Performance Analysis and Optimization of Multilayer Thermal Barrier Coatings for Enhanced Gas Turbine Blade Durability
| International Journal of Mechanical Engineering |
| © 2025 by SSRG - IJME Journal |
| Volume 12 Issue 7 |
| Year of Publication : 2025 |
| Authors : MD Shahbaz Ahmed, Rajiv Kumar Upadhyay |
10.14445/23488360/IJME-V12I7P107
How to Cite?
MD Shahbaz Ahmed, Rajiv Kumar Upadhyay, "Performance Analysis and Optimization of Multilayer Thermal Barrier Coatings for Enhanced Gas Turbine Blade Durability," SSRG International Journal of Mechanical Engineering, vol. 12, no. 7, pp. 48-54, 2025. Crossref, https://doi.org/10.14445/23488360/IJME-V12I7P107
Abstract:
Thermal Barrier Coatings (TBCs) are widely employed to protect turbine components from extreme thermal environments, with Atmospheric Plasma Spray (APS) and Electron Beam Physical Vapor Deposition (EB-PVD) being the two most commonly used deposition methods. Despite their widespread use, a comprehensive, quantitative comparison under realistic service conditions remains critical for guiding material selection in aerospace and power generation applications. This study investigates the thermal, mechanical, and microstructural performance of APS and EB-PVD coatings applied to IN738LC superalloy substrates subjected to up to 1000 thermal cycles at 1100 °C. APS coatings demonstrated superior thermal insulation with a high temperature gradient (>220 °C across 1 mm) and lower thermal conductivity (1.35 ± 0.08 W/m·K), while EB-PVD coatings showed better structural integrity due to their strain-compliant columnar microstructure and higher conductivity (2.45 ± 0.10 W/m·K). APS systems failed earlier (580–640 cycles) with spallation linked to rough TGO growth (4.5–5.2 μm) and high interfacial stress (~145 MPa), whereas EB-PVD coatings remained stable beyond 1000 cycles with smoother TGO layers (2.2–2.8 μm) and lower interfacial stress (~85 MPa). Finite element simulations and acoustic emission analysis confirmed earlier crack initiation in APS and delayed damage in EB-PVD. These findings highlight the trade-offs between thermal insulation and mechanical durability: APS is better suited for stationary components where insulation dominates, while EB-PVD is preferable for rotating parts subjected to severe fatigue. The study contributes to optimized TBC selection and lifecycle prediction strategies, and suggests future work in nano-engineered coatings and AI-driven failure modeling to enhance coating performance further.
Keywords:
Thermal barrier coatings, APS, EB-PVD, Oxidation resistance, Spallation, Fatigue durability.
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