ICMCTF 2012! - CD-Lab Application Oriented Coating Development

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Exhibition Room: Golden Ballroom - Session EX Exhibition Keynote Tuesday Morning, April 24, 2012 9:40am EX-1 Rotatable Magnetrons, Today and Tomorrow, R. De Gryse, Ghent University, Belgium INVITED The continuously increasing demand for a higher quality of life requires the fabrication of products with improved functionality at ever decreasing prices. Moreover, environmental awareness requires that these products are manufactured with so-called “clean“, technologies. These demands have led to a rapid technological progress within the thin film industry. Physical Vapor Deposition (PVD) has been proven able to cope with these requirements, and within the PVD family, magnetron sputtering in all its varieties is probably the best known and most widely spread deposition technology. This success is mainly due to the thin film quality, reproducibility, and flexibility, as well as the scalability of the sputtering process. The concept of magnetron sputtering has been used under many different forms. Probably the best known implementation of magnetically assisted sputtering is to be found in the “classics“ such as in the planar magnetrons, either circular or rectangular. However, magnetically assisted sputtering is also used in many other forms such as inverted magnetrons, cylindrical-post magnetrons, cylindrical hollow cathode magnetrons, facing target magnetrons and rotatable cathode magnetrons. This last variety, the rotatable magnetron, is maybe the least known to the general public but most intensively used in large area coating applications like in web coating and glass coating. In this instance, we will focus on rotatable magnetrons, and their benefits and drawbacks, in addition to their peculiarities. For example, it turns out that in reactive sputtering their behavior is quite different in comparison to a rectangular magnetron of similar dimensions. Also, new trends in rotatable magnetron sputtering will be discussed from a technological point of view, as well as from the viewpoint of market demands. Tuesday Morning, April 24, 2012 38
Coatings for Use at High Temperature Room: Sunrise - Session A2-2 Tuesday Afternoon, April 24, 2012 Thermal and Environmental Barrier Coatings Moderator: R. Wellman, Cranfield University, UK, D. Litton, Pratt & Whitney, US, R. Trice, Purdue University, US 1:50pm A2-2-1 Process and Equipment for Advanced Thermal Barrier Coating Systems, A. Feuerstein (albert_feuerstein@praxair.com), C. Petorak, L. Li, T.A. Taylor, Praxair Surface Technologies, Inc., US INVITED Hot section components in aero and power generation engines utilize advanced thermal barrier coating systems for life extension and better efficiency. Thermally-sprayed ceramic / bondcoat systems are extensively used for combustors and power generation blades and vanes whereas EBPVD TBC on Pt modified diffusion aluminide coating is the coating of choice for highly stressed airfoils in aero engines. New technologies such as the suspension plasma spray process (SPS) are finding more and more interest for applying TBC’s. In addition, challenges such as the trend to low thermal conductivity and CMAS resistant coatings require new compositions, and respective processing technology. The process and coating characteristics of 7wt% YSZ based APS low density and dense vertically cracked (DVC) Zircoat TBC as well as EBPVD coatings are described, highlighting recent advances with ultra pure Zirconia for improved sintering resistance. New coating compositions for low thermal conductivity TBC’s and CMAS resistant TBC’s are also addressed. Lastly, the properties of new coating processes such as SPS are compared with conventional coating processes. 2:30pm A2-2-3 Calcium-Magnesium-Alumino-Silicate (CMAS) degradation of EB-PVD thermal barrier coatings: solubility of different oxides from ZrO2-Y2O3 and ZrO2-Nd2O3 systems in the molten model CMAS, N. Chellah, M.H. Vidal-Sétif (Marie-Helene.Vidal- Setif@onera.fr), Thermal and Environmental Barrier Coatings, France Thermal barrier coatings (TBCs) are used to protect blades and vanes in the hot sections of gas turbines. They consist of a series of layers: the Ni-based superalloy substrate is coated with an alumina forming metallic bond coat onto which a porous ceramic top coat of yttria partially stabilized zirconia (YPSZ) is deposited. The TBC system allows higher gas temperatures, resulting in enhanced engine efficiency and performance. However, in service, engines ingest dust, sand and ash particles which melt on the hot TBC surface at these high operating temperatures and form calciummagnesium-aluminosilicate (CMAS) glass deposits. Previous investigations on blades removed from service showed that the molten CMAS penetrates into the open porosity of the top coat. Firstly, upon cooling, the molten CMAS solidifies and the infiltrated TBC becomes rigid. Thus, delamination cracks can develop in the coating leading to progressive TBC spallation during in-service thermal cycling. Secondly, a chemical interaction can take place between the molten CMAS and the TBC leading to the dissolution of the YPSZ TBC in the molten CMAS. This paper investigates the chemical degradation of an electron beam physical vapor deposited YPSZ TBC by a synthetic model CMAS. The chosen CMAS was the tridymite-pseudowollastonite-anorthite eutectic composition in the ternary (CaO-Al2O3-SiO2) system, melting at 1170°C. The model system has given very good replication of the CMAS corrosion observed on ex-service blades in terms of thermochemical interaction: TBC infiltration, TBC dissolution in the CMAS melt and formation of new crystalline phases. In order to understand the mechanisms of degradation by dissolution of the YPSZ TBC in the molten CMAS, a method was used which was designed initially to measure the solubility of oxides in a glass. First the solubility of different compositions of the ZrO2-Y2O3 system in the glassy model CMAS was studied at several temperatures, in order to access the dissolution kinetics. The solubility limits and thermodynamic equilibrium constants were determined and possible new crystalline phases were identified. The results enabled to improve the understanding of the mechanisms of the chemical degradation of the YPSZ TBC by the CMAS. In a second part, solubility tests of different compositions of the ZrO2- Nd2O3 system in the same model glass were performed. These allowed selecting a new composition to substitute YPSZ for mitigating CMAS attack. The selected new oxide was tested as a dense ceramic and actually it showed restricted chemical degradation by the model CMAS. 2:50pm A2-2-4 Bond Coat Cavitation under CMAS-Infiltrated TBCs, K. Wessels (kwessels@engineering.ucsb.edu), University of California, Santa Barbara, US, D. Konitzer, GE Aviation, US, C.G. Levi, University of California, Santa Barbara, US Turbine airfoils in advanced aircraft turbine engines are protected from the aggressive environment by thermal barrier coating systems (TBCs) comprising an insulating oxide and a metallic bond coat. Environmental contaminants ingested with the intake air form deposits generically known as CMAS (calcium-magnesium alumino-silicates) on the protective coatings. As the deposits melt during the engine cycle a silicate glass forms that infiltrates the porous coating and crystallizes under the imposed thermal gradient, stiffening the TBC and compromising its strain tolerance. Delamination failures have been documented in the past. A new failure mechanism that involves the formation of cavities within the bond coat under regions of the TBC penetrated by CMAS has been identified recently. Examination suggests that cavity formation occurs in regions subject to lateral thermal gradients; channel cracking and scalloping of the TBC are also observed above the bond coat cavities. Once the voids grow large enough to compromise the bond coat, the TBC delaminates and eventually spalls, leaving behind a thermally unprotected airfoil with a residual bond coat. This presentation will discuss the characteristics of this failure mode, and the possible underlying mechanisms. 3:10pm A2-2-5 Assessing the Delamination Behavior of CMAS Infiltrated TBCs under a Thermal Gradient, R.W. Jackson (rwesleyjackson@engineering.ucsb.edu), E. Zaleski, C.G. Levi, University of California, Santa Barbara, US With rising operating temperature, the prevalence of calcium magnesium alumino-silicate (CMAS) deposits melting on the surface of thermal barrier coatings (TBCs) used in gas turbines has increased. These molten CMAS deposits infiltrate and crystallize within the pores of the structure, stiffening the penetrated layer and leading to a loss of strain tolerance. The loss of compliance promotes coating delamination when the strain energy generated from the thermal expansion mismatch during thermal cycling reaches a critical level. A laser thermal gradient test (LGT), in which the thermal gradient and cooling rate can be controlled, was used to assess the TBC durability by imposing a range of thermal stresses. Both 7YSZ and gadolinium zirconate (GZO) TBCs, with and without CMAS deposits, were subjected to the LGT. In the absence of CMAS, no microstructural degradation was observed for either composition. When loaded with CMAS, TBC degradation was found to increase with increased cooling rate, and was generally higher for GZO than for 7YSZ, both materials processed by EB-PVD. The CMAS penetration, phase evolution and crack morphology of the thermally cycled TBCs have been characterized as a function of the thermal history and will be analyzed in the context of current delamination models. This investigation was sponsored by the Office of Naval Research under grant N00014-08-1-0522, monitored by Dr. David Shifler 3:30pm A2-2-6 CMAS infiltration of YSZ thermal barrier coatings and potential protection measures, V. Kuchenreuther (veronica.kuchenreuther@ict.fraunhofer.de), V. Kolarik, M. Juez Lorenzo, Fraunhofer ICT, Germany, W. Stamm, Siemens Power Generation, Germany, H. Fietzek, Fraunhofer ICT, Germany Yttria stabilized zirconia (YSZ) thermal barrier coatings (TBC) are widely used to protect the components in the hot area of power generation turbines. One identified cause of TBC failure is the degradation by molten deposits, mostly calcium-magnesium-alumina-silicates (CMAS), which enter the turbine from the environment. It infiltrates the pores and cracks, reacts with the YSZ and leads to its destabilization. The main purpose of the current research is to investigate to which extent the attack by molten CMAS can be reduced by coating the TBC with alumina. A model CMAS, composed of 38 mol% CaO, 6 mol% MgO, 5 mol%Al2O3, 50 mol% SiO2 and 1 mol% Fe2O3, ultra-milled, molten two times for 4 h at 1400°C and milled again, was deposited on the surface of a free standing sample from a commercial APS TBC. The samples were exposed to 1100°C and 1240°C for 50, 100 and 200 hours in air and were analyzed by X-ray diffraction with micro-focus (µ-XRD) and by field emission SEM. Surface scans by µ-XRD stepwise from the unaffected area to the CMAS infiltrated surface area show at 1100°C considerable portions of the monoclinic phase from the first exposure time of 50h. The micrographs however reveal only superficial infiltration. At 1240°C again the phase decomposition is detected already after 50 h and a deep infiltration is observed in the micrographs, almost across the whole TBC. 39 Tuesday Afternoon, April 24, 2012
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I C M C T F 2 0 1 2 INTERNATIONAL C
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TABLE OF CONTENTS Welcoming Remarks
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2012 ICMCTF SCHEDULE OF EVENTS DAY
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SYMPOSIUM A Coatings for Use at Hig
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Marco Cremona Pontificia Universida
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Exhibitor Keynote Lecture Tuesday,
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2011/12, discuss ideas and prioriti
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At the focus topic, from the experi
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2012 R.F. Bunshah Annual Award & IC
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ICMCTF 2012 Graduate Student Awards
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ICMCTF 2012 thanks Plansee for thei
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ICMCTF 2012 thanks AJA Internationa
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ICMCTF 2012 thanks CemeCon for thei
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ICMCTF 2012 Short Courses April 22
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ICMCTF 2012 Planning Grid We provid
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Key to Session/Paper Numbers A Coat
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Monday Morning, April 23, 2012 Fund
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New Horizons in Coatings and Thin F
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Fundamentals and Technology of Mult
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Advanced Characterization of Coatin
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Hard Coatings and Vapor Deposition
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Tribology & Mechanical Behavior of
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Hard Coatings and Vapor Deposition
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Coatings for Use at High Temperatur
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Applications, Manufacturing, and Eq
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Wednesday Afternoon, April 25, 2012
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Thursday Afternoon Poster Sessions
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Free Caricatures & Massages!! E-1 V
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ICMCTF 2012 EXHIBIT HALL Internatio
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I C M C T F 2012 S P O N S O R S Bo
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All in Good Measure A 24 µm scan o
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Call For Abstracts Deadline: MAY 2,
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CC800 ® /9 HIPIMS true integration
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Exhibit Hall Reception - Atlas Ball
Page 89: Kaufman & Robinson announces their
Page 93 and 94: Miba Coating Group is the specialis
Page 95 and 96: PLANSEE SE, 6600 Reutte, Austria, T
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Page 101 and 102: Plenary Talk Room: Golden Ballroom
Page 103 and 104: content. Analyses of the oxidised c
Page 105 and 106: - The control on the gradient in re
Page 107 and 108: μ = 0.4 to μ = 0.9). On the other
Page 109 and 110: Hard Coatings and Vapor Deposition
Page 111 and 112: application tests the ta-C coated d
Page 113 and 114: 4:10pm C2-2/F4-2-10 Investigation o
Page 115 and 116: process with surfactant on WO3/ITO
Page 117 and 118: is already reported. To further com
Page 119 and 120: conditions. The details of the comp
Page 121 and 122: esidual stress and to the Poisson
Page 123 and 124: Coatings for Use at High Temperatur
Page 125 and 126: eactive gases with the target mater
Page 129 and 130: emerging fields. State-of-the-art t
Page 131 and 132: transparent conducting layers. Howe
Page 133 and 134: methods provide similar carrier den
Page 135 and 136: of AISI 52100 steels by developing
Page 137: deposition based on high power puls
Page 141 and 142: coatings removed from the aluminum
Page 143 and 144: spectroscopy varies from 25 at% to
Page 145 and 146: This article describes how to use s
Page 147 and 148: een demonstrated both theoretically
Page 149 and 150: Furthermore, the silane coupling ag
Page 151 and 152: 10:40am A1-1-9 High temperature oxi
Page 153 and 154: 10:40am B4-2-10 Understanding the d
Page 155 and 156: 11:00am B5-1-10 Hard nanocrystallin
Page 157 and 158: * Sandia National Laboratories is a
Page 159 and 160: fluidized bed of tin, zinc and alum
Page 163 and 164: mechanical and chemical properties.
Page 165 and 166: duration for super-low friction see
Page 167 and 168: stainless steel DIN X42Cr13 surface
Page 169 and 170: 2:30pm TS1-1-3 Surface engineering
Page 175 and 176: X-ray diffraction patterns of the Z
Page 177 and 178: 11:20am B6-1-11 Direct current magn
Page 179 and 180: loading situations could help to ob
Page 181 and 182: Energetic Materials and Micro-Struc
Page 183 and 184: The present work was supported by t
Page 185 and 186: silica-based hydrophilic coatings i
Page 187 and 188: extent depending on the actual grow
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[1] F. Tasnádi, B. Alling, C. Hög
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eproducibility of the preparation o
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showed by the uncoated 4140 steel s
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polarization resistance and corrosi
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thin films in which a multiscale mo
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centers, ascribed to conduction ele
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BP-26 Characterization of laser abl
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BP-38 Stress signature of an amorph
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simultaneously optimize materials p
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CP-17 Effects of UV Light Treatment
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amorphous structure with a smooth s
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addition, it was observed that the
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EP-5 The effective Indenter concept
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the substrates directly or after ra
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as-grown films using textured Si as
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proposed memory device exhibits exc
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FP-24 Effect of hydrogen addition o
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oxide obtained was correlated to th
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Post Deadline Discoveries and Innov
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chemical bonds have also been achie
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9:40am B3-1-6 Compressive stress ge
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10:20am D2-1-8 Corrosion Resistance
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property combination is attractive
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PVD is a challenging task. The pres
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Chang, G.W.: C2-3/F4-3-3, 29; GP-3,
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Huang, K.H.: BP-33, 102 Huang, P.H.
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Moody, N.R.: F6-1-1, 7 Moon, S.: D1
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Szeremley, D.: G3-1-7, 68 Szesz, E.
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NOTES 145
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Description of Research Highlights:
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their presentations in order to eva
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NOTES 151
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153
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