Lifetime Extension of Atmospheric and Suspension Plasma-Sprayed Thermal Barrier Coatings in Burner Rig Tests by Pre-Oxidizing the CoNiCrAlY Bond Coats

Oxidation of the bond coat during turbine operation leads to additional stresses in the thermal barrier coating (TBC) system that promotes spalling of the thermal insulation. Therefore, the oxidation behavior of a TBC system plays an important role in the thermal cycling of a TBC system. To delay the loss of thermal insulation, research has typically focused for a long time on the composition and microstructure of the ceramic topcoats and metallic bond coats. More recently, heat treatment for the diffusion annealing of the bond coat has also become a focus of research. Several studies have shown that pre-oxidation of the bond coat prior to the application of the ceramic topcoat slows down the subsequent oxidation of the bond coat in service. The improved thermal cyclability has been demonstrated in studies for systems with atmospheric plasma-sprayed (APS), suspension plasma-sprayed (SPS) or electron beam physical vapor deposition (EB-PVD) top coatings. However, no study has directly compared the effects of pre-oxidation on different topcoats. Therefore, this study compared the effect of pre-oxidation on APS and SPS coatings with the same bond coat. For both topcoats, pre-oxidation slowed the subsequent TGO growth and thus increased the lifetime of the coatings. The improvement in lifetime was particularly pronounced for the systems with an SPS topcoat. Overall, the lifetime of the coatings with an APS topcoat was higher as the critical energy release rate within the coating was not exceeded in these coatings.