Software Tools for Lifetime Assessment of Thermal Barrier Coatings Part II — Bond Coat Aluminum Depletion Failure

Abstract

The use of thermal barrier coatings (TBCs) made from yttria stabilized zirconia (YSZ) on superalloy base materials has been a significant step to a new level of operational limits in high temperature applications. By the application of a TBC in conjunction with cooling of the component material the operating temperature can be raised and higher efficiencies are achieved. As a consequence of the raised temperature failure of a TBC leads to an increased oxidative attack of the underlying bond coat material and therefore needs to be avoided. The lifetime prediction of thermal barrier coatings is therefore of interest to ensure safe operation within the inspection intervals. Several mechanisms have been identified to play a critical role in the degradation of TBC systems. Here we discuss failure of TBC systems due to bond coat aluminum depletion. This type of chemical failure may occur when the bond coat material is critically depleted of aluminum and instead of a dense slow growing α-alumina the formation of voluminous and fast growing spinels is promoted. Lifetime prediction for this failure mode requires a fundamental understanding of diffusion mechanisms and in particular the interaction of different diffusion rates in the bond coat and substrate material. Aim of this work was therefore to develop software tools that allow user friendly analysis of measured Al profiles for the assessment of diffusion rates and consequently for lifetime prediction.