thermodynamic and kinetic modeling to predict the lifetime
TRANSCRIPT
Thermodynamic and Kinetic Modeling to Predict the Lifetime of Thermal Barrier Coating
on Superalloys
High Temperature Thermochemistry Laboratory&
Korea Institute of Materials ScienceDate: 13th April 2021
Yeon Woo Yoo
High Temperature Thermochemistry Laboratory
2Contents
I. Introduction about Thermal Barrier Coatings
II. Kinetic Modeling
III. Thermodynamic Modeling
3
I. Introduction about Thermal Barrier Coatings
High Temperature Thermochemistry Laboratory
4Introduction
- Thermal Barrier Coatings
β’ Top coating- Yttria stabilized zirconia (8YSZ), GZO(Gd2Zr2O7), LZO(La2Zr2O7)
- Thermal insulation from high temperature environment
- Low thermal conductivity and porous microstructure
β’ Bond coating- MCrAlX M= Ni and/or Co , X = Y, Ta, Hf, and/or Si, other minor
elements
- Intermediate thermal expansion coefficient between top coating and
bottom Ni based superalloys
- Directly related to the thermal lifetime of thermal barrier coatings
β’ Ni based superalloys- Maintain excellent mechanical strength at high temperature
(Ξ³ and Ξ³` phase)
High Temperature Thermochemistry Laboratory
5Introduction
- Failure of Thermal Barrier Coatings
Thermal strain caused by CTE mismatch
ππ = β πΌπΌππππππππ β πΌπΌπ π π π π π ππ β ππ0 = βΞπΌπΌΞππ
Repeating heating and cooling in TBCs as the gas turbine operation
Thermal stress caused by CTE mismatch between bond coating and top coatingFailure
High Temperature Thermochemistry Laboratory
6Introduction
- Thermodynamics and Kinetics in Thermal Barrier Coatings
Con
cent
ratio
nTop coat Bond coat SuperalloyTGO
O
O
Al
Al
Ni, Cr, Co
Al
Al
Al
Al
O Cr, Co
Al
Al
Other Elements
NiNi
Al
Al
AlCo, Cr
Co, Cr
Distance
Outer Beta Depletion Zone
Inner Beta Depletion Zone
SecondaryReaction Zone
7
II. Kinetic Modeling
High Temperature Thermochemistry Laboratory
8Diffusion Equation
π½π½ππ = βπ·π·πππππΆπΆππππππ
- Fickβs first law
- Fickβs second law
πππΆπΆππππππ
= π·π·ππππ2πΆπΆππππππ2
πΆπΆπ»π» πΆπΆπΏπΏ
πΆπΆπ»π»
πΆπΆπΏπΏ
πΆπΆ
For multi-components,
πππΆπΆππππππ
= π·π·ππ,ππππ2πΆπΆππππππ2
+πππ·π·ππ,πππππΆπΆππ
πππΆπΆππππππ
+πππ·π·ππ,πππππΆπΆππ
πππΆπΆππππππ
+πππ·π·ππ,πππππΆπΆππ
πππΆπΆππππππ
πππΆπΆππππππ
+ π·π·ππ,ππππ2πΆπΆππππππ2
+πππ·π·ππ,πππππΆπΆππ
πππΆπΆππππππ
+πππ·π·ππ,πππππΆπΆππ
πππΆπΆππππππ
+πππ·π·ππ,πππππΆπΆππ
πππΆπΆππππππ
πππΆπΆππππππ
+π·π·ππ,ππππ2πΆπΆππππππ2
+πππ·π·ππ,πππππΆπΆππ
πππΆπΆππππππ
+πππ·π·ππ,πππππΆπΆππ
πππΆπΆππππππ
+πππ·π·ππ,πππππΆπΆππ
πππΆπΆππππππ
πππΆπΆππππππ
High Temperature Thermochemistry Laboratory
9Finite Difference Method
- Finite Difference Method
βππ
πΉπΉππ πΉπΉππ+1πΉπΉ0 πΉπΉ1
πππΉπΉππππ
=πΉπΉππ+1 β πΉπΉππβ1
2βππ
πΉπΉππβ1
πππΉπΉππππ
=πΉπΉππ+1 β πΉπΉππ
βππ
πππΉπΉππππ
=πΉπΉππ β πΉπΉππβ1
βππ
: Forwardππ2πΉπΉππππ2
=πΉπΉππ+2 β 2πΉπΉππ+1 + πΉπΉππ
(βππ)2
ππ2πΉπΉππππ2
=πΉπΉππ β 2πΉπΉππβ1 + πΉπΉππβ2
(βππ)2
ππ2πΉπΉππππ2
=πΉπΉππ+1 β 2πΉπΉππ + πΉπΉππβ1
(βππ)2
: Backward
: Central
10
III. Thermodynamic Modeling
High Temperature Thermochemistry Laboratory
11Gibbβs Free Energy & Phase Diagram
G = H β TS
- Gibbβs free energy
- Gibbβs free energy and phase diagram
- At temperature T, the phase which has lowest G is the most stable
Porter, D.A., and Easterling, K.E., Phase Transformation in Metals and Alloys, 2nd Ed. CHAMAN & HALL (1992)
High Temperature Thermochemistry Laboratory
12Gibbβs Free Energy of Solution
- Gibbβs free energy of solution
πΊπΊπ π πππ π ππ = πππ΄π΄πΊπΊπ΄π΄ + πππ΅π΅πΊπΊπ΅π΅ + π π ππ πππ΄π΄ lnπππ΄π΄ + πππ΅π΅ lnπππ΅π΅
πΊπΊπ π πππ π ππ = πππ΄π΄πΊπΊπ΄π΄ + πππ΅π΅πΊπΊπ΅π΅ + Ξ©πππ΄π΄πππ΅π΅ + π π ππ πππ΄π΄ lnπππ΄π΄ + πππ΅π΅ lnπππ΅π΅
πΊπΊπ π πππ π ππ = πππ΄π΄πΊπΊπ΄π΄ + πππ΅π΅πΊπΊπ΅π΅ + οΏ½ππ,ππβ₯1
πππ΄π΄π΅π΅ππππ πππ΄π΄πππππ΅π΅
ππ + π π ππ πππ΄π΄ lnπππ΄π΄ + πππ΅π΅ lnπππ΅π΅
: Ideal solution
: Regular solution
: General solution
βπ»π»ππππππ = 0
βπ»π»ππππππ = Ξ©πππ΄π΄πππ΅π΅
βππππππππ = π π (πππ΄π΄ lnπππ΄π΄ + πππ΅π΅ lnπππ΅π΅)
βππππππππ = π π (πππ΄π΄ lnπππ΄π΄ + πππ΅π΅ lnπππ΅π΅)
High Temperature Thermochemistry Laboratory
13Solution Mixing Model
- Random Mixing Model
πΊπΊπ π πππ π ππ = πππ΄π΄πΊπΊπ΄π΄ + πππ΅π΅πΊπΊπ΅π΅ + π π ππ πππ΄π΄ lnπππ΄π΄ + πππ΅π΅ lnπππ΅π΅ + πποΏ½πππ΄π΄π΅π΅ππππ πππ΄π΄πππππ΅π΅
ππ
πΊπΊπ π πππ π ππ = πππ΄π΄πΊπΊπ΄π΄ + πππ΅π΅πΊπΊπ΅π΅ β ππβππππππππππ + πππ΄π΄π΅π΅(βπππ΄π΄π΅π΅/2)
βππππππππππ = βπ π πππ΄π΄ lnπππ΄π΄ + πππ΅π΅ lnπππ΅π΅ β π π πππ΄π΄π΄π΄ ln(πππ΄π΄π΄π΄πππ΄π΄2
) + πππ΅π΅π΅π΅ ln(πππ΅π΅π΅π΅πππ΅π΅2
) + πππ΄π΄π΅π΅ ln(πππ΄π΄π΅π΅2πππ΄π΄πππ΅π΅
)
ππππ =ππππππππ
ππππππππ + πππππππποΏ½πππ΄π΄π΅π΅2 πππ΄π΄π΄π΄πππ΅π΅π΅π΅ = 4 exp(β βΞπππ΄π΄π΅π΅ π π ππ)
βπππ΄π΄π΅π΅ = ππ ππ,ππ = πππ΄π΄π΅π΅Β° β πππ΄π΄π΅π΅Β° ππ + οΏ½(ππ+ππβ₯1)
(πππ΄π΄π΅π΅ππππ β πππ΄π΄π΅π΅
ππππ ππ)πππ΄π΄πππππ΅π΅ππ
- Modified Quasichemical Model(MQM)
- Random mixing model : βπππ π πππ π ππ = Ξπππππππππππ π
- Quasichemical model : βπππ π πππ π ππ β Ξπππππππππππ π , varied with A-B interaction energy
High Temperature Thermochemistry Laboratory
14Thermodynamic Modeling
Thermodynamic modeling is optimization of parameters related to all solutions
I.H. Jung, et al, CALPHAD, 2007, vol. 31 (2), pp. 192-200
High Temperature Thermochemistry Laboratory
15Application of Thermodynamic Calculation
FCC#1
FCC#1
BCC#1
BCC2#1
L12#1
HCP#1
Liquid
Co + Ni + Cr + Al + Y
Temperature [ oC ]
Wei
ght p
erce
nt [
% ]
600 700 800 900 1000 1100 1200 1300 1400 15000
10
20
30
40
50
60
70
80
90
100
1500
Hf2Ni7
Liquid
FCC#1
FCC#1
BCC#1
SIGMA
BCC2#1
BCC2#1L12#1
L12#1
Ni + Co + Cr + Al + Y + Hf + Si
Temperature [ oC ]
Wei
ght p
erce
nt [
% ]
600 700 800 900 1000 1100 1200 1300 14000
10
20
30
40
50
60
70
80
90
100
FCC#1
FCC#1
BCC#1
SIGMA
BCC2#1
BCC2#1L12#1
Liquid
Ni + Co + Cr + Al + Y
Temperature [ oC ]
Wei
ght p
erce
nt [
% ]
600 700 800 900 1000 1100 1200 1300 1400 15000
10
20
30
40
50
60
70
80
90
100
FCC#1
BCC#1
BCC2#1
L12#1
IN792 - NiCoCrAlY1000 oC
Wei
ght p
erce
nt [
% ]
IN792 NiCoCrAlY0
10
20
30
40
50
60
70
80
90
100
β’ Phase fractions of MCrAlY bond coats as function of a temperature
FCC#1
BCC2#1
IN792 - CoNiCrAlY1000 oC
Wei
ght p
erce
nt [
% ]
IN792 CoNiCrAlY0
10
20
30
40
50
60
70
80
90
100
β’ Secondary reaction expectation in interface between MCrAlY bond coats and Ni superalloys
Substrate SRZ Bondcoat
Ni, Ta, Re, etc.
Al, Cr, Co, Y
High Temperature Thermochemistry Laboratory
16Summary
1. Lifetime prediction of thermal barrier coatings were required due to the difficulty of real parts experiment and long time experiment.
2. Thermodynamics and kinetics should be considered to predict lifetime of thermal barrier coatings.
3. Kinetic modeling of multicomponent diffusion could be solved by finite difference method.
4. Thermodynamic modeling can be used to predict stable phase at high temperature and reaction between bond coat and superalloys.
Thank you for
your attention!