Sanjay Sampath, Gopal Dwivedi, Vaishak Viswanathan Library/Events/2015/utsr/Tuesday... · Sanjay...
Transcript of Sanjay Sampath, Gopal Dwivedi, Vaishak Viswanathan Library/Events/2015/utsr/Tuesday... · Sanjay...
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Manufacturing Science of LayeredMultifunctional coatings
Sanjay Sampath, Gopal Dwivedi, Vaishak ViswanathanDOE UTSR Meeting, Nov 2015
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Hot section coatings having been critical enablers in recent years
These are complex Dynamically Evolving Structures
Photo Courtesy – Dr. Ramesh Subramanian, Siemens
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
TBC Manufacturing Technologies
Plasma Sprayed TBCs
EBPVD TBCs
(a) (b)
SPS TBCs
PSPVD TBCs
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Superalloy
Bondcoat
TopcoatEBPVD
APS
SPS
Ni/Pt-AlAPS
VPSHVOF
LPPS APS SPS High Through-put APS
Liquid Fuel HVOF Gas Fuel HVOF VPS
Thermal spray manufacturing variants
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Layer-2
Layer-1
Layer-3
Layer-1
Layer-2
Evolution of TBC microstructures
Porous DVC
1960-1990 1990 - present 2007 & 2014 2014
Overhaul
& Repair
expands
Poun
ds/y
ear
Plas
ma
Spra
yed
TBC
s
~ 2 M
1960 1970 1980 1990 2000 2010
Space Program
7% YSZAero engine
Plasma spray process
Gas Turbine Engine
Vane
Transition duct
Blade
DOE
Advanced
Turbine
System.
Vertically Cracked
TBCs Invented
Pratt & Whitney
Siemens
Gadolinum
Zirconate
Pratt & Whitney
Implements
zirconate
coatings
GE’s DVC
in manufacturing
ZirconiaCaZr,MgZr 20%YSZ
Evolution of TBC Materials and Thermal Spray Manufacturing
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
FeedstockCharacteristics
ProcessVariables
Component Performance
CoatingStructure
Spray StreamCharacteristics
Substrate Conditions
Coating Property
Deposition Conditions
- Equipment related
(Gun, Gases, Power)- Particle Injection
- Feed rate- Raster / Rotation Rate- Angle of Deposition
- Chemistry- Adsorbates- Temperature- Roughness
- Plume Orientation- Plume Spread- Particle State
- Structural Adhesion, Residual Stress, Toughness, Stiffness, Elastic Modulus
- FunctionalElectrical / Thermal transport,Wear / Erosion / Corrosion Resistance
- Defect (Cracks & Pores)- Crystal (Phase & Composition)- Layering (Splat Characteristics)- Grain (Size)- Anisotropy
- Composition- Morphology- Size Distribution
APS TBC fabrication involves numerous variables
Plasma Spray Grey box
Multitude of spray devices
& parameters
Multitude of evaluation
Criteria and variants
Multitude of applicators
locations
Implications
Extreme variability – local and global
Infant mortality and poor reliability
Difficult to incorporate into life models
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Requires ….- Robust scientific understanding of manufacturing process- Effective tool to assess coating quality and process/coating reliability (both from development and manufacturing point of view)
Quality
# of
coa
tings
Traditional Role of TBC ⇒ Life Extension
Extra protection on substrates
Higher operating temperature
German Aerospace CenterInstitute of Materials Research
Wu et al, NIMS, Japan
Coating Failures
Future Role of TBC ⇒ Prime Reliant
Must protect (super-alloy) substrates
Requires better control of quality variability
TBC Processing Reliability/Quality is becoming increasingly important
Plasma spray is a highly complex deposition process:Materials Synthesized from Extreme Conditions
NON-EQUILIBRIUM PROCESSINGUltra rapid heating and phase changeRapid cooling and solidificationImpact pressure induced transformations
MULTI-SCALE STRUCTURE AND PROPERTIESNano-, micro-, meso- and macro-scalesDefect-dominated attributes
HIGHLY ANISOTROPIC BEHAVIORProcess-induced residual stresses Anisotropic properties across length scalesNon-linear elastic behavior
Resolidified
Unmelted
TsTm D
d
Resolidified
Unmelted
TsTm D
d
-0.005 0 0.005 0.010 0.015 0.020-40
-20
0
20
40
60
Stre
ss (
MP
a)
Strain
Non-linear responsein YSZ
-0.005 0 0.005 0.010 0.015 0.020-40
-20
0
20
40
60
Stre
ss (
MP
a)
Strain
Non-linear responsein YSZ
Non-linear response ceramics Anisotropy
Impact induced changes
Multiscale microstructures
Microsecond time scales
Need to develop interdisciplinary Processing/Manufacturing Science
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Linking Research to Practice
Center for Thermal Spray Research at Stony Brook University
Established as an NSF MRSEC in 1996Integrated InterdisciplinaryResearch Aimed at AdvancingScience, Technology and Outreach for Thermal Spray Technology
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Particle injector
Substra
te
100 µm
1. Plume particle
interactions
2. Deposit formation dynamics
3. Advanced microstructural characterization
4. Multi-scale property
assessment
Stre
ss (M
Pa)
Strain (%)
LoadingNon-linear
Unloading
Hysteresis
A typical Ceramic
Tools, Technologies and Models are now available at each step
Industry has started to adopt these capabilities for manufacturing control,
Enhanced new processes, novel designs, models and applications Article in Integrating Materials and Manufacturing Innovation
PAINT: Partnership for Accelerated Insertion of New Technology:
Case Study for Thermal Spray
http://www.immijournal.com/content/pdf/2193-9772-2-1.pdf
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
A large portfolio of scientific information has been developed manufacturing science of TBCs
1999- Present
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Demonstrated Industrial Benefits of Advanced Manufacturing Science through Joint Experiments: 32 Field Trips in the Last 7 Years
Stony Brook-Caterpillar Team
Volvo Sweden Field Trip
Post-docs and students facilitate effective knowledge transfer to industrial workforce through cooperative experimentation using advanced technologies and scientific methodologies developed in academia.
Simultaneously, they benefit from the industrial insight and priorities
Companies involved in field trips
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Advanced science impacts both efficiency and reliability
E
σ
ε
σT
ε∗
σ∗
ε* = σ*/E + σ*n/EσNn-1
ε*= σ*/ELINEAR
NONLINEAR
E
σ
ε
σT
σ
ε
σT
ε∗
σ∗
ε* = σ*/E + σ*n/EσNn-1
ε*= σ*/ELINEAR
NONLINEAR
Observations of novel phenomena in thermal plasmas (injection sweet spot)
Proof of Concept Demo
2200
2400
2600
2800
3000
1 3 5 7 9180
220
260
300
Plume PositionCarrier Gas Flow (cf/hr)
Tem
pera
ture
(°C
)
Velo
city
(m/s
)
2200
2400
2600
2800
3000
1 3 5 7 9180
220
260
300
Plume PositionCarrier Gas Flow (cf/hr)
Tem
pera
ture
(°C
)
Velo
city
(m/s
)
Injection Sweetspot
2200
2400
2600
2800
3000
1 3 5 7 9180
220
260
300
Plume PositionCarrier Gas Flow (cf/hr)
Tem
pera
ture
(°C
)
Velo
city
(m/s
)
2200
2400
2600
2800
3000
1 3 5 7 9180
220
260
300
Plume PositionCarrier Gas Flow (cf/hr)
Tem
pera
ture
(°C
)
Velo
city
(m/s
)
Injection Sweetspot
Traditional Method New Method(Injection Optimization)
Coa
ting
Thic
knes
s (µ
m)
280
290
300
310
320
Traditional Method New Method(Injection Optimization)
Coa
ting
Thic
knes
s ( µ
m)
280
290
300
310
320~ 10% improvement in process efficiency
Traditional Method New Method(Injection Optimization)
Coa
ting
Thic
knes
s ( µ
m)
280
290
300
310
320
Traditional Method New Method(Injection Optimization)
Coa
ting
Thic
knes
s (µ
m)
280
290
300
310
320~ 10% improvement in process efficiency
Fundamental Science
Tem
pera
ture
(°C
)
Velocity (m/s)
2750
2800
2850
2900
2950
200 210 220 230 240
Tem
pera
ture
(°C
)
Velocity (m/s)
2750
2800
2850
2900
2950
200 210 220 230 240
Traditional Method
New Method
Tem
pera
ture
(°C
)
Velocity (m/s)
2750
2800
2850
2900
2950
200 210 220 230 240
Tem
pera
ture
(°C
)
Velocity (m/s)
2750
2800
2850
2900
2950
200 210 220 230 240
Traditional Method
New Method
0
6
12
18
Evol
ving
Str
ess
( MPa
)
Traditional Method New Method(Injection Optimization)
0
6
12
18
Evol
ving
Str
ess
(MPa
)
Traditional Method New Method(Injection Optimization)
Observations and quantification of non-linear properties of ceramic coatings
Observation
Successful testing of hypothesis in field: Tinker AF Base & Plasma Technology Inc.
In situ & ex situ extraction of non-linear properties
In situ process diagnostics
OUTCOME:
Procedures for simultaneously enhancing process efficiencies
and reliability
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
The Past and Future
Industrial perception of APS manufacturing as a constraint- Lack of understanding of the scientific nuances
- Perception of poor Repeatability, Reproducibility and Reliability
- In effective control and metrology tools
- Lack of integrated understanding
- Disconnect between design, materials and processes
=> Implication: Manufacturing is a “burden”
With advanced science manufacturing can be an enabler- Implemention of Segmented or Dense Vertically Cracked Coatings
- (Directionally solidified, in-plane compliant coatings)
- Understanding the importance of toughness of metastable t” YSZ on durability
- Advanced process control through insitu sensor based feedback
- Predictive microstructures through maps, correlations and models
- Process-property guided layered engineering
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Thermal spray as an additive and layered manufacturing technology
Bring Manufacturing Science and Novel Capabilities
to Expand Design and Materials Options
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Ni based Superalloy Substrate
Mul
tilay
er T
opco
atB
ondc
oat
Oxidation protectionstrength/creep resistant
High fracture toughness layer
Sinter Resistant Low Thermal conductivity
Erosion and CMAS ResistantLow thermal conductivity
Phase stability
Teixeira et al., JTST, 9(2), 2000—191
Padture et al., vol. 296,Science, 280, 2002
E.g. Optimal Layer Design for Improved Durability
Critical microstructural parameters
- Intrinsic Material Toughness
- Manufactured Material Toughness
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015 21
Superalloy Substrate
Overlay BC
Porous YSZLow K
Low E
Conventional TBCsEnhanced Durability
TBCs
Superalloy Substrate
Overlay BCenhanced roughness
Layer-1
Layer-2
High KIC TBC Layer
Porous YSZLow K
Low E
Toughness engineered multilayer TBCs
TBC
life
time
(hou
rs)
0
200
400
600
800
1000
1200
1400
Con
vent
iona
l
Single layer TBCs
Bi-layer TBCs
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
TBC
life
time
(hou
rs)
RT Thermal conductivity (W/m-K)0.6 0.8 1.0 1.2 1.4 1.6 1.8
400
600
800
1000
1200
1400
Single layer YSZ TBCs
bi-layer YSZ-TBCs with improveddurability
Inverse
bi-layer TBC
Simultaneous optimization of durability and functionality
DVC
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Coatings experience multiple failure mechanisms
o Ceramic strength/toughnesso Ceramic coating compliance
and ceramic chemistry
o Bond coat chemistry, Roughnesso Ceramic coating toughness
o Ceramic coating composition
o Coating density o Coating porosity/cracks
o Bond coat roughnesso Coating thickness
o Pore architectureo Coating thickness
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Multilayered architecture to combat multifunctional requirements
(Rene 80 or CMSX4)
Plasma spray is naturally suited for such layered manufacturing
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Superalloy Substrate
High KIC YSZ Layer
Erosion ,CMAS ResistantLow K ,E GZO Layer
Multifunctional Multimaterial TBCs
Bond Coat
Low K
Low ELoca
tion
spec
ific
prop
erty
requ
irem
ents
Design consideration for YSZ- GDZ multilayer architectures
Possible Microstructural Variants
Porous YSZ / Porous GDZ
Dense GDZ / DVC GDZ
DVC / Thin interfacial layer of dense YSZ
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Single Layer TBC
600 hrs
50 +coating conditions
40+ architectures
600+ FCT samples
Adequate erosion resistance
Significantly higher durability
CMAS resistance
Mechanisms and Methodology to incorporate andynew composition
The multilayer TBC architecture
Layer-2
Layer-1
Layer-3
1,200 hrs
Multilayer TBC
Validated through FCT testing both in house, ORNL and industry (Siemens, GE) during UTSR program
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Successfully validated at industrial sites (GE, Siemens, Praxair)
Bond Coat
Porous Single layer
Bond Coat
Bi-layer YSZ
Bond Coat
Multilayer YSZ-GDZ
coating
Bond Coat
Dense Single layer 0
200
400
600
800
TBC
life
time
(cyc
les)
PorousYSZ
DenseYSZ
Bi layerYSZ
YSZ-GDZ
Porous YSZ Dense YSZ Bi layer YSZ YSZ-GDZ
All failed at BC/TC interface
FCT: 2000F (1093oC), 45 mins cyclingCourtesy: Ben Nagaraj
6 x 2000 cycles: No Failure yet
0 500 1000 1500 2000
1600
1800
2000
2200
2400
2600
δT ~ 506
0 500 1000 1500 2000
1600
1800
2000
2200
2400
2600
δT ~ 752 F
0 500 1000 1500 20001600
1700
1800
1900
2000
2100
2200
2300
δT ~ 396
0 500 1000 1500 20001600
1800
2000
2200
2400
2600
2800
Tem
pera
ture
(o F)
δT ~ 818 F
JETS test
Courtesy: Dr. Li Li
J. Mater. Engg. Perf.Ann Bolcavage
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
Superalloy
Bondcoat
TopcoatEBPVDAPSSPS
Ni/Pt-AlAPSVPSHVOF
Increasing Turbine operation TemperatureY:1980 Y:2015
Ni based- Bond Coat
Conventional single layer TBC
Superalloy
Low-KYSZ
Ni based- Bond Coat
Multilayer Advanced TBC
Superalloy
High K1c- YSZ
Low E, K- YSZ
Low K, CMAS ResistantGd2Zr2O7
Si-bondcoat
Yb2SiO5Low water
volatalization
CMCs
Mullite-oxygen barrier
Multilayer Advanced EBCs
oP
hase
-sta
bilit
yo
CM
AS
oP
hase
-sta
bilit
yo
CM
AS
oS
ubst
rate
Tem
p lim
it.
CMCs
O2, H2O
Si
T~1400oC
SiO2(s) + 2H2O(g) = Si(OH)4(g)
TBCs + EBCs EBCs
Cur
rent
TBC
sAp
plic
atio
n ch
alle
nges
Cur
rent
bill
of T
BCs
Applying similar ideas to emergent TBCs, EBCs, T/EBCs
Sanjay Sampath, Stony Brook UniversityPresentation at NIMS, April 2015
MesoPlasma™ 3D-Printing Technology
Printing onto Films
Provides new process capabilities not achieved with conventional plasma spray / cold spray
Precision, multi-layered metallic and ceramic dielectric patterns
Printed thermocouples and high watt density heaters onto parts
Stand-alone heat flux sensor and heater products
Printed patterns onto temperature-sensitive polymer films
Direct Write Technology
Temperature Sensing
Part Heating
Heat Flux Sensor Products