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The water vapor corrosion of Yb-silicates is of interest to their application as environmental barrier coatings in gas turbine technology. In this study, densified samples from the Yb-silicate powder, as well as plasma-sprayed free-standing Yb-silicate coating were tested at a high-velocity steam rig (T = 1400 °C, v = 90 m/s, PH2O = 0.19 atm) for microstructural comparison. After the test, the measured weight losses of the coatings were larger than that of the densified sample. At the same time, the thicknesses of the corroded scales at the coating surfaces were found to be thicker than that of the sintered sample by a factor of two.

The present article describes aspects of the cold gas spray processability of the intermetallic Ti-48Al-2Cr-2Nb (at. %) alloy, which is employed as a structural material in gas turbine engines. The effects of processing parameters, namely, gas pressure, gas temperature, spray distance, as well as the gas atomized feedstock particle size (d50 = 30 and 42 μm, respectively) and phase composition on deposition, were investigated. The results showed that when the highest available gas pressure (40 bar) and temperature (950 °C) were combined with a short spray distance (20 mm), well-adhering coatings could be deposited regardless of the investigated particle size. However, the maximum coating thickness could be achieved was about 30 μm with a deposition efficiency of 1%. Phase composition of the gas atomized feedstock was investigated with HT-XRD and according to the findings, heat treatment of the feedstock under vacuum was carried out. With this treatment, non-equilibrium, disordered α phase of the atomized powder was transformed into an α, α2 and γ phase mixture. At the same time, an increase in the hardness and oxygen content of the powder was detected. Swipe test performed with the heat treated powder revealed no improvement in terms of deposition, in fact, the number of adhering particles on the substrate was decreased in comparison with that of the untreated powder.

In this work, silicon–hafnia (Si-HfO2, 80/20 mol. %) feedstock was plasma sprayed for Environmental Barrier Coating bond coat application. In the as-sprayed coating, hafnium disilicide (HfSi2), HfO2 tetragonal (t), and cubic (c) phases with a total volume of ~20 % were detected together with Si and HfO2 monoclinic (m). The temperature-dependent evolution of these phases was analyzed and paired with microstructural observations. It was found that above 700 °C, HfSi2 oxidizes and HfO2 (t) and (c) transforms into (m) polymorph. Up to this temperature, as-sprayed coating showed a non-linear expansion behavior. Estimated volume expansion at ~750 °C was 3.6 % based on dilatometry measurement. The primary and secondary mechanisms leading to the expansion in the coating were identified as oxidation of HfSi2 and polymorphic phase transitions in HfO2, respectively. As a consequence of the volume expansion, the coating was extensively cracked during cyclic oxidation and hence not protective anymore. After 100 h at 1300 °C, the volume fraction of oxidation product SiO2 was significant in the coating (0.34), while HfO2 was largely consumed (0.1) in the formation of HfSiO4 (0.56). This result suggested that reversible α↔β phase transitions in SiO2-cristobalite could be another factor contributing to the cracking in the coating during cyclic oxidation.

The ceramic top coat has a major influence on the performance of the thermal barrier coating systems (TBCs). Yttria-partially-stabilized zirconia (YSZ) is the top coat material frequently used, and the major deposition processes of the YSZ top coat are atmospheric plasma spraying and electron beam physical vapor deposition. Recently, also new thermal spray processes such as suspension plasma spraying or plasma spray-physical vapor deposition have been intensively investigated for TBC top coat deposition. These new processes and particularly the different coating microstructures that can be deposited with them will be reviewed in this article. Furthermore, the properties and the intrinsic–extrinsic degradation mechanisms of the YSZ will be discussed. Following the TBC deposition processes and standard YSZ material, alternative ceramic materials such as perovskites and hexaaluminates will be summarized, while properties of pyrochlores with regard to their crystal structure will be discussed more in detail. The merits of the pyrochlores such as good CMAS resistance as well as their weaknesses, e.g., low fracture toughness, processability issues, will be outlined.

Dense, crack-free, uniform, and well-adhered environmental barrier coatings (EBCs) are required to enhance the environmental durability of silicon (Si)-based ceramic matrix composites in high pressure, high gas velocity combustion atmospheres. This paper represents an assessment of different thermal spray techniques for the deposition of Yb2Si2O7 EBCs. The Yb2Si2O7 coatings were deposited by means of atmospheric plasma spraying (APS), high-velocity oxygen fuel spraying (HVOF), suspension plasma spraying (SPS), and very low-pressure plasma spraying (VLPPS) techniques. The initial feedstock, as well as the deposited coatings, were characterized and compared in terms of their phase composition. The as-sprayed amorphous content, microstructure, and porosity of the coatings were further analyzed. Based on this preliminary investigation, the HVOF process stood out from the other techniques as it enabled the production of vertical crack-free coatings with higher crystallinity in comparison with the APS and SPS techniques in atmospheric conditions. Nevertheless, VLPPS was found to be the preferred process for the deposition of Yb2Si2O7 coatings with desired characteristics in a controlled-atmosphere chamber.

Double layer thermal barrier coatings (TBCs) consisting of a Gd2Zr2O7 (GZO) top and an ytrria stabilized zirconia (YSZ) interlayer have been tested in a burner rig facility and the results compared to the ones of conventional YSZ single layers. In order to gain insight in the high temperature capability of the alternative TBC material, high surface temperatures of up to 1550 °C have been chosen while keeping the bond coat temperature similar. It turned out that the performance of all systems is largely depending on the microstructure of the coatings especially reduced porosity levels of GZO being detrimental. In addition, it was more difficult in GZO than in YSZ coatings to obtain highly porous and still properly bonded microstructures. Another finding was the reduced lifetime with increasing surface temperatures, the amount of reduction is depending on the investigated system. The reasons for this behavior are analyzed and discussed in detail.

Gadolinium zirconate (Gd2Zr2O7, GZO) as an advanced thermal barrier coating (TBC) material, has lower thermal conductivity, better phase stability, sintering resistance, and calcium‐magnesium‐alumino‐silicates (CMAS) attack resistance than yttria‐stabilized zirconia (YSZ, 6‐8 wt%) at temperatures above 1200°C. However, the drawbacks of GZO, such as the low fracture toughness and the formation of deleterious interphases with thermally grown alumina have to be considered for the application as TBC. Using atmospheric plasma spraying (APS) and suspension plasma spraying (SPS), double‐layered YSZ/GZO TBCs, and triple‐layered YSZ/GZO TBCs were manufactured. In thermal cycling tests, both multilayered TBCs showed a significant longer lifetime than conventional single‐layered APS YSZ TBCs. The failure mechanism of TBCs in thermal cycling test was investigated. In addition, the CMAS attack resistance of both TBCs was also investigated in a modified burner rig facility. The triple‐layered TBCs had an extremely long lifetime under CMAS attack. The failure mechanism of TBCs under CMAS attack and the CMAS infiltration mechanism were investigated and discussed.

The chapter describes the different aspects of ceramic materials in gas turbines. The operation conditions such as high-pressure ratio and high temperatures result in improved efficiencies and make necessary the use of materials with high-temperature capability. In addition to the often used single-crystal alloys ceramic materials are discussed. Different bulk ceramics, for example, based on silicon nitride are described. A special focus is laid on ceramic matric composites, both oxide and nonoxide-based materials, which are of increasing interest for gas-turbine applications. In addition to the structural applications ceramics are also often used as coating material. Standard coating processes for protective coatings in gas turbines are described. Furthermore, thermal barrier coatings, a widely used coating system in gas turbines, and environmental barrier coatings as protective coatings for ceramic matrix composites are discussed in detail. Finally, also degradation and failure modes for the different high-temperature coating systems are the topics of this chapter.

In this study, burner rig testing of Si/Yb2Si2O7 environmental barrier coating protected SiC-based ceramic matrix composites was conducted. Tests were performed at standard conditions as well as with liquid water injection to the flame. Furthermore, the influence of the impingement angle of the flame (45° vs. 90°) on water vapor corrosion was explored. Gas flow rates were adapted in each test to adjust 1250 °C at the sample surface. The comparison of test results showed that water injection advances the corrosion of the Yb2Si2O7 topcoat and the impingement angle affects the size and shape of the corroded area on the sample surface.

Gas turbine components are often operated in harsh conditions, which can lead to severe damage. As it is highly desirable from both an economical and an ecological point of view to restore these worn areas instead of manufacturing new components, repair technologies are of huge interest for companies supplying maintenance and overhaul of gas turbines. In this article, two thermal techniques are described that can be used for this application: cold gas spraying (CGS) and vacuum plasma spraying (VPS). The CGS process allows the deposition of metallic coatings with excellent mechanical properties; several examples including γ‐TiAl, Inconel (IN) 718, and IN 738 are given. Essential for the deposition of high‐performance coatings in CGS is to exceed the so‐called critical velocity. This is discussed also with experimental findings. As a final topic, experiments that use VPS for the repair of single‐crystal alloys are described.

Environmental barrier coatings (EBCs) are essential to protect ceramic matrix composites against water vapor recession in typical gas turbine environments. Both oxide and non-oxide-based ceramic matrix composites (CMCs) need such coatings as they show only a limited stability. As the thermal expansion coefficients are quite different between the two CMCs, the suitable EBC materials for both applications are different. In the paper examples of EBCs for both types of CMCs are presented. In case of EBCs for oxide-based CMCs, the limited strength of the CMC leads to damage of the surface if standard grit-blasting techniques are used. Only in the case of oxide-based CMCs different processes as laser ablation have been used to optimize the surface topography. Another result for many EBCs for oxide-based CMC is the possibility to deposit them by standard atmospheric plasma spraying (APS) as crystalline coatings. Hence, in case of these coatings only the APS process will be described. For the EBCs for non-oxide CMCs the state-of-the-art materials are rare earth or yttrium silicates. Here the major challenge is to obtain dense and crystalline coatings. While for the Y2SiO5 a promising microstructure could be obtained by a heat-treatment of an APS coating, this was not the case for Yb2Si2O7. Here also other thermal spray processes as high velocity oxygen fuel (HVOF), suspension plasma spraying (SPS), and very low-pressure plasma spraying (VLPPS) are used and the results described mainly with respect to crystallinity and porosity.

The purpose of this research was to investigate the corrosion behavior of the low/high Yb2SiO5 containing Yb2Si2O7 coatings under high-velocity water vapor flow. To that end, Yb2Si2O7 and Si coatings were deposited by atmospheric plasma spraying on SiC substrates. The corrosion tests were performed in the burned natural gas under atmospheric pressure, with a gas flow velocity of 100 m/s at 1200 °C for 200 h. After the test, a 25 mm thick, porous corrosion layer at the surface of the Yb2Si2O7 rich coatings was found accompanied with a mass reduction, whereas samples with Yb2SiO5 rich coatings showed mass gain indicating the greater resistance of Yb2SiO5 against water vapor. A comparison of the Yb2Si2O7 rich coatings tested in this work and Yb2Si2O7 bulk samples tested in an earlier work at the same facility revealed significantly different recession rates. Possible mechanisms responsible for this distinct behavior are discussed in the manuscript.

In this work, the delamination toughness and the sintering behavior of modern double-layer thermal barrier coatings of type gadolinium zirconate (GZO)/yttrium-stabilized zirconia (YSZ) are investigated in detail. These properties mainly determine the strain tolerance and thus the performance of thermal barrier coatings (TBCs). The delamination toughness was determined using a modified four-point bending setup. It is shown that the delamination behavior differs significantly from conventional monolayer coatings and is highly dependent on the specific microstructure of the GZO layer. The stiffness and sintering behavior of freestanding GZO layers were determined using impulse excitation, a test method sensitive to the global stiffness of the ceramic coating. The increase in stiffness is thereby correlated to microstructural changes, explicitly the healing of micro-cracks and the sintering of inter-lamellar cracks and unmolten particles. The results reveal that the specific spray structure of GZO has a great influence on the sinter stability which results in a characteristic temperature dependency. In this case the GZO coatings have an advantage in comparison to conventional YSZ coatings at temperatures above 1300 °C.

During the past decade, gadolinium zirconate (Gd2Zr2O7, GZO) has attracted interest as an alternative material to partially yttria-stabilized zirconia (YSZ) for thermal barrier coatings (TBCs). Despite the well-known benefits of GZO, such as lower thermal conductivity and superior temperature capability compared to YSZ, processing of GZO via atmospheric plasma spraying (APS) still remains a challenge. Here, we report on APS experiments which were performed to investigate the influence of processing on GZO microstructure and lifetime of GZO/YSZ double-layer TBCs. Different microstructures of GZO were produced and characterized in terms of porosity, stoichiometry, Young′s modulus, and their effects on the lifetime of YSZ/GZO double-layer TBCs were discussed. Particle diagnostics were utilized for the optimization of the process parameters with respect to different microstructures of GZO and stoichiometry. It was found that both cumulative porosity of GZO and pore size distribution, which alter the Young′s modulus significantly, govern the lifetime of double layers. In addition, it was shown that the deviation in GZO stoichiometry due to gadolinia evaporation in the investigated range does not display any critical effect on lifetime.

A series of disazo pyrazole disperse dyes were synthesized and reported at our previous work. These 8 synthesized disazo pyrazole disperse dyes (3a-3h) were applied to poly(lactic acid) (PLA), poly(ethylene terephthalate) (PET), and polyamide 6.6 fibers. Their colorimetric and color fastness properties were investigated. All studied fibers dyed with these synthesized dyes exhibited yellow-red shades. 3c (p-Cl), 3e (m-Cl), and 3h (o-Cl) disazo disperse dyes, having auxochrome -Cl, led to the lowest color yield values for all three studied fibers. The same dyes resulted in higher color strength with darker shades on the PET and PLA fabrics in comparison PA 6.6 fabrics. 3a (p-NO2), 3b (p-OCH3), 3d (m-NO2), 3f (o-NO2), and 3g (o-OCH3) disazo disperse dyes can be recommended for PLA and PET dyeing from the color point of view leading to medium to heavy depth of shades. The wash, alkaline and acidic perspiration, dry and wet rub, water and sea water fastness levels of PLA, PET, and PA 6.6 samples dyed with 3a-3h dyes were generally quite high and in the commercially acceptable range with few exceptions. Dyed PLA fabrics displayed better sublimation fastness levels than dyed PET and PA 6.6 fabrics. Synthesized disperse dyes resulted in high light fastness performance on especially PET and PLA fibers. Light fastness level was better for dyed PET samples by comparison with dyed PLA and PA 6.6 fabrics. © 2018, The Korean Fiber Society and Springer Science+Business Media B.V., part of Springer Nature. Firat University Scientific Research Projects Management Unit: 2012FBE035 This study is sponsored and supported by Pamukkale University Scientific Research Project Coordination Unit PAUBAP by the project number of 2012FBE035.

Processing of Gd2Zr2O7 by atmospheric plasma spraying (APS) is challenging due to the difference in vapor pressure between gadolinia and zirconia. Gadolinia is volatilized to a greater extent than zirconia and the coating composition unfavorably deviates from the initial stoichiometry. Aiming at stoichiometric coatings, APS experiments were performed with a TriplexPro™ plasma torch at different current levels. Particle diagnostics proved to be an effective tool for the detection of potential degrees of evaporation via particle temperature measurements at these varied current levels. Optimized spray parameters for Gd2Zr2O7 in terms of porosity and stoichiometry were used to produce double-layer TBCs with an underlying yttria-stabilized zirconia (7YSZ) layer. For comparison, double layers were also deposited with relatively high torch currents during Gd2Zr2O7 deposition, which led to a considerable amount of evaporation and relatively low porosities. These coatings were tested in thermal cycling rigs at 1400°C surface temperature. Double layers manufactured with optimized Gd2Zr2O7 spray parameters revealed very good thermal cycling performance in comparison to standard 7YSZ coatings, whereas the others showed early failures. Furthermore, different failure modes were observed; coatings with long lifetime failed due to TGO growth, while the coatings displaying early failures spalled through crack propagation in the upper part of the 7YSZ layer.