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中，要求减少燃油消耗，运营成本和温室气体排放的需求继续推动燃气​​轮机发动机（GTE）设计师找到提高GTE效率并延长运营寿命的方法。增加涡轮机入口温度是增加功率输出而不增加燃料燃烧的关键方法。随着涡轮机入口温度的上升，对在Harmsh环境下连续运行的需求以及向替代燃料的转变，热截面材料正受到机械应力和环境攻击的增加。尽管用于制造涡轮叶片，叶片和组合组件的最先进的超合金可以在高达1093°C的温度下（2000°F）保持强度，但大多数当前和所有下一代GTE设计都需要可以安全运行的材料，这些材料可以安全地超出此温度。只有使用热屏障涂料（TBC）系统和冷却技术才有可能。此外，由于CR含量较低，许多现代超级合金降低了环境阻力，以稳定在较高温度和机械载荷下的微观结构。因此，现在要求TBC提供热屏障和环境保护功能，并成为现代GTE不可或缺的一部分。为了将TBC指定为GTE设计中的“主要敏感”的目标，需要进一步的TBC性能提高和可靠性。Mjor挑战GTE设计师面临的挑战包括：对底物对TBC Life的影响不足； GTE操作过程中元素的内向和外部扩散的存在导致早期涂层失败；陶瓷面漆材料的温度和抗断裂性不足；缺乏基于微观结构和服务条件的普遍方法来预测TBC失败机制和生命。因此，该研究计划的目标是探索新的TBC材料和结构，以提高性能，以了解不同服务条件下的微观结构演化和故障模式，并启用TBC生活评估。这项研究的结果将包括新的涂层材料组成和结构，具有增强的耐久性，用于不同的涡轮蓝色材料和不同的型号和A型材料，并适用于不同的型号和选择。这项研究还将在极端的机械和环境条件下增强对涂层和底物相互作用的理解，并为HQP提供培训。寻找更耐用的涂料组成和结构将直接受益于加拿大OEM（例如Pratt＆Whitney Canada，Magellan Aerospace），燃气轮机用户（TransCanada Pipelines，Union Gas）和涂料提供商（MDS涂料技术，Liburdi turnii，Liburdi Turmine Turbine Turbine Services，Northwest Mettech）。