Advanced cooling techniques involving internal enhanced heat transfer and external film cooling and thermal barrier coatings (TBCs) are employed for gas turbine hot components to reduce metal temperatures and to extend their lifetime. A deeper understanding of the interaction mechanism of these thermal protection methods and the conjugate thermal behaviours of the turbine parts provides valuable guideline for the design stage. In this study, a conjugate heat transfer model of a turbine vane endwall with internal impingement and external film cooling is constructed to document the effects of TBCs on the overall cooling effectiveness using numerical simulations. Experiments on the same model with no TBCs are performed to validate the computational methods. Round and crater holes due to the inclusion of TBCs are investigated as well to address how film-cooling configurations affect the aero-thermal performance of the endwall. Results show that the TBCs have a profound effect in reducing the endwall metal temperatures for both cases. The TBC thermal protection for the endwall is shown to be more significant than the effect of increasing coolant mass flow rate. Although the crater holes have better film cooling performance than the traditional round holes, a slight decrement of overall cooling effectiveness is found for the crater configuration due to more endwall metal surfaces directly exposed to external mainstream flows. Energy loss coefficients at the vane passage exit show a relevant negative impact of adding TBCs on the cascade aerodynamic performance, particularly for the round hole case.

The cyclic oxidation experiment of yttria-stabilized zirconia coatings deposited on NiCoCrAlYHf alloys by air plasma spraying was investigated at 1050 °C in air and in air containing water vapor. The results revealed that water vapor has a great influence on the oxidation resistance of the thermal barrier coatings (TBCs). Compared with the samples oxidized in air atmosphere, TBCs oxidized in air containing water vapor had a longer lifetime. It was also found that different atmospheres could lead to different HfO2 formation positions, which could decrease the rumpling in the oxide layer. In particular, after the coatings on Hf-doped NiCoCrAlY were first pretreated in air containing water vapor for 24 h at 1050 °C, the lifetime of the pretreated coating was doubled compared to the coating in laboratory air only. The water vapor pretreatment of the coatings could be an important method for optimizing the lifetime of TBCs.

Reliability of thermal barrier coatings (TBC) hinges on the adhesion of a thermally grown oxide scale to an insulative ceramic topcoat and an underlying metallic bondcoat. The width of the scale and its interfaces makes transmission electron microscopy (TEM) an appropriate tool for its analysis. However, specimen preparation has proven to be a challenging obstacle leading to a dearth of TEM research on TBCs. A new approach to cross-section TBC TEM specimen preparation is described. The principal advantages of this technique are reproducibility, reduced specimen damage, and time savings resulting from decreased ion milling. This technique has been successfully applied to numerous TBC specimens with various thermal histories.