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Mechanical Integrity of Thermal Barrier Coatings: Coating Development and Micromechanics

Torben, Fiedler and Rösler, Joachim and Bäker, Martin and Hötte, Felix and von Sethe, Christoph and Daub, Dennis and Haupt, Matthias and Haidn, Oskar and Esser, Burkard and Gülhan, Ali (2021) Mechanical Integrity of Thermal Barrier Coatings: Coating Development and Micromechanics. In: Future Space-Transport-System Components under High Thermal and Mechanical Loads Notes on Numerical Fluid Mechanics and Multidisciplinary Design, 146. Springer. pp. 295-307. doi: 10.1007/978-3-030-53847-7_19. ISBN 978-3-030-53846-0.

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Official URL: https://link.springer.com/chapter/10.1007/978-3-030-53847-7_19


To protect the copper liners of liquid-fuel rocket combustion chambers, a thermal barrier coating can be applied. Previously, a new metallic coating system was developed, consisting of a NiCuCrAl bond-coat and a Rene 80 top-coat, applied with high velocity oxyfuel spray (HVOF). The coatings are tested in laser cycling experiments to develop a detailed failure model, and critical loads for coating failure were defined. In this work, a coating system is designed for a generic engine to demonstrate the benefits of TBCs in rocket engines, and the mechanical loads and possible coating failure are analysed. Finally, the coatings are tested in a hypersonic wind tunnel with surface temperatures of 1350 K and above, where no coating failure was observed. Furthermore, cyclic experiments with a subscale combustion chamber were carried out. With a diffusion heat treatment, no large-scale coating delamination was observed, but the coating cracked vertically due to large cooling-induced stresses. These cracks are inevitable in rocket engines due to the very large thermal-strain differences between hot coating and cooled substrate. It is supposed that the cracks can be tolerated in rocket-engine application.

Item URL in elib:https://elib.dlr.de/136981/
Document Type:Contribution to a Collection
Title:Mechanical Integrity of Thermal Barrier Coatings: Coating Development and Micromechanics
AuthorsInstitution or Email of AuthorsAuthor's ORCID iD
Torben, FiedlerTU BraunschweigUNSPECIFIED
Rösler, JoachimTU BraunschweigUNSPECIFIED
Bäker, MartinTU BraunschweigUNSPECIFIED
Hötte, FelixIFL TU BraunschweigUNSPECIFIED
von Sethe, ChristophTU MünchenUNSPECIFIED
Daub, DennisDennis.Daub (at) dlr.deUNSPECIFIED
Haupt, MatthiasIFL, TU BraunschweigUNSPECIFIED
Haidn, OskarOskar.Haidn (at) dlr.deUNSPECIFIED
Esser, BurkardBurkard.Esser (at) dlr.deUNSPECIFIED
Gülhan, AliAli.Guelhan (at) dlr.deUNSPECIFIED
Journal or Publication Title:Future Space-Transport-System Components under High Thermal and Mechanical Loads
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In ISI Web of Science:No
DOI :10.1007/978-3-030-53847-7_19
Page Range:pp. 295-307
EditorsEmailEditor's ORCID iD
Adams, Nikolaus A.TU-MünchenUNSPECIFIED
Schröder, WolfgangAIA, RWTH AachenUNSPECIFIED
Radespiel, RolfTU-BraunschweigUNSPECIFIED
Haidn, OskarOskar.Haidn@dlr.deUNSPECIFIED
Sattelmayer, ThomasTU München, Lehrst. f. ThermoedynamikUNSPECIFIED
Stemmer, ChristianTU MünchenUNSPECIFIED
Weigand, BernhardITLR, Universität StuttgartUNSPECIFIED
Series Name:Notes on Numerical Fluid Mechanics and Multidisciplinary Design
Keywords:Thermal Barrier Coating, TBC, Rocket Combustion Chamber, Wind Tunnel Testing
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Space
HGF - Program Themes:Space Transportation
DLR - Research area:Raumfahrt
DLR - Program:R RP - Space Transportation
DLR - Research theme (Project):R - Wiederverwendbare Raumfahrtsysteme (old)
Location: Köln-Porz
Institutes and Institutions:Institute for Aerodynamics and Flow Technology > Supersonoc and Hypersonic Technology
Deposited By: Daub, Dennis
Deposited On:26 Nov 2020 12:05
Last Modified:15 Mar 2022 15:49

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