Ivo Šulák

Effect of Thermal Barrier Coating on Low Cycle Fatigue Behavior of Cast Inconel 713LC at 900 °C

The effect of thermal barrier coating (TBC) on low cycle fatigue behavior of cast superalloy Inconel 713 LC has been studied at 900 °C. The TBC consisting of a CoNiCrAlY bond coat and a zirconia (ZrO2) top coat stabilized by 8% yttria (Y2O3) was deposited on the gauge section of cylindrical specimens using the atmospheric plasma spray technique. Cylindrical specimens of Inconel 713LC in as-received condition and with surface treatment were cyclically strained under strain control with constant total strain amplitude in symmetrical cycle at 900 °C in air. Hardening/softening curves, cyclic stress-strain curve and fatigue life data of coated and uncoated material were obtained. The stress response of the TBC coated specimens is lower in comparison with the uncoated specimens. Detrimental effect of surface treatment on the Basquin curve is documented. Specimen sectioning and fracture surface observations revealed fatigue damage mechanisms and help to discuss differences in fatigue behavior of the coated and uncoated superalloy.

High Temperature Low Cycle Fatigue Characteristics of Grit Blasted Polycrystalline Ni-Base Superalloy

The present work is focused on the study of low cycle fatigue behavior of grit blasted nickel-base superalloy Inconel 713LC (IN 713LC). Grit blasting parameters are obtained. Button end specimens of IN 713LC in as-received condition and with grit blasted surface were fatigued under strain control with constant total strain amplitude in symmetrical cycle at 900 °C in air. Hardening/softening curves, cyclic stress-strain curve and fatigue life data of both materials were obtained. Both materials exhibit the same stress-strain response. It has not been observed any improvement or reduction of low cycle fatigue life in representation of total strain amplitude versus number of cycles to failure of grit blasted material in comparison with as-received material. Surface relief and fracture surface were observed in SEM. The little effect of surface treatment on fatigue characteristics is discussed.

Degradation of YSZ/EUCOR TBC Coating System during High Temperature Low Cycle Fatigue Tests

Thermal barrier coatings are widely used to protect the substrate from high temperature and extremely aggressive environments in gas engines. In the present article, authors have been studied degradation of complex thermal barrier coating system deposited on polycrystalline nickel superalloy IN 713LC. The substrate material was grit blasted with alumina (Al2O3) particles prior to air plasma deposition of CoNiCrAlY bond coat. Top coat consists of conventional zirconia (ZrO2) stabilized by yttria (Y2O3) -YSZ ceramic in combination with a eutectic nanocrystalline ceramic Eucor made of zirconia (ZrO2), alumina (Al2O3) and silicia (SiO2) –in the ratio of 50/50 in wt. %. The top coat was deposited using water stabilized plasma. Test specimens with the TBC coating system were fatigued under strain control condition in fully reversed symmetrical push-pull cycles at 900°C in air. The microstructure of TBC was characterized with scanning electron microscopy and energy dispersion X-ray analysis. The coating hardness and thickness were measured. Fracture surface and polished sections parallel to the specimen axis were examined to study damage mechanisms in coatings under cyclic loading at high temperature. TBC delamination was observed at the top coat/bond coat interface after cyclic loading at high temperature. Fatigue crack initiation sites are documented. Majority of fatigue cracks start from the surface and top coat/bond coat interface.

Comparative Study of Microstructure and High Temperature Low Cycle Fatigue Behaviour of Nickel Base Superalloys Inconel 713LC and MAR-M247

The present work is focused on the study of microstructure and low cycle fatigue behavior of the first generation nickel-base superalloy IN 713LC (low carbon) and its promising second generation successor MAR-M247 HIP (hot isostatic pressing) at 900 °C. Microstructure of both alloys was studied by means of scanning electron microscopy (SEM). The microstructure of both materials is characterized by dendritic grains, carbides and casting defects. Size and morphology of precipitates and casting defects were evaluated. Fractographic observations have been made with the aim to reveal the fatigue crack initiation place and relation to the casting defects and material microstructure. Low cycle fatigue tests were conducted on cylindrical specimens in symmetrical push-pull cycle under strain control with constant total strain amplitude and strain rate at 900 °C in air. Hardening/softening curves, cyclic stress-strain curve and fatigue life data of both materials were obtained. Cyclic stress-strain curve of MAR M247 is shifted approximately to 120 MPa higher stress amplitudes in comparison with IN 713LC. Significantly higher fatigue life of MAR-M247 has been observed in Basquin representation. On the other hand IN 713LC shows prolonged lifetime compared with MAR-M247 in the Coffin-Manson representation. Results obtained from high temperature low cycle fatigue tests are discussed.

High-Temperature Low Cycle Fatigue Resistance of Inconel 713LC Coated with Novel Thermal Barrier Coating

Inconel 713LC was developed in the 1950s and is still widely used in power generation especially because of favourable price in conjunction with satisfying properties. However, the need for higher efficiency of high-temperature facilities leads to increase operating temperature that causes severe degradation of the material. In order to enhance the life-time of material, the protective coatings are applied. For the purpose of this study, nineteen cylindrical specimens were cut from rods manufactured using investment castings technique and subsequently, 10 specimens were coated with novel complex thermal barrier coating (TBC) system. The TBC system comprises a metallic CoNiCrAlY bond coat (BC) and a complex ceramic top coat (TC). The TC is a mixture of conventional YSZ ceramic and a eutectic nanocrystalline ceramic Eucor in the ratio of 50/50 in wt%. Eucor is made of zirconia (ZrO2), alumina (Al2O3) and silica (SiO2). Low cycle fatigue tests were performed in symmetrical push-pull cycle under strain control at 900 °C. Cyclic hardening/softening curves, cyclic stress-strain curves and fatigue life curves of coated and uncoated material were obtained. Fracture surfaces and polished sections parallel to the loading axis of specimens in as-coated conditions and after cyclic loading were observed by means of scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) to study degradation mechanisms during high-temperature low cycle fatigue. TBC delamination was observed at the TC/BC interface and rafting of precipitates occurred after high-temperature exposure. The microstructural investigations help discuss the differences in the stress-strain response and fatigue life of coated and uncoated superalloy.

Fatigue Crack Initiation in Nickel-Based Superalloy MAR-M247 at High Temperature

The present work is focused on the study of crack initiation during low cycle fatigue (LCF) loading of the second generation nickel-based superalloy MAR-M247 treated with hot isostatic pressing. LCF tests were conducted on cylindrical specimens in symmetrical push-pull cycle under strain control with constant total strain amplitude and strain rate at 800 °C in air atmosphere. Selected specimens were electrolytically polished to facilitate surface relief observations. Crack initiation sites were studied by means of scanning electron microscopy (SEM) in dual beam microscope TESCAN LYRA 3 XMU FESEM equipped with focus ion beam (FIB). The microstructure of the material is characterised by coarse dendritic grains with numerous carbides and small casting defects. The average grain size was 2.1 ± 0.3 mm. Fractographic analysis revealed the fatigue crack initiation sites and their relation to the casting defects and material microstructure. Casting defects, carbide inclusions and interdendritic areas were found to be important crack nucleation sites. Specimens’ surface observations revealed the formation of pronounced surface relief with short worm-like markings. Fatigue crack initiation in these places is documented and discussed.

Durability of Amorphous and Crystalline BMAS Thermal Barrier Coatings Produced by Plasma Spraying

Barium-Magnesium-Aluminium-Silicate (BMAS) powder was produced from a mixture of initial compounds BaO–MgO–Al2O3–SiO2 by means of solid state synthesis at the temperature of 1200 °C for 3 hours in a laboratory furnace. Synthetized powder was crushed into the fraction of 15-45 μm in a planetary ball mill. Thermal barrier coating system consisting of CoNiCrAlY (bond coat) and BMAS (top coat) was sprayed by atmospheric plasma spray technique onto the polycrystalline nickel-based superalloy substrate. During plasma spraying process, the BMAS underwent phase transformation and the amorphous phase within the top coat was produced. Therefore, after the spraying, several samples were crystallized via annealing in a furnace (4 hours at 1200 °C or 24 hours at 1000 °C) or by subjecting them to several passes of plasma jet. Both samples with an amorphous phase and fully-crystallized samples were subjected to the fire in a burner-rig test (propane-oxygen flame, single 3 + 3 minute cycle), where the top coat reached the temperature of 1150 °C. Top coat failure occurred during the cooling period due to the transformation of the amorphous phase into the crystalline one and/or due to the difference in thermal conductivity and expansion between the top coat and the bond coat.