Erosion behavior of Al2O3 + Sm2SrAl2O7 composite thermal barrier coatings

Abstract

Thermal barrier coatings (TBC) are applied in gas turbines to protect the components from critical operating conditions at high temperatures. Foreign object damage is a major failure cause of turbine components due to erosion of the topcoat ceramic layer of the TBC system. In the present study, Samarium Strontium Aluminate (Sm<inf>2</inf>SrAl<inf>2</inf>O<inf>7</inf>) powders have been synthesized in the laboratory through molten salt synthesis, and thermal barrier coatings were developed using Atmospheric Plasma Spray (APS) technique on an Inconel substrate with NiCrAlY as a bond coat. The erosion behavior of the composite TBC system at temperatures of 200 °C and 800 °C at 30° and 90° impingement angles was analyzed using alumina erodent with a grit size of 50 µm. The erosion weight loss was measured in regular intervals and plotted against erodent mass. The samples exhibited a higher volumetric erosion at 90° and 800 °C. The morphological analysis of developed 70% Al<inf>2</inf>O<inf>3</inf> + 30% Sm<inf>2</inf>SrAl<inf>2</inf>O<inf>7</inf> composite coatings and eroded areas were performed using XRD, SEM, and surface profilometer. Erosion scars and surrounding deformed areas have been identified in the samples. The microstructure of the eroded areas in the samples showed micro-cutting and plowing as the major material removal mechanisms. Detailed phase analysis of the eroded locations in samples has been reported. © 2022