CCS and Power Systems

Advanced Energy Systems - Hydrogen Turbines

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

Performer: The Research Foundation of State University of New York

Project No: FE0004771


  • Completed the process map for plasma spraying of gadolinium ium zirconate (Gd2Zr2O7 [GZO]) with controlled mechanical properties (achieving process-enabled elastic moduli ranging from 13 to 34 gigapascals) thus facilitating the design of a compliant TBC.
  • Optimized HVOF spray parameters for nickel-cobalt-chromium-aluminum-yttrium (NiCoCrAlY) and nickel-cobalt-chromium-aluminum-yttrium-hafnium-silicon (NiCoCrAlYHfSi) bond coats to minimize porosity and achieve a compressive residual stress state.
  • Determined the Larson-Miller parameter for plasma-sprayed GZO as a function of spray condition in order to understand sintering kinetics and demonstrate that the material sinters more slowly than YSZ.
  • Produced a multilayer TBC-YSZ/compliant GZO/dense GZO for initial industrial rig testing and ash exposure.
  • Characterized the erosion resistance of GZO and compared it to that of state-of-the-art YSZ.
  • Investigated the role of HVOF bond coat roughness on TBC life and developed processing strategies to address the same.
  • Determined the fracture toughness of both TBC materials YSZ and GZO and also studied the thermal aging effects on the toughness of both.
  • Identified durability strategy for bi layered YSZ coatings based on the parameters of fracture toughness and elastic modulus.

Project Details