AP23489951 "Development of a combined method of obtaining YSZ/GZO thermal barrier coating for heat-stressed parts and assemblies of rocket-space engineering products"

HomeResearchScientific and scientific-technical projects on grant and program-targeted financing ProjectsAP23489951 "Development of a combined method of obtaining YSZ/GZO thermal barrier coating for heat-stressed parts and assemblies of rocket-space engineering products"

AP23489951 "Development of a combined method of obtaining YSZ/GZO thermal barrier coating for heat-stressed parts and assemblies of rocket-space engineering products"

Competition name:Competition for grant financing of scientific and technical projects for 2024-2026.

Project Manager: Saule A. Abdulina, PhD, professor.

Identifiers:

Scopus Author ID: 56389550800 (https://www.scopus.com/authid/detail.uri?authorId=56389550800),
ORCID: https://orcid.org/0000-0001-6328-8652,
Web of Science ResearcherID: ABC-5778-2021,
Google Scholar ID: Nbg6V2cAAAAJ.

Project Research Team

№	Full name	Project position	Identifiers (Scopus Author ID, Researcher ID, ORCID, if any) and links to related profiles
1.	Saule A. Abdulina	SRF	Scopus Author ID: 56389550800 (https://www.scopus.com/authid/detail.uri?authorId=56389550800), ORCID: https://orcid.org/0000-0001-6328-8652, Web of Science ResearcherID: ABC-5778-2021, Google Scholar ID: Nbg6V2cAAAAJ.
Young scientists (under 40 + teaching staff (Students, undergraduates)
	Full name	Project position	Identifiers (Scopus Author ID, Researcher ID, ORCID, if any) and links to related profiles	Note (Teaching staff, student, Master's student, doctoral student)
1	A.B. Kengesbekov		Scopus Author ID: 57205287682, Web of Science Researcher ID: AAJ-2006-2021, Google Scholar ID: qiSsE64AAAAJ&hl, ORCID: 0000-0002-5630-9467.	Teaching staff
2	D.K. Yeskermesov		Scopus Author ID: 57225097090, Web of Science Researcher ID: ABC-5876-2021, ORCID: https://orcid.org/0000-0002-2206-8132, Google Scholar ID: WdqfuZ0AAAAJ&hl=ru	Teaching staff
3	A.E. Kusainov		Scopus Author ID: 59065558000, ORCID: https://orcid.org/0000-0003-4623-4681.	Doctoral student
4	I.K. Abizhanova		Web of Science Researcher ID: ADR-8182-2022, ORCID:: 0009-0006-3218-7246.	Doctoral student
5	A.K. Apsezhanova		Scopus Author ID: 57225969663, ORCID: 0009-0001-7778-7767.	Master
6	E.S. Otarov
7	O.A. Andreeva
8	E.S. Molbosynov		Scopus Author ID: 59345086000, ORCID: 0009-0009-0578-6544, https://www.researchgate.net/profile/Ermahan-Molbosynov.	Bachelor

Project abstract

The project is aimed at developing a combined method for producing a YSZ/GZO thermal barrier coating for heat-stressed units of rocket and space technology products. Within the framework of this project, it is proposed to combine two methods, APS and HVOF, to produce a two-layer coating in order to reduce the destruction of TBC due to coating peeling. In order to combine the strong adhesive properties of HVOF coatings with the best heat-shielding properties of APS coatings, it is proposed to produce a lower layer of YSZ by the HVOF method, and an upper layer of Gd₂Zr₂O by the APS method. In order to optimize the multilayer structure, it is proposed to conduct comprehensive experimental studies of changes in the structural-phase states, mechanical and thermal-physical characteristics of YSZ/GZO thermal barrier coatings depending on the spraying parameters, the composition and structure of the original powder, the porosity and thickness of the layers. It is also proposed to study the coefficient of thermal expansion, hardness, elasticity, cyclic durability, hot corrosion and high-temperature oxidation of YSZ/GZO coatings. The relationships between the thermomechanical properties of YSZ/GZO coatings and their structural and phase state will be established. The features of mechanical stress formation in interlayer bonding layer/YSZ/GZO joints under cyclic thermal effects will be studied depending on the crystalline structure of the layers. The optimal structure of YSZ/GZO coatings that can operate under extreme conditions of temperature and mechanical effects will be selected. As a result of successful implementation of the project, a combined method for obtaining a YSZ/GZO thermal barrier coating will be developed, promising for use in heat-stressed units of rocket and space technology products.

This project will undoubtedly contribute to the replenishment of a reliable database on materials used in the rocket and space industry. Obtaining a reliable database on thermal barrier coatings that ensure the stability and safety of thermally stressed units of rocket and space technology is a very urgent materials science task in the development of the rocket and space industry. The rocket and space industry makes a significant contribution to ensuring national security and is one of the most developed and competitive industries of the domestic economy.

Expected and achieved results of the project:

Year	The results obtained from the research. Publications (with links to them) and patents; information for potential users
2024	Experiments will be conducted on sandblasting the surface under various conditions. The speed, shape and size of the abrasive particles will be varied in the experiments. The optimal mode of sandblasting the surface will be selected. A series of experiments will be conducted on obtaining a NiCrAlY bonding layer under various atmospheric plasma spraying conditions. The effect of alloy preheating on the adhesive strength of the bonding layer will also be studied. A technique for obtaining a NiCrAlY bonding layer with low porosity and high adhesive strength on the superalloy surface will be developed. The optimal mode of high-speed oxygen-fuel spraying will be determined, which will allow obtaining YSZ coatings with high adhesive strength and low porosity. Changes in the morphology and properties of YSZ coatings will be studied depending on the HVOF parameter modes (gas ratio, spraying distance, gas flow rate, powder feed rate).
2025	The microstructure, phase composition and mechanical properties of the obtained YSZ coatings will be studied depending on the Y₂O₃ content. The patterns of YSZ coating formation will be established depending on the Y₂O₃ content. An atmospheric plasma spraying unit will be created, which consists of a power source, an electric arc ignition system, a plasma torch, a cooling unit and a gas communication system. The results of previously conducted studies will be used in creating the unit. Optimal modes for obtaining GZO coatings with high physical and mechanical characteristics will be developed. The surface microhardness will be measured, and a graph of the microhardness distribution by sample depth on a transverse section will be obtained. Coatings will be tested for adhesion strength using the pull-off method, and the coating roughness will be measured using the probe method. Comprehensive experimental sudies will be conducted on changes in the structural-phase states and thermomechanical characteristics of YSZ/GZO thermal barrier coatings depending on the spraying parameters, the composition and structure of the original powder, and the porosity and thickness of the layers. The thermal expansion coefficient will be measured from 100°C to 1000°C at a heating rate of 5°C/min using a Q400EM thermomechanical analyzer.
2026	Cyclic durability, hot corrosion and high-temperature oxidation of YSZ/GZO coatings will be studied. Hot corrosion of thermal barrier coatings will be studied under the influence of a melt of a mixture of calcium, magnesium, aluminum and silicon oxides (CMAS). Features of the formation of mechanical stresses in interlayer bonding layer/YSZ/GZO joints under cyclic thermal effects will be studied depending on the crystalline structure of the layers. The relationships between the thermomechanical properties of YSZ/GZO coatings and its structural-phase state will be studied. A combined method for obtaining a YSZ/GZO thermal barrier coating will be developed. A recommendation will be developed for the use of the developed YSZ/GZO thermal barrier coating to protect heat-stressed parts and units of rocket and space technology products.

Year

The results obtained from the research.
Publications (with links to them) and patents; information for potential users

2024

Experiments will be conducted on sandblasting the surface under various conditions. The speed, shape and size of the abrasive particles will be varied in the experiments. The optimal mode of sandblasting the surface will be selected.
A series of experiments will be conducted on obtaining a NiCrAlY bonding layer under various atmospheric plasma spraying conditions. The effect of alloy preheating on the adhesive strength of the bonding layer will also be studied. A technique for obtaining a NiCrAlY bonding layer with low porosity and high adhesive strength on the superalloy surface will be developed.

The optimal mode of high-speed oxygen-fuel spraying will be determined, which will allow obtaining YSZ coatings with high adhesive strength and low porosity. Changes in the morphology and properties of YSZ coatings will be studied depending on the HVOF parameter modes (gas ratio, spraying distance, gas flow rate, powder feed rate).

2025

The microstructure, phase composition and mechanical properties of the obtained YSZ coatings will be studied depending on the Y₂O₃ content. The patterns of YSZ coating formation will be established depending on the Y₂O₃ content. An atmospheric plasma spraying unit will be created, which consists of a power source, an electric arc ignition system, a plasma torch, a cooling unit and a gas communication system. The results of previously conducted studies will be used in creating the unit.

Optimal modes for obtaining GZO coatings with high physical and mechanical characteristics will be developed. The surface microhardness will be measured, and a graph of the microhardness distribution by sample depth on a transverse section will be obtained. Coatings will be tested for adhesion strength using the pull-off method, and the coating roughness will be measured using the probe method.

Comprehensive experimental sudies will be conducted on changes in the structural-phase states and thermomechanical characteristics of YSZ/GZO thermal barrier coatings depending on the spraying parameters, the composition and structure of the original powder, and the porosity and thickness of the layers. The thermal expansion coefficient will be measured from 100°C to 1000°C at a heating rate of 5°C/min using a Q400EM thermomechanical analyzer.

2026

Cyclic durability, hot corrosion and high-temperature oxidation of YSZ/GZO coatings will be studied. Hot corrosion of thermal barrier coatings will be studied under the influence of a melt of a mixture of calcium, magnesium, aluminum and silicon oxides (CMAS).

Features of the formation of mechanical stresses in interlayer bonding layer/YSZ/GZO joints under cyclic thermal effects will be studied depending on the crystalline structure of the layers.

The relationships between the thermomechanical properties of YSZ/GZO coatings and its structural-phase state will be studied.

A combined method for obtaining a YSZ/GZO thermal barrier coating will be developed. A recommendation will be developed for the use of the developed YSZ/GZO thermal barrier coating to protect heat-stressed parts and units of rocket and space technology products.

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