Synthesis and Application of Nano structured Bi layer YSZ LZ Thermal Barrier Coating

  • Radhakanta Satpathy DRDO-Defence Metallurgical Research Laboratory, Hyderabad - 500 058
  • B. R. Mishra Indian Rare Earths Limited, Chatrapur - 761 045
  • B. Mallick Hindustan Aeronautics Limited, Koraput-763 004
  • B. K. Mishra Indian Institute of Technology, Goa - 403 401
Keywords: Nano materials, Aeroengine application, IR Nano particles interaction, Lanthanum Zirconate (LZ)-YSZ bilayer TBC, Monazite beach sand, Zircon, Ilmenite

Abstract

Present work is on synthesis of high purity Nano-structured TBC materials, Lanthanum Zirconate and YSZ. They were prepared via wet chemical routes, starting from the indigenous source minerals such as zircon and monazite available in the beach sand. This is first time that the results of TBC materials synthesis from these base minerals, their purification and a high end application being presented comprehensively. Their characterisation and thermal barrier application on aeroengine components have been presented. The total oxide impurities being critical to the life of the coating, could be controlled within 0.03 per cent by weight. On comparison with other powders it was found that the indigenously synthesised YSZ powder had practically 100 per cent tetragonal prime phase and no monoclinic phase; whereas others had significant amounts of monoclinic phases present in them. Both YSZ and LZ powders were sinter agglomerated at 850 °C to preclude the possibility of any contamination and sieved. APS process was used to realise nano-structured bi-layer coating on the exhaust nozzle parts of an aeroengine. The components were subjected to rapid thermal transients during long accelerated endurance testing, equivalent to 1000 h of engine operations. The coatings also withstood the gas erosion of supersonic combustion products, vibratory loads of 4 g and more than 30000 nozzle actuations similar to aircraft maneuver. The paper also presents a brief review of implications of a nano-structured thermal barrier coating and certain nuances of chemical synthesis which forms the backbone of the strategies for durable coatings.

Author Biographies

Radhakanta Satpathy, DRDO-Defence Metallurgical Research Laboratory, Hyderabad - 500 058

Mr R.K. Satpathy, received his BE (Metallurgy) from REC, Rourkela and MTech (Aircraft Production Engg.) from IIT, Madras. Presently working as Scientist ‘G’, at DRDO-Defence Metallurgical Research Laboratory, Hyderabad. He has research experience in all facets of gas turbines starting from manufacturing to operations. As a chairman of the Joint Service Specifications (JSS) on coatings, he standardised 15 JSS. He also authored one coating compendium pertaining to aeroengines.

Contribution in the current study, he is main researcher and primary author.

B. R. Mishra, Indian Rare Earths Limited, Chatrapur - 761 045

Dr B.R. Mishra, received his PhD (Chemistry) from Berhampur University, Odisha. Currently working as DGM (R&D) in Indian Rare Earths Limited, Chatrapur. He has industrial experience in the field of process, quality control. He has specialised in solvent extraction process to beach sand heavy minerals like Ilmenite, Zircon and rare earths bearing monazite and Xenotime. Has five patents to his credit.

Contribution in the current study, he did raw materials and TBC material synthesis. 

B. Mallick, Hindustan Aeronautics Limited, Koraput-763 004

Mr B. Mallick, Chief Manager –Indigenisation, Hindustan Aeronautics Limited, Koraput. He has received his ME in Mechanical Engineering from REC Rourkela in 1995. Earlier he worked as structural design engineer in aviation gas turbine and thermo gas dynamics and performance engineer. He has contributed immensely to indigenisation of compressor and turbine blades of helicopter and transport aircraft engines. 

Contribution in the current study, he did APS Coating studies and coating qualifications support. 

B. K. Mishra, Indian Institute of Technology, Goa - 403 401

Prof. B.K. Mishra, is graduated in Metallurgy from NIT Rourkela, and received PhD from University of Utah, USA. Presently working as Director Indian Institute of Technology, Goa. . Has published over 240 research papers in minerals, materials, and environmental engineering area. He is the recipient of the National Geoscience Award and is a fellow of the INAE. For his contribution to industrial R&D he received the most coveted VASVIK Award and CSIR Technology Award (team award).

Contribution in the current study, he did research guidance and support.

Published
2019-03-06
How to Cite
Satpathy, R., Mishra, B., Mallick, B., & Mishra, B. (2019). Synthesis and Application of Nano structured Bi layer YSZ LZ Thermal Barrier Coating. Defence Science Journal, 69(2), 185-194. https://doi.org/10.14429/dsj.69.13212