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A special issue of Coatings (ISSN 2079-6412).

Deadline for manuscript submissions: closed (31 December 2019) | Viewed by 43261

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Special Issue Editor

Dr. Kang N. Lee

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Guest Editor

NASA Glenn Research Center, Cleveland, USA
Interests: environmental barrier coatings; thermal barrier coatings; high temperature oxidation; high temperature materials chemistry; solid-state batteries
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The global increase in air travel will require commercial vehicles to be more efficient than ever before. Advanced engine hot section materials are a key technology required to keep fuel consumption and emission to a minimum in next-generation gas turbines. Ceramic matrix composites (CMCs) are the most promising material to revolutionize gas turbine hot section materials technology because of their excellent high‐temperature properties. Rapid surface recession due to volatilization by water vapor is the Achilles heel of CMCs. Environmental barrier coatings (EBCs) is an enabling technology for CMCs, since it protects CMCs from water vapor. The first CMC component entered into service in 2016 in a commercial engine, and more CMC components are scheduled to follow within the next few years. One of the most difficult challenges to CMC components is EBC durability, because failure of EBC leads to a rapid reduction in CMC component life. Key contributors to EBC failure include recession, oxidation, degradation by calcium‐aluminum‐magnesium silicates (CMAS) deposits, thermal and thermo‐mechanical strains, particle erosion, and foreign object damage (FOD). Novel EBC chemistries, creative EBC designs, and robust processes are required to meet EBC durability challenges. Engine-relevant testing, characterization, and lifing methods need to be developed to improve EBC reliability. The aim of this Special Issue is to present recent advances in EBC technology to address these issues.

In particular, topics of interest include but are not limited to the following:

Novel EBC chemistries and designs;
Processing including plasma spray, suspension plasma spray, solution precursor plasma spray, slurry process, PS-PVD, EB-PVD, and CVD;
Testing, characterization, and modeling;
Lifing.

Dr. Kang N. Lee
Guest Editor

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Keywords

Environmental barrier coating (EBC)
Ceramic matrix composite (CMC)
Durability
Oxidation
Lifing

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Published Papers (10 papers)

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Editorial

Jump to: Research

4 pages, 170 KiB

Open AccessEditorial

Special Issue: Environmental Barrier Coatings

by Kang N. Lee

Coatings 2020, 10(6), 512; https://doi.org/10.3390/coatings10060512 - 27 May 2020

Cited by 11 | Viewed by 3708

Abstract

The global increase in air travel will require commercial vehicles to be more efficient than ever before. Advanced turbine hot section materials are a key technology required to keep fuel consumption and emission to a minimum. Ceramic matrix composites (CMCs) are the most promising material to revolutionize turbine hot section materials because of their excellent high-temperature properties. Rapid surface recession due to volatilization by water vapor is the Achilles heel of CMCs. Environmental barrier coatings (EBCs), which protect CMCs from water vapor, is an enabling technology for CMCs. The first CMC component entered into service in 2016 in a commercial engine, and more CMC components are scheduled to follow within the next few years. One of the most difficult challenges to CMC components is EBC durability because failure of EBC leads to a rapid reduction in CMC component life. Novel EBC chemistries, creative EBC designs, and robust processes are required to meet EBC durability challenges. Engine-relevant testing, characterization, and lifting methods need to be developed to improve EBC reliability. The aim of this Special Issue is to present recent advances in EBC technology to address current EBC challenges. Full article

(This article belongs to the Special Issue Environmental Barrier Coatings)

Research

Jump to: Editorial

10 pages, 13923 KiB

Open AccessFeature PaperArticle

Relative Ti₂AlC Scale Volatility under 1300 °C Combustion Conditions

by James L. Smialek

Coatings 2020, 10(2), 142; https://doi.org/10.3390/coatings10020142 - 5 Feb 2020

Cited by 8 | Viewed by 2149

Abstract

Turbine environments may degrade high temperature ceramics because of volatile hydroxide reaction products formed in water vapor. Accordingly, the volatility of transient TiO₂ and steady-state Al₂O₃ scales formed on the oxidation-resistant Ti₂AlC MAX phase ceramic was examined in 1300 °C high velocity (Mach 0.3, 100 m/s) and high pressure (6 atm, 25 m/s) burner rig tests (BRT). Unlike metals, the ceramic was stable at 1300 °C. Unlike SiC and Si₃N₄, neither burner test produced a weight loss, unless heavily pre-oxidized. Lower mass gains were produced in the BRT compared to furnace tests. The commonly observed initial, fast TiO₂ transient scale was preferentially removed in hot burner gas (~10% water vapor). A lesser degree of gradual Al₂O₃ volatilization occurred, indicated by grain boundary porosity and crystallographic etching. Modified cubic-linear (growth-volatility) kinetics are suggested. Gas velocity and water vapor pressure play specific roles for each scale. Furthermore, a 7YSZ TBC on Ti₂AlC survived for 500 h in the Mach 0.3 burner test at 1300 °C with no indication of volatility or spalling. Full article

(This article belongs to the Special Issue Environmental Barrier Coatings)

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20 pages, 4671 KiB

Open AccessArticle

Characterization of Thermochemical and Thermomechanical Properties of Eyjafjallajökull Volcanic Ash Glass

by Rebekah I. Webster, Narottam P. Bansal, Jonathan A. Salem, Elizabeth J. Opila and Valerie L. Wiesner

Coatings 2020, 10(2), 100; https://doi.org/10.3390/coatings10020100 - 23 Jan 2020

Cited by 19 | Viewed by 3802

Abstract

The properties of a volcanic ash glass obtained from the Eyjafjallajökull eruption of 2010 were studied. Crystallization experiments were carried out on bulk and powdered glass samples at temperatures between 900 and 1300 °C. Iron oxides, Fe₃O₄ and Fe₂O₃, and a silicate plagioclase, (Na,Ca)(Si,Al)₄O₈, were observed. Bulk samples remained mostly amorphous after up to 40 h at temperature. Powdered glass samples showed increased crystallinity after heat treatment compared to bulk samples. The average coefficient of thermal expansion of the glass was 7.00 × 10⁻⁶ K⁻¹ over 25–720 °C. The Vickers hardness of the glass was 6–7 GPa and the indentation fracture toughness, 1–2 MPa √m Values for density, elastic modulus, and Poisson’s ratio were 2.52 g/cm³, 75 GPa, and 0.24, respectively. The viscosity of the glass was determined experimentally and compared to three common models from the literature. The implications for the deposition of volcanic ash on hot section components of aircraft turbine engines are discussed. Full article

(This article belongs to the Special Issue Environmental Barrier Coatings)

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11 pages, 15929 KiB

Open AccessFeature PaperEditor’s ChoiceArticle

Delayed Formation of Thermally Grown Oxide in Environmental Barrier Coatings for Non-Oxide Ceramic Matrix Composites

by Hagen Klemm, Katrin Schönfeld and Willy Kunz

Coatings 2020, 10(1), 6; https://doi.org/10.3390/coatings10010006 - 19 Dec 2019

Cited by 9 | Viewed by 4196

Abstract

The oxidation and corrosion behavior at elevated temperatures of a SiC_F/SiC(N) composite with two plasma-sprayed environmental barrier coating (EBC) systems were studied. After both processes, the formation of a silica-based thermally grown oxide (TGO) layer was observed. The formation of this TGO caused two principal failure mechanisms of the EBC. Firstly, spallation of the EBC induced by stresses from volume expansion and phase transformation to crystalline SiO₂ was observed. Water vapor corrosion of the TGO with gap formation in the top region of the TGO was found to be a second failure mechanism. After a burner rig test of the Al₂O₃-YAG EBC system, this corrosion process was observed at the TGO surface and in the volume of the Al₂O₃ bond coat. In the case of the second system, Si-Yb₂Si₂O₇/SiC-Yb₂SiO₅, the formation of the TGO could be delayed by introducing an additional intermediate layer based on Yb₂Si₂O₇ filled with SiC particles. The SiC particles in the intermediate layer were oxidized and served as getter to reduce the permeation of oxidants (O₂, H₂O) into the material. In this way, the formation of the TGO and the failure mechanisms caused by their formation and growth could be delayed. Full article

(This article belongs to the Special Issue Environmental Barrier Coatings)

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22 pages, 10484 KiB

Open AccessFeature PaperArticle

Environmental Barrier Coatings Made by Different Thermal Spray Technologies

by Robert Vaßen, Emine Bakan, Caren Gatzen, Seongwong Kim, Daniel Emil Mack and Olivier Guillon

Coatings 2019, 9(12), 784; https://doi.org/10.3390/coatings9120784 - 22 Nov 2019

Cited by 32 | Viewed by 6585

Abstract

Environmental barrier coatings (EBCs) are essential to protect ceramic matrix composites against water vapor recession in typical gas turbine environments. Both oxide and non-oxide-based ceramic matrix composites (CMCs) need such coatings as they show only a limited stability. As the thermal expansion coefficients are quite different between the two CMCs, the suitable EBC materials for both applications are different. In the paper examples of EBCs for both types of CMCs are presented. In case of EBCs for oxide-based CMCs, the limited strength of the CMC leads to damage of the surface if standard grit-blasting techniques are used. Only in the case of oxide-based CMCs different processes as laser ablation have been used to optimize the surface topography. Another result for many EBCs for oxide-based CMC is the possibility to deposit them by standard atmospheric plasma spraying (APS) as crystalline coatings. Hence, in case of these coatings only the APS process will be described. For the EBCs for non-oxide CMCs the state-of-the-art materials are rare earth or yttrium silicates. Here the major challenge is to obtain dense and crystalline coatings. While for the Y₂SiO₅ a promising microstructure could be obtained by a heat-treatment of an APS coating, this was not the case for Yb₂Si₂O₇. Here also other thermal spray processes as high velocity oxygen fuel (HVOF), suspension plasma spraying (SPS), and very low-pressure plasma spraying (VLPPS) are used and the results described mainly with respect to crystallinity and porosity. Full article

(This article belongs to the Special Issue Environmental Barrier Coatings)

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27 pages, 7446 KiB

Open AccessArticle

Crack Initiation Criteria in EBC under Thermal Stress

by Emi Kawai, Hideki Kakisawa, Atsushi Kubo, Norio Yamaguchi, Taishi Yokoi, Takashi Akatsu, Satoshi Kitaoka and Yoshitaka Umeno

Coatings 2019, 9(11), 697; https://doi.org/10.3390/coatings9110697 - 24 Oct 2019

Cited by 14 | Viewed by 4054

Abstract

For design of multi-layered environmental barrier coatings (EBCs), it is essential to assure mechanical reliability against interface crack initiation and propagation induced by thermal stress owing to a misfit of the coefficients of thermal expansion between the coating layers and SiC/SiC substrate. We conducted finite element method (FEM) analyses to evaluate energy release rate (ERR) for interface cracks and performed experiment to obtain interface fracture toughness to assess mechanical reliability of an EBC with a function of thermal barrier (T/EBC; SiC/SiAlON/mullite/Yb-silicate gradient composition layer/Yb₂SiO₅ with porous segment structure) on an SiC/SiC substrate under thermal stress due to cooling in fabrication process. Our FEM analysis revealed that a thinner SiAlON layer and a thicker mullite layer are most suitable to reduce ERRs for crack initiation at the SiC/SiAlON, SiAlON/mullite and mullite/Yb₂Si₂O₇ interfaces. Interface fracture tests of the T/EBC with layer thicknesses within the proposed range exhibited fracture at the SiC/SiAlON and SiAlON/mullite interfaces. We also estimated the approximate fracture toughness for the SiC/SiAlON and SiAlON/mullite interfaces and lower limit of fracture toughness for the mullite/Yb₂Si₂O₇ interface. Comparison between ERR and fracture toughness indicates that the fabricated T/EBC possesses sufficient mechanical reliability against interface crack initiation and propagation. Full article

(This article belongs to the Special Issue Environmental Barrier Coatings)

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10 pages, 3565 KiB

Open AccessArticle

Structural Stabilization of Mullite Films Exposed to Oxygen Potential Gradients at High Temperatures

by Satoshi Kitaoka, Tsuneaki Matsudaira, Naoki Kawashima, Daisaku Yokoe, Takeharu Kato and Masasuke Takata

Coatings 2019, 9(10), 630; https://doi.org/10.3390/coatings9100630 - 30 Sep 2019

Cited by 9 | Viewed by 2533

Abstract

The oxygen shielding properties of polycrystalline Al_4+2xSi_2−2xO_10−x (mullite) films applied as environmental barrier coatings (EBCs) on SiC fiber-reinforced SiC matrix composites (SiC/SiC) are determined by the grain boundary (GB) diffusion of oxide ions in the films, from the higher oxygen partial pressure (P_O₂) surface to the lower P_O₂ surface, with simultaneous GB diffusion of Al ions in the opposite direction. Herein, strategies to improve the oxygen shielding and phase stability of these films when applied to SiC/SiC substrates through bond coats are proposed, based on oxygen permeation data for mullite at high temperatures. The validity of these strategies is verified using experimental trials at 1673 K with bilayer specimens consisting of mullite films and bond coat substrates, serving as model EBCs. The data show that employing a bond coat made of β’-SiAlON rather than Si provides a source of Al for the overlying mullite film that greatly improves the phase stability of the film in the vicinity of the junction interface. Because the minimum equilibrium P_O₂ values required to form SiO₂ due to oxidation of the β’-SiAlON on a thermodynamic basis are significantly larger than those for oxidation of Si, the inward GB diffusion of oxide ions is effectively retarded, resulting in excellent oxygen shielding characteristics. Full article

(This article belongs to the Special Issue Environmental Barrier Coatings)

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13 pages, 7303 KiB

Open AccessArticle

YAlO₃—A Novel Environmental Barrier Coating for Al₂O₃/Al₂O₃–Ceramic Matrix Composites

by Caren Gatzen, Daniel Emil Mack, Olivier Guillon and Robert Vaßen

Coatings 2019, 9(10), 609; https://doi.org/10.3390/coatings9100609 - 25 Sep 2019

Cited by 33 | Viewed by 4788

Abstract

Ceramic matrix composites (CMCs) are promising materials for high-temperature applications. Environmental barrier coatings (EBCs) are needed to protect the components against water vapor attack. A new potential EBC material, YAlO₃, was studied in this paper. Different plasma-spraying techniques were used for the production of coatings on an alumina-based CMC, such as atmospheric plasma spraying (APS) and very low pressure plasma spraying (VLPPS). No bond coats or surface treatments were applied. The performance was tested by pull–adhesion tests, burner rig tests, and calcium-magnesium-aluminum-silicate (CMAS) corrosion tests. The samples were subsequently analyzed by means of X-ray diffraction, scanning electron microscopy, and energy-dispersive X-ray spectroscopy. Special attention was paid to the interaction at the interface between coating and substrate. The results show that fully crystalline and good adherent YAlO₃ coatings can be produced without further substrate preparation such as surface pretreatment or bond coat application. The formation of a thin reaction layer between coating and substrate seems to promote adhesion. Full article

(This article belongs to the Special Issue Environmental Barrier Coatings)

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13 pages, 12269 KiB

Open AccessArticle

Crack Healing in Mullite-Based EBC during Thermal Shock Cycle

by Hyoung-IL Seo, Daejong Kim and Kee Sung Lee

Coatings 2019, 9(9), 585; https://doi.org/10.3390/coatings9090585 - 17 Sep 2019

Cited by 8 | Viewed by 3382

Abstract

Crack healing phenomena were observed in mullite and mullite + Yb₂SiO₅ environmental barrier coating (EBC) materials during thermal shock cycles. Air plasma spray coating was used to deposit the EBC materials onto a Si bondcoat on a SiC_f/SiC composite substrate. This study reveals that unidirectional vertical cracks (mud cracks) formed after several thermal shock cycles; however, the cracks were stable for 5000 thermal shock cycles at a maximum temperature of 1350 °C. Moreover, the crack densities decreased with an increasing number of thermal shock cycles. After 3000 thermal shock cycles, cracks were healed via melting of a phase containing SiO₂ phase, which partially filled the gaps of the cracks and resulted in the precipitation of crystalline Al₂O₃ in the mullite. Post-indentation tests after thermal shock cycling indicated that the mullite-based EBC maintained its initial mechanical behavior compared to Y₂SiO₅. The indentation load–displacement tests revealed that, among the materials investigated in the present study, the mullite + Yb₂SiO₅ EBC demonstrated the best durability during repetitive thermal shocks. Full article

(This article belongs to the Special Issue Environmental Barrier Coatings)

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24 pages, 12326 KiB

Open AccessEditor’s ChoiceArticle

Flow Kinetics of Molten Silicates through Thermal Barrier Coating: A Numerical Study

by Mohammad Rizviul Kabir, Anil Kumar Sirigiri, Ravisankar Naraparaju and Uwe Schulz

Coatings 2019, 9(5), 332; https://doi.org/10.3390/coatings9050332 - 23 May 2019

Cited by 20 | Viewed by 4874

Abstract

Infiltration of molten calcium–magnesium–alumina–silicates (CMAS) through thermal barrier coatings (TBCs) causes structural degradation of TBC layers. The infiltration kinetics can be altered by careful tailoring of the electron beam physical vapor deposition (EB-PVD) microstructure such as feather arm lengths and inter-columnar gaps, etc. Morphology of the feathery columns and their inherent porosities directly influences the infiltration kinetics of molten CMAS. To understand the influence of columnar morphology on the kinetics of the CAMS flow, a finite element based parametric model was developed for describing a variety of EB-PVD top coat microstructures. A detailed numerical study was performed considering fluid-solid interactions (FSI) between the CMAS and TBC top coat (TC). The CMAS flow characteristics through these microstructures were assessed quantitatively and qualitatively. Finally, correlations between the morphological parameters and CMAS flow kinetics were established. It was shown that the rate of longitudinal and lateral infiltration could be minimized by reducing the gap between columns and increasing the length of the feather arms. The results also show that the microstructures with long feather arms having a lower lateral inclination decrease the CMAS infiltration rate, therefore, reduce the CMAS infiltration depth. The analyses allow the identification of key morphological features that are important for mitigating the CMAS infiltration. Full article

(This article belongs to the Special Issue Environmental Barrier Coatings)

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