Analysis and optimization of thermal barrier coating on gas turbine rotor blade using YSZ with variable bond coat
DOI:
https://doi.org/10.22399/ijcesen.2110Keywords:
TBC, 8YSZ, Plasma Coat, Bond Coat, Thermal resistance, OptimizationAbstract
Thermal barrier coatings on gas turbine blades is one of the most research area in heat resisted applications. The study focuses on enhancing the performance and durability of gas turbine rotor blades by analyzing the thermal barrier coating (TBC) system. The primary objective of this work is to improve the overall efficiency of turbines and enhance their heat resistance by utilizing yttrium-stabilized zirconia (YSZ) with a variable bond coat. We achieved ideal coatings with minimal defects by employing optimized spraying parameters. However, even with advanced spraying techniques, issues such as porosity remain unresolved. This article examines atmospheric plasma spraying of zirconium oxide, in combination with titanium oxide and carbide, as a method for assessing porosity in plasma-spraying coatings. To analyzed an L16 orthogonal array, treating the bond coat as a variable. The selected and optimized parameters include spray distance, bond coat, torch input power, and temperature, using Taguchi prediction with Mini-Tab. A bond coat thickness of 100 µm, with an input power of 35 kW, at a spray distance of 75 mm and a temperature of 12000 °C, yielded the best results.
References
[1] Daniel Tejero-Martin, Chris Bennett, Tanvir Hussain (2021) ,“ A review on environmental barrier coatings: history, current state of the art and future developments” Journal of the European Ceramic Society 41;1747–1768; https://doi.org/10.1016/j.jeurceramsoc.2020.10.057.
[2] Sohn Y. H., Lee E. Y., Nagaraj B. A., Biederman R. R., and SissonR. D.Jr., (2001) Microstructural characterization of thermal barrier coatings on high pressure turbine blades, Surface and Coatings Technology. 146-147, 132–139, 2-s2.0-17544388839,
[3] Gurrappa I. and Rao A. S., (2006) Thermal barrier coatings for enhanced efficiency of gas turbine engines, Surface and Coatings Technology.201, no. 6, 3016–3029.
[4] Yang L., Liu Q. X., Zhou Y. C., Mao W. G., and Lu C., (2014) Finite element simulation on thermal fatigue of a turbine blade with thermal barrier coatings, Journal of Materials Science & Technology. 30, 371–380.
[5] Zhu W., Cai M., Yang L., Guo J. W., Zhou Y. C., and Lu C., (2015) The effect of morphology of thermally grown oxide on the stress field in a turbine blade with thermal barrier coatings, Surface and Coatings Technology. 276, 160–167, 2-s2.0-84939125838,
[6] Brown, A.; Jubran, B.A.; Martin, B.M. (1993) Coolant optimization of a gas turbine engine. Proc. Inst. Mech. Eng. Part A J. Power Energy 207, 31–47.
[7] Moon, S.W.; Kwon, H.M.; Kim, T.S.; Do, W.K. (2017) A novel coolant cooling method for enhancing the performance of the gas turbine combined cycle. Energy, 160, 625–634
[8] Sahu, M.K. (2017) Thermo-Economic investigation of power utilities: Intercooled recuperated gas turbine cycle featuring cooled turbine blades. Energy, 138, 490–499.
[9] Salpingidou, C.; Tsakmakidou, D.; Vlahostergios, Z.; Misirlis, D.; Flouros, M.; Yakinthos, K. (2018) Analysis of turbine blade cooling effect on recuperative gas turbines cycles performance. Energy 164, 1271–1285.
[10] Okajima, Y.; Kudo, D.; Okaya, N.; Torigoe, T.; Kaneko, H.; Mega, M.; Ito, E.; Masada, J.; Tsukagoshi, K. (2014) Evolution of thermal barrier coatings for land-based gas turbines at MHI. Therm. Spray Technol., 6, 56–62.
[11] Ogiriki, E.A.; Li, Y.G.; Nikolaidis, T.; Isaiah, T.E.; Sule, G. (2015) Effect of fouling, thermal barrier coating degradation and film cooling holes blockage on gas turbine engine creep life. Procedia CIRP, 38, 228–233.
[12] Sahith, M.S.; Giridhara, G.; Kumar, R.S. (2018) Development and analysis of thermal barrier coating on gas turbine blades—A review. Mater. Today Proc., 5, 2746–2751.
[13] Wu, S.; Zhao, Y.; Li, W.; Liu, W.; Wu, Y.; Liu, F. (2021) Research progresses on ceramic materials of thermal barrier coatings on gas turbine. Coatings 11, 79.
[14] Gurrappa, I.; Sambasiva Rao, A. (2006) Thermal barrier coatings for enhanced efficiency of gas turbine engines. Surf. Coat. Technol. 201, 3016–3029.
[15] Ziaei-Asl, A.; Ramezanlou, M.T. (2019) Thermo-Mechanical behavior of gas turbine blade equipped with cooling ducts and protective coating with different thicknesses. Int. J. Mech. Sci. 150, 656–664.
[16] Sankar, V.; Ramkumar, P.B.; Sebastian, D.; Joseph, D.; Jose, J.; Kurian, A. (2019) Optimized thermal barrier coating for gas turbine blades. Mater. Today Proc., 11, 912–919.
[17] Nagabandi, K.; Pujari, A.K.; Iyer, D.S. (2020) Thermo-Mechanical assessment of gas turbine combustor tile using locally varying thermal barrier coating thickness. Appl. Therm. Eng. , 179, 115657.
[18] Huang, X.; Pu, J.; Wang, J.H.; Qu, Y.-F.; He, J.-H. (2020), Sensitivity analysis of internal layout and coating thickness to overall cooling performances of laminated cooling configurations with surface thermal barrier coatings. Appl. Therm. Eng. 181, 116020.
[19] Frackowiak, A.; Olejnik, A.; Wróblewska, A.; Cialkowski, M. (2021) Application of the protective coating for blade’s thermal protection. Energies , 14, 50.
[20] Radhakrishnan, K.; Park, J.S. (2021), Thermal analysis and creep lifetime prediction based on the effectiveness of thermal barrier coating on a gas turbine combustor liner using coupled CFD and FEM simulation. Energies 14, 3817.
[21] Yunus, S.M.; Mahalingam, S.; Manap, A.; Afandi, N.M.; Satgunam, M. Test-Rig simulation on hybrid thermal barrier coating air system for advanced gas turbine under prolonged exposures—A review. Coatings 2021, 11, 560
[22] R. Sudarshan, Sriram Venkatesh, K.Balasubramanian, Noundla Ramya, (2019) Preparation, Deposition and Characterization of Solution Precursor, IOP Conf. Series: Journal of Physics: Conf. Series 1172; 012022
[23] Amir hossein Pakseresht, Kamalan kirubaharan Amirtharaj Mosas, Ceramic Coatings for High-Temperature Environments from Thermal Barrier to Environmental Barrier Applications, ISBN: 978-3-031-40808-3 December 2023
[24] Biao Li, Yixiu Shu, Yazhi Li, (2022). Interface cracking behavior in high-temperature coatings with non-uniformly distributed segmentation cracks, European Journal of Mechanics - A/Solids, Volume 96, November–December 2022, 104674
[25] Keshri, Anup Kumar, "Comprehensive process maps for synthesizing high density aluminum oxide-carbon nanotube coatings by plasma spraying for improved mechanical and wear properties" (2010). ProQuest ETD Collection for FIU. AAI3431318.
[26] Akilesh, M., Elango, P. R., Devanand, A. A., Soundararajan, R., & Varthanan, P. A. (2018). Optimization of Selective Laser Sintering Process Parameters on Surface Quality. 3D Printing and Additive Manufacturing Technologies, 141–157.
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2025 International Journal of Computational and Experimental Science and Engineering
This work is licensed under a Creative Commons Attribution 4.0 International License.
