Advanced Thermal Barrier Coating Systems for Gas Turbine Application: Microstructure, Properties, and Performance

适用于燃气轮机应用的先进热障涂层系统：微观结构、特性和性能

• 批准号: RGPIN-2015-05862
• 负责人: Huang, Xiao
• 金额: $ 5.1万
• 依托单位: Carleton University
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2022
• 资助国家: 加拿大
• 起止时间: 2022-01-01 至 2023-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=759512
• 关键词: Advanced; Thermal; Barrier; Coating; Systems

In the aerospace and power generation industries, demands to reduce fuel consumption, operating costs, and greenhouse gas emissions continue to push gas turbine engine (GTE) designers to find ways to improve GTE efficiency and extend operating lives. Increasing the turbine inlet temperature is a key way to increase power output without increasing fuel burn. With rising turbine inlet temperatures, demands for continuous operation under harsh environments, and a shift towards alternative fuels, hot section materials are being subjected to increased mechanical stresses and environmental attack. While state-of-the-art superalloys used to manufacture turbine blades, vanes, and combustion components can maintain strength at temperatures up to 1093°C (2000°F), most current and all next generation GTE designs require materials that can safely operate well beyond this temperature. This is only possible with the use of thermal barrier coating (TBC) systems and cooling technology. In addition, many modern superalloys have reduced environmental resistance due to lower Cr content, done to stabilize the microstructure under higher temperatures and mechanical loads. Therefore, TBCs are now required to provide both thermal barrier and environmental protection functions, and have become integral to modern GTEs. With the industry's goal to designate TBCs as a "prime reliant" in GTE design, further TBC performance improvement and reliability are needed.Major challenges GTE designers face include: lack of understanding of substrate influence on TBC life; the existence of inward and outward diffusion of elements during GTE operation leading to early coating failure; insufficient temperature and fracture resistance of ceramic top coat materials; and lack of a universal approach to predict TBC failure mechanism(s) and life based on microstructure and service condition. Therefore, the objectives of this research program are to explore new TBC materials and structures for improved performance, to understand the microstructure evolution and failure mode(s) under different service conditions, and to enable TBC life assessment.The outcomes of this research will include new coating material compositions and structures with enhanced durability, a coating design and selection protocol for different turbine blade substrate materials and operating conditions, and a tool to accurately predict TBC system life. This research will also enhance the understanding of coating and substrate interaction under extreme mechanical and environmental conditions and provide training to HQPs. Finding more durable coating compositions and structures will directly benefit Canadian OEMs (such as Pratt & Whitney Canada, Magellan Aerospace), gas turbine users (TransCanada Pipelines, Union Gas) and coating providers (MDS Coating Technologies, Liburdi Turbine Services, Northwest Mettech).

在航空航天和发电行业，降低燃料消耗、运营成本和温室气体排放的需求不断推动燃气涡轮发动机 (GTE) 设计人员寻找提高 GTE 效率和延长运行寿命的方法。随着涡轮机入口温度的升高、在恶劣环境下连续运行的要求以及向替代燃料的转变，热部件材料在使用过程中会受到越来越大的机械应力和环境影响。 -最先进的用于制造涡轮机叶片、轮叶和燃烧部件的超级合金可以在高达 1093°C (2000°F) 的温度下保持强度，大多数当前和所有下一代 GTE 设计都需要能够在远高于此温度的情况下安全运行的材料。通过使用热障涂层 (TBC) 系统和冷却技术，许多现代高温合金由于铬含量较低而降低了耐环境性，从而在较高温度和机械载荷下稳定微观结构。现在需要提供热障和环境保护功能，并且已成为现代 GTE 的组成部分。随着业界将 TBC 指定为 GTE 设计中的“主要依赖”的目标，需要进一步提高 TBC 的性能和可靠性。GTE 面临的主要挑战。设计人员面临的问题包括：缺乏对基体对 TBC 寿命影响的了解；GTE 操作过程中元素向内和向外扩散导致陶瓷面涂层材料的早期失效；以及缺乏通用的解决方法；预测基于微观结构和使用条件的 TBC 失效机制和寿命因此，本研究项目的目标是探索新的 TBC 材料和结构以提高性能，了解不同使用条件下的微观结构演变和失效模式。 ，并实现 TBC 寿命评估。这项研究的成果将包括具有增强耐用性的新型涂层材料成分和结构、针对不同涡轮叶片基材材料和操作条件的涂层设计和选择协议，以及准确预测 TBC 系统寿命的工具这项研究也将增进对涂层的理解和。极端机械和环境条件下的基材相互作用，并为总部提供培训，寻找更耐用的涂层组合物和结构将直接使加拿大原始设备制造商（例如普惠加拿大公司、麦哲伦航空航天公司）、燃气轮机用户（加拿大横贯管道公司、联合天然气公司）和涂层公司受益。供应商（MDS Coating Technologies、Liburdi Turbine Services、Northwest Mettech）。