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To fully realize the potential application of spalled thermal barrier coating systems (TBCs) in gas turbine blades, it is essential to evaluate the service behavior of TBCs and the critical spallation size for safety servicing. For this purpose, the evaluation of the localized spallation of TBCs under high-temperature gas was investigated experimentally and numerically. Thermal insulation experiments and a conjugate heat transfer numerical algorithm were used to clarify the over-temperature phenomenon, temperature distributions, the relevant flow characteristics of the high-temperature gas in the localized spallation region of TBCs, and the influencing mechanisms that consider the spallation width were identified. The results suggested that when the spallation width was less than 10 µm, the temperature in the TBCs did not change due to the weak impression of gas. When the spallation width exceeded the security coefficient of about 3 mm, the TBCs were difficult to service safely due to the impact of high-temperature gas. Furthermore, the concept of an over-temperature coefficient was proposed to describe the over-temperature damage and a nonlinear fitting equation was obtained to reveal and predict the evolution of the over-temperature coefficient. The over-temperature coefficient may serve as a valuable metric in determining the performance degradation of TBCs.

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Fibers crystallize and become brittle at high temperatures for a long time, so the surface coating must maintain long-lasting emission performance, which requires superior antioxidant properties of the high-emissivity fillers. To improve the radiation performance of the coating and the tensile strength of the fiber fabric, a double-layer coating with high emissivity was prepared on the surface of flexible aluminum silicate fiber fabric (ASFF) using MoSi2 and SiC as emissive agents. The incorporation of borosilicate glass into the outer coating during high-temperature oxidation of ZrB2 results in superior encapsulation of emitter particles, effectively filling the pores of the coating and significantly reducing the oxidation rate of MoSi2 and SiC. Furthermore, the addition of an intermediate ZrO2 layer enhances the fiber bundle's toughness. The obtained double-coated ASFF exhibits an exceptionally high tensile strength of 57.6 MPa and a high bond strength of 156.2 kPa. After being subjected to a 3 h heating process, the emissivity exhibits a minimal decrease of only 0.032, while still maintaining a high value above 0.9. The thermal insulation composites, consisting of a flexible ASFF matrix and a ZrB2-modified double-layer coating, exhibit significant potential for broad applications in the field of thermal protection.

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Self-made agglomerated nanometer CeO2-Y2O3-ZrO2 (CYSZ) powders for plasma spray-physical vapor deposition (PS-PVD) were prepared by spray-drying, followed by calcination treatment at four different temperatures (600 °C, 700 °C, 800 °C, 900 °C). The physical properties, microstructure, and phase composition of the calcined powders were investigated using a laser particle size analyzer, scanning electron microscopy (SEM), and X-ray diffraction (XRD). The results showed that compared to the agglomerated powders obtained through spray-drying, the particle size of the agglomerated powders changed with increasing calcination temperature, accompanied by an increase in the self-bonding force of the agglomerated powder particles. The proper calcination temperature improved the sprayability of the powders. Additionally, with the increase in the calcination temperature, a transformation from the m-phase to the t-phase occurred in the powder, with Ce4+ partially entering the Zr lattice to form the t-Zr0.84Ce0.16O2 phase, which facilitated the suppression of the m-phase and improved the high-temperature phase stability. It was also found that the PS-PVD coatings prepared using the aforementioned powders exhibited coarser columnar structures with increasing powder calcination temperature.

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In this study, the induction plasma spheroidization (IPS) technique was adopted to improve the microstructure and properties of the traditional agglomerated ZrO2-7wt%Y2O3 (YSZ) powders used in thermal barrier coating (TBC) applications. Compared with agglomerated YSZ powders, IPS-treated powder has a more desirable microstructure, and the overall performance of the spray powders for TBC preparation is significantly improved. Specifically, IPS-treated powder has a dense, solid, defect-free, and chemically uniform microstructure, and its apparent density, flowability, and powder strength are significantly improved, which is believed to substantially enhance the coating performance when prepared with this IPS-treated powder.

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Contemporary gas turbine engines rely on thermal barrier coatings (TBCs), which protect the structural components of the engine against degradation at extremely high operating temperatures (1300-1500 °C). The operational efficiencies of aircraft engines have seen significant improvement in recent years, primarily through the increase in operating temperatures; however, the longevity of TBCs can be potentially impacted by several types of degradation mechanisms. In this comprehensive study, a wide range of novel columnar suspension plasma sprayed (SPS) coatings were developed for their erosion, calcium-magnesium-aluminum-silicate (CMAS), and furnace cycling test (FCT) performance. Through a comprehensive investigation, the first of its kind, we achieved a range of SPS microstructures by modifying the spray parameters and measuring their microhardness, fracture toughness, column densities, and residual stresses using Raman spectroscopy. We were able to produce dendritic, lateral, branched, and columnar microstructures with a unique set of processing parameters. Coatings enhanced with a refined columnar microstructure, achieved by modulating the distance from the plasma torch, exhibited superior thermal cycling resilience. Conversely, the development of a columnar microstructure with dendritic branches, obtained by decreasing the robot's traversal speed during deposition, bolstered resistance to erosion and minimized damage from molten CMAS infiltration, thereby notably augmenting the coating's lifespan and robustness. The pursuit of the optimal columnar microstructure led to the conclusion that for each SPS coating, a general framework of optimization needs to be conducted to achieve their desired thermo-chemico-mechanical resistance as the properties required for TBCs are intertwined.

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Energy consumption and management have emerged as crucial production functions because of the high cost of energy. Since the total consumption of fossil fuels like diesel has increased proportionally to the expansion in demand for power generation, industry, and transportation services, researchers have long been interested in constructing a more energy-efficient engine. With its improved efficiency, reduced fuel consumption, and fewer emissions, the application of nano-coating technology to engine components has become more popular in recent years. This study involved the application of a thermal barrier coating (TBC) using zirconia on the test engine piston. The aim of this research is to examine the impact of aluminium oxide nano-additives in rapeseed biodiesel blends on the performance of a diesel engine with a thermal barrier-coated piston. The four test fuels were prepared using 20% and 40% blends of rapeseed biodiesel with and without the addition of aluminium oxide at 25 ppm and 50 ppm. The full factorial design methodology was employed to examine the influential factors, specifically the rapeseed blend ratio and aluminium oxide concentration, in order to enhance performance and reduce emissions. The blends of RSB20AO25 and RSB20AO50 showed significant results on energy consumption and emissions. The RSB20AO50 blend performed with a 5.4% increase in brake thermal efficiency and a 6.5% reduction in fuel consumption compared with standard diesel. Similarly, blends of RSB20AO25 and RSB20AO50 show 6% and 11% reductions in carbon monoxide and 5.2% and 9.5% reductions in hydrocarbon emissions.

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This research study was conducted to investigate the laser melting parameters of NiCrAlY-APS coating. High-temperature oxidation was investigated using yttria partially stabilized zirconia (YSZ) ceramic coating. Also, the oxidation behavior of the TBC coating was investigated and studied before to and after laser surface melting of the NiCrAlY coating. Microstructural characterization was done using a scanning electron microscope (SEM), elemental analysis by energy dispersive spectroscopy (EDS), and phase analysis by X-ray diffraction (XRD). Surface melting was then performed in the power range of 150-300 W and scanning speed of 2-6 mm s-1. Surface melting was also conducted on the coating using two strategies: single-pass and multi-pass. The obtained results showed that the average melting depth and thickness reduction were directly related to the laser power, while they had an inverse relation with the laser scanning speed. Furthermore, multi-pass surface melting parameters reduced porosity to less than 0.1 %. Roughness measurements also showed a decrease in the coating's surface hardness after surface melting, as compared to the APS coating. The structure consisted of oriented columnar dendrites after melting the laser. The adhesion strength of the TBC coating and laser surface melting coating was at 41 MPa and 53 MPa, respectively. After 200 h of oxidation in the G1504 sample, the TGO layer's growth was decreased; due to the growth of a single oxide layer, it had better oxidation resistance in comparison to the other sample.

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This paper focused on studying the performance of a nanostructured thermal barrier coating (TBC) system deposited by APS, which had a bond coat with inter-lamellar porosities that resulted during the manufacturing process. The higher porosity level of the bond coat was studied as a possible way to keep the thickness of the TGO under control, as it is distributed on a higher surface, thereby reducing the chance of top-coat (TC) spallation during long-term oxidation and high-temperature thermal shock. The TBC system consisted of nanostructured yttria partially stabilized zirconia (YSZ) as a top coat and a conventional NiCrAlY bond coat. Inter-lamellar porosities ensured the development of a TGO distributed on a higher surface without affecting the overall coating performance. Based on long-term isothermal oxidation tests performed at 1150 °C, the inter-lamellar pores do not affect the high resistance of nanostructured TBCs in case of long-term iso-thermal oxidation at 1150 °C. The ceramic layer withstands the high-temperature exposure for 800 h of maintaining without showing major exfoliation. Fine cracks were discovered in the ceramic coating after 400 h of isothermal oxidation, and larger cracks were found after 800 h of exposure. An increase in both ceramic and bond-coat compaction was observed after prolonged high-temperature exposure, and this was sustained by the higher adhesion strength. Moreover, in extreme conditions, under high-temperature thermal shock cycles, the TBC withstands for 1242 cycles at 1200 °C and 555 cycles at 1250 °C.

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To mitigate the challenges pertaining to coating damage and processing defects arising from the utilization of ultrafast laser drilling for microhole creation in thermal barrier coatings (TBCs), thereby exerting substantial influence on the long-term durability of these microholes, the investigation proposes a comprehensive methodology. It encompasses the design of a two-factor four-level full factorial experiment and the execution of experimental research on picosecond laser drilling of TBC microholes. By meticulously analyzing the morphology of the microholes and the coating interface, the damage mechanisms associated with picosecond laser drilling of TBC microholes, as well as the influence of laser process parameters on coating damage, are revealed. The findings reveal that the optimal microhole entrance quality and the lowest roughness along the hole perimeter are attained at a laser power of 12 W and a scanning speed of 320 mm/s. Moreover, at a laser power of 30 W and a scanning speed of 320 mm/s, the minimal crack length on the blunt angle side of the hole and the highest machining quality are observed.

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In ecosystems threatened by the expansion of croplands, habitat fragmentation and climate change, two of the main extinction drivers, may have thermoregulation-mediated interacting effects on demographic trends of terrestrial ectotherms. We studied the thermal biology of a metapopulation of the widespread Mediterranean lacertid Psammodromus algirus in ten fragments of evergreen or deciduous oak forests interspersed among cereal fields. We obtained thermoregulation statistics (selected temperature range, body and operative temperatures, thermal quality of the habitat, and precision, accuracy, and effectiveness of thermoregulation) that could be compared among fragments and with conspecific populations living in unfragmented habitat. We also measured the selection (use vs. availability) and spatial distribution of sunlit and shaded patches used for behavioral thermoregulation in fragments, and we estimated operative temperatures and thermal habitat quality in the agricultural matrix surrounding the fragments. Variation of the thermal environment was much larger within fragments than among them, and thermoregulation was accurate, precise, and efficient throughout the fragmented landscape; its effectiveness was similar to that of previously studied unfragmented populations. The average distance between sunlit and shaded patches was shorter in deciduous than in evergreen fragments, producing a more clumped distribution of the mosaic of thermal resources. Consequently, in evergreen habitat the cost of thermoregulation was higher, because lizards were more selective in their choice of sunlit sites (i.e. they used sunlit patches closer to shade and refuge than expected at random, and the extent of such selection was larger than at deciduous habitat). Temperatures available in croplands were too high to allow lizard dispersal, at least in the post-breeding season. This result confirms the role of croplands as a thermal barrier that promotes inbreeding and associated fitness losses in isolated fragments, and it forecasts a dark future for populations of forest lizards in agricultural landscapes under the combined effects of habitat fragmentation and global warming.

Asunto(s)

RESUMEN

Thermal spray coatings are material systems with unique structures and properties that have enabled the growth and evolution of key modern technologies (i.e., gas turbines, structurally integrated components, etc.). The inherent nature of these sprayed coatings, such as their distinctive thermal and mechanical properties, has been a driving force for maintaining industrial interest. Despite these benefits and proven success in several fields, the adoption of thermal spray technology in new applications (i.e., clean energy conversion, semiconductor thermally sprayed materials, biomedical applications, etc.) at times, however, has been hindered. One possible cause could be the difficulty in concurrently maintaining coating design considerations while overcoming the complexities of the coatings and their fabrication. For instance, a coating designer must consider inherent property anisotropy, in-flight decomposition of molten material (i.e., loss of stoichiometry), and occasionally the formation of amorphous materials during deposition. It is surmisable for these challenges to increase the risk of adoption of thermal spray technology in new fields. Nevertheless, industries other than those already mentioned have benefited from taking on the risk of implementing thermal spray coatings in their infrastructure. Benefits can be quantified, for example, based on reduced manufacturing cost or enhanced component performance. In this overview paper, a historical presentation of the technological development of thermal spray coatings in several of these industries is presented. Additionally, emerging industries that have not yet attained this level of thermal spray maturation will also be discussed. Finally, where applicable, the utility and benefits of multilayer functional thermal spray coating designs will be demonstrated.

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A mathematical model of heat generation due to friction in a disc-pad braking system was developed with consideration of a thermal barrier coating (TBC) on the friction surface of the disc. The coating was made of functionally graded material (FGM). The three-element geometrical scheme of the system consisted of two homogeneous half-spaces (pad and disc) and a functionally graded coating (FGC) deposited on the friction surface of the disc. It was assumed that the frictional heat generated on the coating-pad contact surface was absorbed to the insides of friction elements along the normal to this surface. Thermal contact of friction between the coating and the pad as well as the heat contact between the coating and the substrate were perfect. On the basis of such assumptions, the thermal friction problem was formulated, and its exact solution was obtained for constant and linearly descending specific friction power over time. For the first case, the asymptotic solutions for small and large values of time were also found. A numerical analysis was performed on an example of the system containing a metal ceramic (FMC-11) pad, sliding on the surface of a FGC (ZrO2-Ti-6Al-4V) applied on a cast iron (ChNMKh) disc. It was established that the application of a TBC made of FGM on the surface of a disc could effectively reduce the level of temperature achieved during braking.

RESUMEN

Countless research has suggested Yttria-stabilized Zirconia (YSZ) to be a top candidate for being implemented as thermal barrier coatings (TBC). However, when exposed to prolonged service, temperature and stress variations succeed in initiating a catastrophic phase transformation from tetragonal to monoclinic structure in Zirconia. Hence, the estimation of endurance for YSZ-based TBC is necessary to minimize failure in such situations. The main purpose of this research was to determine the relationship between tribological investigations and the estimated lifespan of YSZ coatings accurately. The study used various methods such as wear resistance testing, optical profilometry, specific wear rate, and coefficient of friction to estimate the maximum durability of TBCs. The research also provided insights into the composition and microstructure of the TBC system and found the optimized concentration of Yttrium doping to be 3.5 wt %. The study discovered that erosion was the main cause of roughness depreciation from SN to S1000. The estimation of the service life was primarily made based on optical profilometry, specific wear rate (SWR), coefficient of friction (COF) and wear resistance values which were further supported by the results of chemical characterization of the samples through electron dispersive spectroscopy (EDS), wavelength dispersive spectroscopy (WDS) and X-Ray Diffraction (XRD) analysis. The results were reliable and accurate and suggested future areas of investigation, such as 3D profilometry for surface roughness and thermal conductivity evaluation using laser-assisted infrared thermometers.

RESUMEN

Electron beam physical vapour deposition (EB-PVD) technology is a standard industrial method for the preparation of a thermal barrier coating (TBC) deposition on aeroengines. The internal stress of EB-PVD TBCs, including stress inside the top coating (TC) and thermal oxidation stress during long-term service is one of the key reasons for thermal barrier failures. However, research on the synergistic characterization of the internal stress of EB-PVD TBCs is still lacking. In this work, the stress inside the TC layer and the thermal oxidation stress of EB-PVD TBC during long-term thermal cycles were synergistically detected, combining Cr3+-PLPS and THz-TDS technologies. Based on a self-built THz-TDS system, stress-THz coefficients c1 and c2 of the EB-PVD TBC, which are the core parameters for stress characterization, were calibrated for the first time. According to experimental results, the evolution law of the internal stress of the TC layer was similar to that of the TGO stress, which were interrelated and influenced by each other. In addition, the internal stress of the TC layer was less than that of the TGO stress due to the columnar crystal microstructure of EB-PVD TBCs.

RESUMEN

A mathematical model for determining the temperature distribution in the system consisting of a coating deposited on the surface of substrate was proposed. The foundation material is homogeneous, while the coating is made of a functionally gradient material (FGM) with thermal conductivity increasing exponentially along the thickness. Heating processes of the outer surface of the coating were considered with a constant and linearly decreasing in time intensity of the heat flux. Such thermal loads are common in thermal problems of friction, particularly regarding frictional heating during braking. An exact (in quadrature) solution of the corresponding boundary-value problems of parabolic heat conduction was obtained. Asymptotic solutions to these problems were also found for small and large values of the Fourier number. Calculations were performed for a coating made of two-component FGM ZrO2-Ti-6Al-4V, applied on a cast iron substrate. In order to explain the effect of FGM on temperature, corresponding analysis was carried out for the coating made of a homogeneous (ZrO2) material.

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As the operation temperature of next generation gas turbine is targeted to be 1800 °C toward a higher efficiency and lower carbon emission, the near-infrared (NIR) thermal radiation becomes a major concern for the durability of the metallic turbine blades. Although thermal barrier coatings (TBCs) are applied to provide thermal insulations, they are translucent to the NIR radiation. It is a major challenge for TBCs to achieve optically thick with limited physical thickness (usually < 1 mm) for effectively shielding the NIR radiation damage. Here, an NIR metamaterial is reported, where a Gd2 Zr2 O7 ceramic matrix is randomly dispersed with microscale Pt (0.53 vol%) nanoparticles with a size of 100-500 nm. Attenuated by the Gd2 Zr2 O7 matrix, a broadband NIR extinction is achieved through the red-shifted plasmon resonance frequencies and higher-order multipole resonances of the Pt nanoparticles. A very high absorption coefficient of ≈3 × 104 m-1 , approaching the Rosseland diffusion limit for a typical coating thickness, minimizes the radiative thermal conductivity to ≈10-2  W m-1 K-1 and successfully shields the radiative heat transfer. This work suggests that constructing a conductor/ceramic metamaterial with tunable plasmonics could be a strategy to shield NIR thermal radiation for high temperature applications.

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Volcanic ash is a major threat to aviation safety. The softening/melting temperatures of volcanic ash lie far below typical aero-engine operating temperatures. Thus, molten ash can accelerate the failure of thermal barrier coatings (TBCs). Here, inspired by natural superhydrophobic surfaces (e.g., the lotus leaf), a molten-volcanic-ash-phobic TBC, which provides a large possibility to eliminate molten ash issues of TBCs, is developed. A hierarchically structured surface is first prepared on a (Gd0.9 Yb0.1 )2 Zr2 O7 (GYbZ) pellet by ultrafast laser direct writing technology, aiming to confirm the feasibility of the biomimetic microstructure to repel molten volcanic ash wetting. Then biomimetic-structured GYbZ TBCs are successfully fabricated using plasma spray physical vapor deposition, which reveals "silicate" phobicity at high temperatures. The exciting molten-volcanic-ash-phobic attribute of the designed surfaces is attributed to the lotus-leaf-like dual-scale microstructure, emulating in particular the existence of nanoparticles. These findings may be an important step toward the development of next-generation aviation engines with greatly reduced vulnerability to environmental siliceous debris.

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Conductors consisting of thin layers are commonly used in many industries as protective, insulating or thermal barrier coatings (TBC). Nondestructive testing of these types of structures allows one to determine their dimensions and technical condition, while also detecting defects, which significantly reduces the risk of failures and accidents. This work presents an eddy current system for testing thin layers and coatings, which has never been presented before. It consists of an analytical model and a pot-core sensor. The analytical model was derived through the employment of the truncated region eigenfunction expansion (TREE) method. The final formulas for the sensor impedance have been presented in a closed form and implemented in Matlab. The results of the calculations of the pot-core sensor impedance for thin layers with a thickness above 0.1 mm were compared with the measurement results. The calculations made for the TBC were verified with a numerical model created using the finite element method (FEM) in Comsol Multiphysics. In all the cases, the error in determining changes in the components of the pot-core sensor impedance was less than 4%. At the same time, it was shown that the sensitivity of the applied pot-core sensor in the case of thin-layer testing is much higher than the sensitivity of the air-core sensor and the I-core sensor.

Asunto(s)

RESUMEN

The growth stress induced by thermally grown oxide (TGO) is one of the main reasons for the failure of thermal barrier coatings (TBCs). In this study, the failure behavior of TBCs was examined based on different growth modes of TGO. A TBC thermo-mechanical model with a simplified sinusoidal interface morphology was established by the secondary development of a numerical simulation. The plasticity and creep behavior of materials were considered. Based on the subroutine development, the non-uniform growth of the TGO layer was realized. Cohesive elements were also applied to the TC/TGO interface. The stress distribution and evolution at the TC/TGO interface were investigated. Then, the cracking behavior near the interface was studied. The results show that lateral growth causes the off-valley site to replace the previous off-peak site as a vulnerable site. The non-uniform growth accelerates damage in the off-valley site, which leads to a change in the failure behavior. These results will provide significant guidance for understanding the TBC failure and the development of advanced TBCs.

RESUMEN

The failure of thermal barrier coatings (TBCs) during operation depends mainly on the thermal mismatch between the ceramic top coat (TC) and the metal bond coat (BC). The thermal mismatch at the interface is influenced by the dynamic changes in the composition and morphology of the thermally grown oxide (TGO) between TC and BC during thermal cycling. This work focuses on the establishment of a TGO dynamic growth model, which considers the changes in TGO composition and morphology for investigating the effect of dynamic growth of TGO on local mismatch stresses during thermal cycling. The results show that the sharp locations at the TGO/BC interface are more prone to high tensile stresses during thermal cycling due to the uneven growth behavior of TGO, leading to crack initiation. The valley region of the interface is in a state of compressive stress σxx during the early stages of thermal exposure. The peak region preferentially forms a concentration of tensile stress σyy. Once large-scale "layer" (Ni, Co)Al2O4-based spinel-like mixed oxides(MO) growth occurs in TGO, the stress σxx changes from compressive stress to tensile stress in the valley region, eventually forming high tensile stress (Max: +158 MPa). The maximum tensile stress σyy in the peak region is increased to 256 MPa, which is more than two times larger than the early period of thermal exposure. As a result, the dramatic changes in local stresses seriously affect the time and location of microcracks.