Krupajal Engineering College Bhubaneswar: Thermal Barrier Coating

KRUPAJAL ENGINEERING COLLEGE
BHUBANESWAR
SEMINAR REPORT ON
THERMAL BARRIER COATING
Submitted by:-
NITISH KUMAR
REGD.NO:-0701223318
ROLL.NO:-07ML079
ACKNOWLEDGEMENT
I express my sincere gratitude to Mr. S.S.PATI of Mechanical Engineering

Department for giving me an opportunity to accomplish seminar on Thermal
Barrier Coating .Without his active support and guidance, this seminar would not
have been successfully completed.
I also thank Prof. B.D. SAHOO Head of Department of Mechanical

Engineering for consistent support, guidance and help in this seminar. I am highly
indebted for his help.
NITISH KUMAR
Regd.No. -0701223318
Date - Roll No:-07ml079
Branch – Mechanical Engg.
CERTIFICATE
This is to certify that the seminar entitled “THERMAL BARRIER
COATING” presented by NITISH KUMAR bearing registration
No. 0701223318 of Department of Mechanical Engineering in Krupajal
Engineering College ,Bhubaneswar has been completed successfully.
This is the partial fulfillment of the requirements of Bachelor Degree
in Mechanicals Engineering under Biju Pattnaik University of
Technology, Rourkela, and Orissa.
I wish her success in all future endeavors.
Signature of H.O.D Signature of Guide

Prof. B.D Sahoo Lect. S.S. Pati
DECLARATION
I hereby declare that seminar entitled “THERMAL
BARRIER COATING” submitted to Department of
Mechanical Engineering of Krupajal Engineering College
under the affiliation of Biju patnaik University
of Technology ,Rourkela ,Orissa is towards partial
fulfillment of the requirement of the award of degree in
Bachelor of Engineering.
This seminar has not been submitted elsewhere and is an

authenticated work of mine.
NTISH KUMAR
Department of Mechanical Engineering
Krupajal engineering College
Regd no:070122331
Roll no:07ML079
ABSTRACT
Thermal barrier coatings are highly advanced material

systems usually applied to metallic surfaces, such as gas
turbine or aero-engine parts, operating at elevated
temperatures, as a form of Exhaust Heat Management.
These coatings serve to insulate components from large
and prolonged heat loads by utilizing thermally insulating
materials which can sustain an appreciable temperature
difference between the load bearing alloys and the coating
surface. In doing so, these coatings can allow for
higher operating temperatures while limiting the thermal
exposure of structural components, extending part life by
reducing oxidation and thermal fatigue. In conjunction
with active film cooling, TBCs permit working fluid
temperatures higher than the melting point of the metal
airfoil in some turbine applications.
CONTENTS
 Introduction
 Anatomy
 Uses
 Processing
 Conclusion
 References
INTRODUCTION
Thermal barrier coatings (TBCs) perform the
important function of insulating components, such
as gas turbine and aeroengine parts, operating at
elevated temperature. Typical examples are turbine
blades, combustor cans, ducting and nozzle guide
vanes. TBCs have made possible the increase in
operating temperature of gas turbines. In doing so,
these coatings can allow for higher operating
temperatures while limiting the thermal exposure of
structural components, extending part life by
reducing oxidation and thermal fatigue. In
conjunction with active film cooling, TBCs permit
working fluid temperatures higher than the melting
point of the metal airfoil in some turbine
applications.
ANATOMY
Thermal barrier coatings consist of four layers: the metal
substrate, metallic bond coat, thermally grown oxide, and
ceramic topcoat. The ceramic topcoat is typically
composed of yttria-stabilized zirconia (YSZ) which is
desirable for having very low conductivity while
remaining stable at nominal operating temperatures
typically seen in applications.
The oxide that is commonly used is Zirconia oxide (ZrO2)
and Yttrium oxide (Y2O3). The metallic bond coat is an
oxidation/hot corrosion resistant layer. The bond coat is
empherically represented as MCrAlY alloy where
M - Metals like Ni, Co or Fe.

Y - Reactive metals like Yttrium.
CrAl - base metal.
Coatings are well established as an important
underpinning technology for the manufacture of
aeroengine and industrial turbines. Higher turbine
combustion temperatures are desirable for increased
engine efficiency and environmental reasons (reduction in
pollutant emissions, particularly NOx), but place severe
demands on the physical and chemical properties of the
basic materials of fabrication.
In this context, MCrAlY coatings (where M = Co, Ni or

Co/Ni) are widely applied to first and second stage
turbine blades and nozzle guide vanes, where they may be
used as corrosion resistant overlays or as bond-coats for
use with thermal barrier coatings.
Layers of TBC in a Turbine Blade
Recent advancements in finding an alternative for YSZ

ceramic topcoat identified many novel ceramics (rare earth
zirconates) having superior performance at temperatures
above 1200 °C, however with inferior fracture toughness
compared to that of YSZ. This ceramic layer creates the
largest thermal gradient of the TBC and keeps the lower
layers at a lower temperature than the surface.
TBCs fail through various degradation modes that include
mechanical rumpling of bond coat during thermal cyclic
exposure, especially, coatings in aircraft engines;
accelerated oxidation, hot corrosion, molten deposit
degradation. There are issues with oxidation (areas of the
TBC getting stripped off) of the TBC also, which reduces
the life of the metal drastically, which leads to thermal
fatigue.
TBCs with dual functionality: protection and sensing

Knowing the temperature of the surface of the TBC
and at the interface between the bondcoat and the
thermally grown oxide under realistic conditions is
highly desirable. As the major life-controlling factors
for TBC systems are thermally activated, therefore
linked with temperature, this would provide useful
data for a better understanding of these phenomena
and to assess the remaining life time of the TBC. The
integration of an on-line temperature detection
system would enable the full potential of TBCs to be
realised due to improved precision in temperature
measurement and early warning of degradation. The
TBC is locally modified so it acts as a thermographic
phosphor. Phosphors are an innovative way of
remotely measuring temperatures and also other
physical properties at different depths in the coating
using photo stimulated phosphorescence.
USES OF TBC
Thermal barrier ceramic-coatings are becoming more common in
automotive applications. They are specifically designed to reduce
heat loss from engine exhaust system components including
exhaust manifolds, turbocharger casings, exhaust headers,
downpipes and tailpipes.
This process is also known as Exhaust Heat Management.
When used under-bonnet, these have the positive effect of

reducing engine bay temperatures, therefore lessening the
intake temperature.
Although most ceramic-coatings are applied to metallic
parts directly related to the engine exhaust system, some
new technology has been introduced that allows thermal
barrier coatings to applied via plasma spray onto
composite materials. This is now commonplace to find on
high-performance automobiles and in various race series
such as in Formula 1. As well as providing thermal
protection, these coatings are also used to prevent physical
degradation of the composite due to frictional processes.
This is possible because the ceramic material bonds with
the composite (instead of merely sticking on the surface
with paint), therefore forming a tough coating that doesn't
chip or flake easily.
Although thermal barrier coatings have been applied to
the inside of exhaust systems, this has encountered
problems due to the inability to prepare the internal
surface prior to coating.
INDUSTRIAL USES
In industrial applications, where space is at a premium,
thermal barrier coatings are commonly used to protect
from heat loss (or gain).
PROCESSING
In industry, thermal barrier coatings are produced in a
number of ways:
 Electron Beam Physical Vapor Deposition: EBPVD
 Air Plasma Spray: APS
 Electrostatic Spray Assisted Vapour Deposition:
ESAVD
 Direct Vapor Deposition
Additionally, the development of advanced coatings and

processing methods is a field of active research. One such
example is the Solution precursor plasma spray process
which has been used to create TBCs with some of the
lowest reported thermal conductivities while not
sacrificing thermal cyclic durability.
ELECTRON BEAM PHYSICAL VAPOUR
COATING DEPOSITION
 Electron Beam Physical Vapor Deposition or

EBPVD is a form of physical vapor deposition in
which a target anode is bombarded with an
electron beam given off by a charged tungsten
filament under high vacuum. The electron beam
causes atoms from the target to transform into
the gaseous phase. These atoms then precipitate
into solid form, coating everything in the
vacuum chamber (within line of sight) with a
thin layer of the anode material.
AIR PLASMA SPRAY

 In plasma spraying process, the material to
be deposited (feedstock) — typically as a
powder, sometimes as a liquid, suspension
or wire — is introduced into the plasma jet,
emanating from a plasma torch. In the jet,
where the temperature is on the order of
10,000 K, the material is melted and
propelled towards a substrate. There, the
molten droplets flatten, rapidly solidify and
form a deposit
ELECTRONIC SPRAY ASSISTED

VAPOUR DEPOSTION
 Electrostatic spray assisted vapour
deposition (ESAVD) is a technique
(developed by a company called IMPT) to
deposit both thin and thick layers of a
coating onto various substrates. In simple
terms chemical precursors are sprayed
across an electrostatic field towards a
heated substrate, the chemicals undergo a
controlled chemical reaction and are
deposited on the substrate as the required
coating.
DIRECT VAPOUR DEPOSTION

 Producing a film of metal on a heated
surface, often in a vacuum, either by
decomposition of the vapour of a
compound at the work surface or by direct
reaction between the work surface and the
vapour. Also known as vacuum plating.
CONCLUSION
TBC is a very useful technique and has a
wide application in industries as well as
in automobile manufacturing.
REFERENCES
 www.wikipedia.org
 www.jap.aip.org

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KRUPAJAL ENGINEERING COLLEGE

THERMAL BARRIER COATING

I express my sincere gratitude to Mr. S.S.PATI of Mechanical Engineering

I also thank Prof. B.D. SAHOO Head of Department of Mechanical

Date - Roll No:-07ml079

Branch – Mechanical Engg.

Signature of H.O.D Signature of Guide

This seminar has not been submitted elsewhere and is an

Thermal barrier coatings are highly advanced material

M - Metals like Ni, Co or Fe.

In this context, MCrAlY coatings (where M = Co, Ni or

Recent advancements in finding an alternative for YSZ

TBCs with dual functionality: protection and sensing

This process is also known as Exhaust Heat Management.

When used under-bonnet, these have the positive effect of

Additionally, the development of advanced coatings and

 Electron Beam Physical Vapor Deposition or

AIR PLASMA SPRAY

ELECTRONIC SPRAY ASSISTED

DIRECT VAPOUR DEPOSTION

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