Advanced Thermal Barrier Coatings for Operation in High Hydrogen Content Fueled Gas Turbines

 

Performer: 
The Research Foundation of State University of New York
Website:  The Research Foundation of State University of New York
Award Number:  FE0004771
Project Duration:  10/01/2010 – 12/31/2014
Total Award Value:  $517,035.00
DOE Share:  $401,238.00
Performer Share:  $115,797.00
Technology Area:  Hydrogen Turbines
Key Technology:  Hydrogen Turbines
Location:  Stony Brook, New York
Cross-sectional scanning electron microscope image of the tri-layer TBC on NiCoCrAlY bond coated substrate.
Cross-sectional scanning electron microscope image of the tri-layer TBC on NiCoCrAlY bond coated substrate.

Project Description

Recent research data indicate that the current bill of coating materials is not directly compatible with the moisture-rich, ash-laden environment present with coal-derived high hydrogen content (HHC) fuels. Thus, Stony Brook University research focuses on a multi-layer, multifunctional strategy that includes discretely engineered coating layers to combat various technical issues through a concerted effort integrating material science, processing science, and performance studies, including recent developments in advanced, in situ thermal spray coating property measurement for full-field enhancement of coating and process reliability. This project will further the science-based understanding of thermal barrier coatings (TBCs) and elevate the roles that processing and novel materials can play in extending bond coat and top coat lifetimes, and provide a new framework for examining the processing-performance relationship in multilayer thermal barriers as a pathway for reliable integrated gasification combined cycle (IGCC) coating development, and provide new insight for the thermal spray industry.

In this project, TBCs will be developed through investigation into how processing affects the oxidation behavior of metallic bond coats in water vapor environments, and by developing ceramic top coat architectures using thermal spray processing of emerging zirconate materials that have shown promise as advanced thermal barriers. Novel, in situ particle and coating state sensors will be used to accelerate process development and understand processing-microstructure relationships and process reliability. A systematic evaluation of multilayer coatings on nickel superalloys will determine properties (including microstructure, compliance, residual stress, thermal conductivity, and sintering behavior) and degradation mechanisms due to high-temperature water vapor and ash exposure as well as erosion.

Project Benefits

This project will improve science-based understanding of thermal barrier coatings (TBCs) to create a pathway for reliable IGCC coating development. Turbine materials research seeks to improve coating materials that will allow for higher temperature operation and increased durability leading to increased turbine efficiency and reduced maintenance. Specifically, this project will develop TBCs through investigation into how processing affects the oxidation behavior of metallic bond coats in water vapor environments and by developing ceramic top coat architectures using thermal spray processing of emerging zirconate materials that have shown promise as advanced thermal barriers.

Contact Information

Federal Project Manager 
Briggs White: briggs.white@netl.doe.gov
Technology Manager 
Richard Dennis: richard.dennis@netl.doe.gov
Principal Investigator 
Sanjay Sampath: sanjay.sampath@stonybrook.edu
 

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