The Effect of Environment on Thermal Barrier Coating Lifetime

Abstract

While the water vapor content of the combustion gas in natural gasfired landbased turbines is ∼10%, it can be 20–85% with coalderived (syngas or H2) fuels or innovative turbine concepts for more efficient carbon capture. Additional concepts envisage working fluids with high CO2 contents to facilitate carbon capture and sequestration. To investigate the effects of changes in the gas composition on thermal barrier coating (TBC) lifetime, furnace cycling tests (1h and 100h cycles) were performed in air with 10, 50, and 90 vol. % water vapor and CO210% H2O and compared to prior results in dry air or O2. Two types of TBCs were investigated: (1) diffusion bond coatings (Ptdiffusion or Ptmodified aluminide) with commercial electronbeam physical vapordeposited yttriastabilized zirconia (YSZ) top coatings on secondgeneration superalloy N5 and N515 substrates and (2) highvelocity oxygen fuel (HVOF) sprayed MCrAlYHfSi bond coatings with air plasmasprayed YSZ top coatings on superalloys X4, 1483, or 247 substrates. For both types of coatings exposed in 1h cycles, the addition of water vapor resulted in a decrease in coating lifetime, except for Ptdiffusion coatings which were unaffected by the environment. In 100h cycles, environment was less critical, perhaps because coating failure was chemical (i.e., due to interdiffusion) rather than mechanical. In both 1h and 100h cycles, CO2 did not appear to have any negative effect on coating lifetime.