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Modelling of microstructural evolution in multi-layered overlay coatings.

M S A Karunaratne1, M A E Jepson1, N J Simms2

  • 11Department of Materials, Loughborough University, Loughborough, Leicestershire LE11 3TU UK.

Journal of Materials Science
|February 7, 2020
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Summary
This summary is machine-generated.

This study presents a model to predict microstructural changes in multi-layered coatings for industrial gas turbines, enhancing corrosion protection. The model accurately simulates coating evolution, aiding in the design of advanced protective layers.

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Area of Science:

  • Materials Science and Engineering
  • Surface Engineering
  • Computational Materials Science

Background:

  • Industrial gas turbines require robust materials for high-temperature corrosion protection.
  • Multi-layered coatings offer enhanced performance but their microstructural evolution is complex.
  • Understanding coating degradation is crucial for extending turbine lifespan.

Purpose of the Study:

  • To develop and validate a computational model simulating microstructural evolution in functionally graded, multi-layered coatings.
  • To predict phase and concentration profiles within coating systems under operational conditions.
  • To assess the model's utility for designing advanced coatings for industrial gas turbine aerofoils.

Main Methods:

  • Development of a simulation model integrating diffusion, equilibrium thermodynamics, and oxidation.
  • Application of the model to a multi-layered coating system (Al-rich outer, Cr-enriched middle, MCrAlY inner) on a superalloy substrate.
  • Comparison of model predictions with experimental data from the coated system.

Main Results:

  • The model successfully predicted concentration distributions within the multi-layered coating.
  • Key microstructural features observed experimentally were accurately reproduced by the simulation.
  • The model demonstrates a strong capability to forecast coating behavior.

Conclusions:

  • The developed model is a valuable tool for predicting the microstructural evolution of multi-layered coatings.
  • This predictive capability can guide the design and optimization of protective coatings for industrial gas turbines.
  • The findings support the use of such advanced coatings on gas turbine aerofoils for improved durability.