corresponds with changes in surface morphology, and surface composition, including the oxidation state of copper solids. The effects of corrosion inhibitors on copper surface chemistry and cuprosolvency were investigated. Most copper scales had X-ray photoelectron spectroscopy binding energies consistent with a mixture of Cu2O, CuO, Cu(OH)2, and other copper (II) salts. Orthophosphate and silica were detected on copper surfaces exposed to each inhibitor. All phosphate and silicate inhibitors reduced copper release relative to the no inhibitor treatments, keeping total copper below the 1.3 mg/L MCLG for all water quality blends. All three kinds of phosphate inhibitors, when added at 1 mg/L as P, corresponded with a 60% reduction in copper release relative to the no inhibitor control. On average, this percent reduction was consistent across varying water quality conditions in all four phases. Similarly when silicate inhibitor was added at 6 mg/L as SiO2, this corresponded with a 25-40% reduction in copper release relative to the no inhibitor control. Hence, on average, for the given inhibitors and doses, phosphate inhibitors provided more predictable control of copper release across changing water quality conditions. A plot of cupric ion concentration versus orthophosphate concentration showed a decrease in copper release consistent with mechanistic control by either cupric phosphate solubility or a diffusion limiting phosphate film. Thermodynamic models were developed to identify feasible controlling solids. For the no inhibitor treatment, Cu(OH)2 provided the closest prediction of copper release. With phosphate inhibitors both Cu(OH)2 and Cu(PO4)·2H2O models provided plausible predictions. Similarly, with silicate inhibitor, the Cu(OH)2 and CuSiO3·H2O models provided plausible predictions.
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Date Issued
2008
Identifier
CFE0002001, ucf:47621
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0002001
Characterization of Anisotropic Mechanical Performance of As-Built Additively Manufactured Metals
Title
Characterization of Anisotropic Mechanical Performance of As-Built Additively Manufactured Metals.
Creator
Siddiqui, Sanna, Gordon, Ali, Raghavan, Seetha, Bai, Yuanli, Sohn, Yongho, University of Central Florida
Abstract / Description
Additive manufacturing (AM) technologies use a 3D Computer Aided Design (CAD) model to develop a component through a deposition and fusion layer process, allowing for rapid design and geometric flexibility of metal components, for use in the aerospace, energy and biomedical industries. Challenges exist with additive manufacturing that limits its replacement of conventional manufacturing techniques, most especially a comprehensive understanding of the anisotropic behavior of these materials...
Show moreAdditive manufacturing (AM) technologies use a 3D Computer Aided Design (CAD) model to develop a component through a deposition and fusion layer process, allowing for rapid design and geometric flexibility of metal components, for use in the aerospace, energy and biomedical industries. Challenges exist with additive manufacturing that limits its replacement of conventional manufacturing techniques, most especially a comprehensive understanding of the anisotropic behavior of these materials and how it is reflected in observed tensile, torsional and fatigue mechanical responses. As such, there is a need to understand how the build orientation of as-built additively manufactured metals, affects mechanical performance (e.g. monotonic and cyclic behavior, cyclically hardening/softening behavior, plasticity effects on fatigue life etc.); and to use constitutive modeling to both support experimental findings, and provide approximations of expected behavior (e.g. failure surfaces, monotonic and cyclic response, correlations between tensile and fatigue properties), for orientations and experiments not tested, due to the expensive cost associated with AM. A comprehensive framework has been developed to characterize the anisotropic behavior of as-built additively manufactured metals (i.e. Stainless Steel GP1 (SS GP1), similar in chemical composition to Stainless Steel 17-4PH), through a series of mechanical testing, microscopic evaluation and constitutive modeling, which were used to identify a reduced specimen size for characterizing these materials. An analysis of the torsional response of additively manufactured Inconel 718 has been performed to assess the impact of build orientation and as-built conditions on the shearing behavior of this material. Experimental results from DMLS SS GP1 and AM Inconel 718 from literature were used to constitutively model the material responses of these additively manufactured metals. Overall, this framework has been designed to serve as standard, from which build orientation selection can be used to meet specific desired industry requirements.
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Date Issued
2018
Identifier
CFE0007097, ucf:52883
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0007097