ABOUT THE AUTHOR ............................................... ix
PREFACE ........................................................ xi
Chapter 1
Introduction .................................................... 1
1.1 High-Temperature Environment ............................... 1
References ................................................. 4
Chapter 2
Fundamental Concepts ............................................ 5
2.1 Thermodynamic Concepts ..................................... 5
2.2 Concept of Kinetics ........................................ 7
2.3 Crystal Structure ......................................... 11
2.4 Equilibrium Phases ........................................ 14
References ..................................................... 16
Chapter 3
Substrate Alloys ............................................... 17
3.1 Temperature Capability of Metals and Alloys ............... 17
3.2 Strengthening Mechanisms .................................. 17
3.3 Titanium Alloys ........................................... 19
3.4 Steels .................................................... 21
3.5 Nickel-Iron Alloys ........................................ 23
3.6 Nickel and Cobalt Base Superalloys ........................ 23
3.7 Need for Coatings ......................................... 26
References ..................................................... 27
Chapter 4
Oxidation ...................................................... 29
4.1 Oxidation Process ......................................... 29
4.2 Oxidation Testing and Evaluation .......................... 34
4.3 Oxidation of Alloys ....................................... 41
4.4 Roles of Specific Alloying Constituents ................... 46
4.5 Oxidation in the Presence of Water Vapor .................. 50
4.6 Oxidation of Polycrystalline Versus Single-Crystal
Alloys .................................................... 50
References ..................................................... 51
Chapter 5
High-Temperature Corrosion ..................................... 53
5.1 Hot Corrosion Processes ................................... 53
5.2 Hot Corrosion of Metals and Alloys ........................ 60
5.3 Role of Specific Alloying Elements in Hot Corrosion of
Ni and Co Based Alloys and Coatings ....................... 62
5.4 Influence of other Contaminants ........................... 65
5.5 Hot Corrosion of TBCs ..................................... 67
5.6 Hot Corrosion-like Degradation ............................ 68
References ..................................................... 69
Chapter 6
Oxidation- and Corrosion-Resistant Coatings .................... 71
6.1 Requirements for Metallic Coatings ........................ 71
6.2 Coating Processes ......................................... 73
6.3 Diffusion Coatings ........................................ 73
6.4 Overlay Coatings .......................................... 96
6.5 Overlay Coatings by Spray and Arc Processes ............... 97
6.6 Overlay Coatings by Physical Vapor Deposition (PVD) ...... 116
6.7 Relative Oxidation and Corrosion Resistance of
Coatings ................................................. 134
6.8 Modeling of Oxidation and Corrosion Life ................. 137
6.9 Interaction of Erosion-Oxidation and Erosion-Corrosion ... 148
References .................................................... 149
Chapter 7
Thermal Barrier Coatings (TBCs) ............................... 155
7.1 Temperature Reduction by TBCs ............................ 155
7.2 Materials Requirements for TBCs .......................... 159
7.3 Partially Stabilized Zirconia ............................ 160
7.4 Plasma Sprayed TBCs ...................................... 162
7.5 Electron Beam Physical Vapor Deposited (EB-PVD) TBCs ..... 184
7.6 Environmental Barrier Coatings (EBCs) .................... 225
References .................................................... 226
Chapter 8
Nondestructive Inspection (NDI) of Coatings ................... 233
8.1 NDI Techniques ........................................... 233
References .................................................... 245
Chapter 9
Coatings Repair ............................................... 247
9.1 Limits to Coatings Repair ................................ 247
9.2 The Repair Process ....................................... 248
9.3 Recoating and Material Restoration ....................... 250
References .................................................... 251
Chapter 10
Field and Simulated Field Experience .......................... 253
10.1 Gas Turbine Engine Application ........................... 253
10.2 Other Applications ....................................... 270
References .................................................... 274
APPENDIX ...................................................... 277
AUTHOR INDEX .................................................. 283
SUBJECT INDEX ................................................. 293
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