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Advances in Thermal Barrier and Abradable Ceramic Coatings by Chemically Bonded Composite Sol-Gel Technology

[+] Author Affiliations
Junlong Fu, Quanzu Yang, Tom Troczynski

University of British Columbia, Vancouver, BC, Canada

Paper No. GT2004-54051, pp. 425-429; 5 pages
doi:10.1115/GT2004-54051
From:
  • ASME Turbo Expo 2004: Power for Land, Sea, and Air
  • Volume 2: Turbo Expo 2004
  • Vienna, Austria, June 14–17, 2004
  • Conference Sponsors: International Gas Turbine Institute
  • ISBN: 0-7918-4167-7 | eISBN: 0-7918-3739-4
  • Copyright © 2004 by ASME

abstract

The novel technology of chemically bonded composite sol-gel (CB-CSG) coatings has been developed at UBCeram. This essentially “ceramic paint” technology operates with CSG slurries formulated to contain a sol-gel “glue”, e.g. hydrated alumina sol, and inert filler, e.g. alpha alumina or yttria stabilized zirconia (YSZ), suspended in water or other solvent. The CSG is spray-deposited on metallic surfaces, and heat-treated at about 300°C to partially dehydrate the gel-derived hydroxides. CSG film is subsequently chemically bonded (CB) through reaction of the gel-derived active alumina with metal phosphates, such as aluminum phosphate. Effectively, the microstructure of such coating includes a porous network of refractory phosphate bonded alumina and/or YSZ. The vol% of porosity can be easily controlled in 5–60% range by adjusting spray conditions. Structural integrity (e.g. hardness and “abradability”) of the coatings can be controlled through the degree of chemical bonding treatment given. The spray-heat treat operations can be repeated to build porous films in excess of 1 mm thickness. The paper reviews the basics of CB-CSG technology. This research has focused on achieving the unique, strain-tolerant columnar microstructure of the coatings, somewhat resembling that of TBC by EB-PVD. Explanation of the process parameters controlling development of the columnar microstructure of the coatings is attempted.

Copyright © 2004 by ASME

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