| 1. |
- Sun, Xiaoyu, et al.
(författare)
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Revealing microstructural degradation mechanism induced by interdiffusion between Amdry365 coating and IN792 superalloy
- 2024
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Ingår i: Materials & design. - 0264-1275 .- 1873-4197. ; 241, s. 112937-112937
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Tidskriftsartikel (övrigt vetenskapligt/konstnärligt)abstract
- Metallic coatings are widely employed to improve the oxidation resistance of superalloys. However, the interdiffusion between the metallic coatings and the superalloys leads to microstructural degradation in both. Some of the underlying degradation mechanisms are still elusive, e.g., the γ′ (Ni3Al) phase depletion in superalloys, where a large amount of γ′ precipitates are dissolved in the γ matrix even though the incoming Al from coatings indeed increases the Al content. Here, we investigated the interdiffusion behavior between the Amdry365 coating and the IN792 superalloy at 1100 °C, using multiple microscopic techniques and thermodynamics calculations. Our results showed an excellent agreement between experiments and thermodynamics simulations, indicating the dominant role of Al on the initial diffusion-induced phase transitions. We proposed the Al-Cr interference effect to account for the pile-up behavior of Cr and the reduced Al content near the coating/superalloy interface. The local phase equilibrium calculations revealed that the γ′ depletion in the superalloy is primarily attributed to the loss of γ′-forming elements, such as Ta and Ti. Our findings opened up an avenue for studies on the superalloy/coating interdiffusion, contributing to reducing this damaging impact.
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| 2. |
- Jonnalagadda, Krisha Praveen, 1988-, et al.
(författare)
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Comparison of Damage Evolution During Thermal Cycling in a High Purity Nano and Conventional Thermal Barrier Coating
- 2017
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Ingår i: Surface & Coatings Technology. - : Elsevier. - 0257-8972 .- 1879-3347. ; 332, s. 47-56
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Tidskriftsartikel (refereegranskat)abstract
- Thermal barrier coatings (TBCs), consisting of a ceramic top coat and a metallic bond coat, offer resistance against high temperature degradation of turbine components. Cyclic oxidation of the bond coat, thermal stresses due to their thermal mismatches during cyclic operations, and sintering of the top coat are considered to be the common ways by which thermal barrier coatings fail. To reduce sintering, a nano structured high purity yttria stabilized zirconia (YSZ) was developed. The focus of this work is to compare the damage development of such high purity nano YSZ TBC during thermal cycling with a conventional YSZ TBC. Thermal cyclic fatigue (TCF) tests were conducted on both the TBC systems between 100 °C and 1100 °C with a 1 h hold time at 1100 °C. TCF test results showed that conventional YSZ TBC exhibited much higher life compared to the high purity nano YSZ TBC. The difference in the lifetime is explained by the use of microstructural investigations, crack length measurements along the cross-section and the difference in the elastic modulus. Furthermore, stress intensity factors were calculated in order to understand the difference(s) in the damage development between the two TBC systems.
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| 3. |
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| 4. |
- Jonnalagadda, Krisha Praveen
(författare)
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Failure mechanisms in APS and SPS thermal barrier coatings during cyclic oxidation and hot corrosion
- 2017
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Thermal Barrier Coatings (TBCs) are advanced material systems that are being used in the hot sections of gas turbines such as combustor, turbine blades, and vanes. The top ceramic coating in TBCs provides insulation against the hot gases and the intermediate metallic bond coat provides oxidation and corrosion resistance to the underlying turbine components.Durability of thermal barrier coatings is very important for the overall performance of the gas turbine. TBCs can fail in several different ways and there is a combination of more than one failure mechanism in most situations. One of the most widely used TBC is atmospheric plasma sprayed (APS) yttria stabilized zirconia (YSZ). Both the deposition technique and the TBC material have certain limitations. The main aim of this research is to study new TBC materials and/or new deposition techniques and compare with the conventional YSZ and understand their failure mechanisms during cyclic oxidation and hot corrosion.Thermal cyclic oxidation of a newly developed high purity nano YSZ thermal barrier coating has been studied. Cross sectional analysis of exposed as well as completely failed samples showed a mixed-type failure caused by crack propagation parallel to the bond coat/top coat interface. The majority of the damage occurred towards the end of the coating life. A finite element model has been developed to study the probability of crack growth along different paths that leads to the final failure.Hot corrosion mechanism in suspension plasma sprayed two-layer gadolinium zirconate/YSZ, three-layer dense gadolinium zirconate/gadolinium zirconate/YSZ, and a single-layer YSZ has been studied in the presence of sodium sulfate and vanadium pentoxide. The test results showed that gadolinium zirconate coatings were more susceptible to corrosion compared to YSZ coatings despite gadolinium zirconate coatings having lower reactivity with the corrosive salts.Thermal cycling behavior of a high chromium bond coat has been studied. Cross-sectional analysis showed formation of sandwich type microstructure with chromium rich oxide and alumina as the top and the bottom layers.Inter-diffusion of minor elements between different MCrAlY coatings – substrate systems has been studied using, diffusion simulation software, DICTRA. The simulation results showed that the diffusion of minor elements in the coatings is dependent on the rate of β phase depletion in the beginning. After the depletion of β phase there was no clear dependence of the coating composition on the diffusion of minor elements.
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| 5. |
- Jonnalagadda, Krishna Praveen, 1988-, et al.
(författare)
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Failure of Multilayer Suspension Plasma Sprayed Thermal Barrier Coatings in the Presence of Na2SO4 and NaCl at 900 °C
- 2019
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Ingår i: Journal of thermal spray technology (Print). - : Springer Science and Business Media LLC. - 1059-9630 .- 1544-1016. ; 28:1-2, s. 212-222
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Tidskriftsartikel (refereegranskat)abstract
- The current investigation focuses on understanding the influence of a columnar microstructure and a sealing layer on the corrosion behavior of suspension plasma sprayed thermal barrier coatings (TBCs). Two different TBC systems were studied in this work. First is a double layer made of a composite of gadolinium zirconate + yttria stabilized zirconia (YSZ) deposited on top of YSZ. Second is a triple layer made of dense gadolinium zirconate deposited on top of gadolinium zirconate + YSZ over YSZ. Cyclic corrosion tests were conducted between 25 and 900 °C with an exposure time of 8 h at 900 °C. 75 wt.% Na2SO4 + 25 wt.% NaCl were used as the corrosive salts at a concentration of 6 mg/cm2. Scanning electron microscopy analysis of the samples’ cross sections showed that severe bond coat degradation had taken place for both the TBC systems, and the extent of bond coat degradation was relatively higher in the triple-layer system. It is believed that the sealing layer in the triple-layer system reduced the number of infiltration channels for the molten salts which resulted in overflowing of the salts to the sample edges and caused damage to develop relatively more from the edge.
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| 6. |
- Jonnalagadda, Krishna Praveen, 1988-, et al.
(författare)
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Fatigue life prediction of thermal barrier coatings using a simplified crack growth model
- 2019
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Ingår i: Journal of the European Ceramic Society. - : Elsevier BV. - 0955-2219 .- 1873-619X. ; 39:5, s. 1869-1876
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Tidskriftsartikel (refereegranskat)abstract
- Models that can predict the life of thermal barrier coatings (TBCs) during thermal cycling fatigue (TCF) tests are highly desirable. The present work focuses on developing and validating a simplified model based on the relation between the energy release rate and the TCF cycles to failure. The model accounts for stresses due to thermal mismatch, influence of sintering, and the growth of TGO (alumina and other non-protective oxides). The experimental investigation of TBCs included; 1) TCF tests at maximum temperatures of 1050 °C, 1100 °C, 1150 °C and a minimum temperature of 100 °C with 1 h and 5 h (1100 °C) hold times. 2) Isothermal oxidation tests at 900, 1000 and 1100 °C for times up to 8000 h. The model was calibrated and validated with the experimental results. It has been shown that the model is able to predict the TCF life and effect of hold time with good accuracy.
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| 7. |
- Jonnalagadda, Krishna Praveen, et al.
(författare)
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Hot corrosion behavior of multi-layer suspension plasma sprayed Gd2Zr2O7/YSZ thermal barrier coatings
- 2017
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Ingår i: InterCeram: International Ceramic Review. - Düsseldorf : Expert Fachmedien GmbH. - 0020-5214 .- 2523-8957. ; 66:5, s. 180-184
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Tidskriftsartikel (refereegranskat)abstract
- This study investigates the corrosion resistance of double layer Gd2Zr2O7/YSZ, triple layer dense Gd2Zr2O7 / Gd2Zr2O7/YSZ and a reference single layer YSZ coating with a similar overall top coat thickness of 300-320 Όm. All the coatings were manufactured by suspension plasma spraying (SPS), resulting in a columnar structure. Corrosion tests were conducted at 900°C for 8 hours using vanadium pentoxide and sodium sulphate as corrosive salts at a concentration of 4 mg/cm2. SEM investigations after the corrosion tests show that Gd2Zr2O7 coatings exhibited lower corrosion resistance than the reference material, YSZ. Reaction between the corrosive salts and Gd2Zr2O7 results in the formation of gadolinium vanadate ( GdVO4) along the top surface and between the columns. While the stresses due to phase transformation of zirconia can be relieved to some extent by realigning of the columns in the top coat, it is believed that GdVO4 formation between the columns, along with low fracture toughness of Gd2Zr2O7 had resulted in lower corrosion resistance. Furthermore, the presence of a relatively dense layer of Gd2Zr2O7 on the top, as a preventive layer for salt infiltration, did not improve the corrosion resistance.
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| 8. |
- Jonnalagadda, Krisha Praveen, et al.
(författare)
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Hot Corrosion Mechanism in Multi-Layer Suspension Plasma Sprayed Gd2Zr2O7 /YSZ Thermal Barrier Coatings in the Presence of V2O5 + Na2SO4
- 2017
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Ingår i: Journal of thermal spray technology (Print). - New York : Springer Science and Business Media LLC. - 1059-9630 .- 1544-1016. ; 26:1-2, s. 140-149
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Tidskriftsartikel (refereegranskat)abstract
- This study investigates the corrosion resistance of two-layer Gd2Zr2O7/YSZ, three-layer dense Gd2Zr2O7/ Gd2Zr2O7/YSZ, and a reference single-layer YSZ coating with a similar overall top coat thickness of 300-320 µm. All the coatings were manufactured by suspension plasma spraying resulting in a columnar structure except for the dense layer. Corrosion tests were conducted at 900 °C for 8 h using V2O5 and Na2SO4 as corrosive salts at a concentration of approximately 4 mg/cm2. SEM investigations after the corrosion tests show that Gd2Zr2O7-based coatings exhibited lower reactivity with the corrosive salts and the formation of gadolinium vanadate (GdVO4), accompanied by the phase transformation of zirconia was observed. It is believed that the GdVO4 formation between the columns reduced the strain tolerance of the coating and also due to the fact that Gd2Zr2O7 has a lower fracture toughness value made it more susceptible to corrosion-induced damage. Furthermore, the presence of a relatively dense layer of Gd2Zr2O7 on the top did not improve in reducing the corrosion-induced damage. For the reference YSZ coating, the observed corrosion-induced damage was lower probably due to combination of more limited salt penetration, the SPS microstructure and superior fracture toughness of YSZ.
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| 9. |
- Jonnalagadda, Krishna Praveen, 1988-, et al.
(författare)
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Hot gas corrosion and its influence on the thermal cycling performance of suspension plasma spray TBCs
- 2019
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Ingår i: Proceedings of ASME Turbo Expo 2019. - New York, NY : American Society of Mechanical Engineers. - 9780791858677
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Konferensbidrag (refereegranskat)abstract
- Thermal barrier coatings (TBCs) manufactured with suspension plasma spray (SPS) are promising candidates for use in gas turbines due to their high strain tolerance during thermal cyclic fatigue (TCF). However, corrosion often occurs alongside thermal fatigue and coating durability under these conditions is highly desirable. The current study focuses on understanding the corrosion behavior and its influence on the thermal cyclic fatigue life of SPS TBCs. Corrosion tests were conducted at 780 OC using a mixed-gas (1SO2-0.1CO-20CO2-N2(bal.) in vol. %) for 168h. They were later thermally cycled between 100-1100 ⁰C with a 1h hold time at 1100 ⁰C. Corrosion test results indicated that the damage predominantly started from the edges and a milder damage was observed at the center. Nickel sulfide was observed on top of the top coat and also in the columnar gaps of the top coat. Chromium oxides were observed inside the top coat columnar gaps but close to the bond coat/top coat interface. They were believed to reduce the strain tolerance of SPS TBCs to an extent and also amplify the thermal mismatch stresses during TCF tests. This, together with a fast growth of alumina during the TCF, resulted in a significant drop in the TCF life compared to the standard TCF tests.
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| 10. |
- Jonnalagadda, Krishna Praveen, 1988-, et al.
(författare)
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Influence of Top Coat and Bond Coat Pre-Oxidation on the Corrosion Resistance of Thermal Barrier Coatings in the Presence of SO2
- 2018
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Ingår i: PROCEEDINGS OF THE ASME TURBO EXPO: TURBOMACHINERY TECHNICAL CONFERENCE AND EXPOSITION, 2018, VOL 6. - : AMER SOC MECHANICAL ENGINEERS. - 9780791851128
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Konferensbidrag (refereegranskat)abstract
- Thermal barrier coatings (TBCs) degradation due to corrosion is one of the commonly observed failure types in land-based gas turbines due to the usage of low grade fuels. Sulfur in its gaseous form, as SO2, can attack the TBC system and result in the degradation of both the coating and the turbine component. The present study aims to understand the difference in the corrosion induced damage caused by SO2 gas mixture in different coating architectures. Corrosion tests were conducted at 780 degrees C in a tube furnace for a period of 168h. The inlet test gas had a composition of 1SO(2)-0.1CO-20CO(2)-N-2 (bal.) in vol. %. The coating architectures consisted of 1) an overlay coating, 2) a single-side bond coat TBC, 3) an all-side bond coat TBC, 4) an all-side bond coat TBC subjected to pre-oxidation prior to the corrosion tests. The results from the corrosion tests showed that the damage was the most severe for the overlay followed by single-side bond coat TBC. Between the other two systems, the TBC subjected to pre-oxidation had relatively lower corrosion damage. The corrosion damage started from the edges for the overlay and single-side bond coat TBC and as well as through the penetration of the gas through the coating. For the coatings with bond coat on all sides, the edge damage appeared to be considerably reduced and the damage is predominantly through the gas infiltration.
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