Fabrication of Burner Rig and Testing of Thermal Barrier Coatings

Bibhum Shrestha; Sreenivas Subramaiah

doi:doi:10.11648/j.ijmea.20241206.12

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| Peer-Reviewed

Fabrication of Burner Rig and Testing of Thermal Barrier Coatings

Bibhum Shrestha^*

, Sreenivas Subramaiah

Published in International Journal of Mechanical Engineering and Applications (Volume 12, Issue 6)

Received: 31 October 2024 Accepted: 27 November 2024 Published: 31 December 2024

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Abstract

This research explores the design and fabrication of burner rig to test Thermal Barrier Coatings (TBCs) aimed at enhancing the longevity and performance of gas turbines. Gas turbines, commonly used in aviation and power generation, face extreme operating conditions with high temperatures and thermal gradients that can lead to significant component damage. TBCs, ceramic coatings applied to engine components, play a crucial role in providing thermal insulation and mitigating thermal fatigue, oxidation, and thermal shock. The study involved designing a burner rig, modeled in Solid Works and fabricated from mild steel, to replicate the high temperature environment of gas turbines. The experimental setup was enhanced by the precise machining of components like the aluminum alloy 6061 substrate, achieved through EDM wire cutting. The study demonstrates how factors such as material selection, bond coat and topcoat thickness, porosity, and thermal cycling significantly influence TBC performance. Testing with the burner rig showed that TBCs can greatly enhance engine efficiency and lifespan by providing robust thermal insulation. Advanced monitoring techniques, including infrared thermography and acoustic emission testing, were employed to evaluate the behavior of TBCs under thermal cycling. The findings underscore the need for balancing thermal insulation with thermal stress resistance to maximize coating performance. This research serves as a foundation for further advancements in TBC materials and testing methodologies, with the goal of enhancing the operational efficiency, longevity, and environmental sustainability of gas turbine engines.

Published in	International Journal of Mechanical Engineering and Applications (Volume 12, Issue 6)
DOI	10.11648/j.ijmea.20241206.12
Page(s)	142-151
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2024. Published by Science Publishing Group

Keywords

Thermal Barrier Coatings (TBCs), Gas Turbine Engines, High-temperature Protection, Plasma Spray Coating, Thermal Insulation, Coating Durability

References

[1]	Shrestha B, Sreenivas S, Kulkarni SK, Kulkarni A, Parthiban P, Prajwal S, Kumar SA. Testing of Thermal Barrier Coatings for Fatigue Life. IUP Journal of Mechanical Engineering. 2023 May 1; 16(2).
[2]	Shrestha, B., Parthiban, P., Sreenivas, S., Manjunath, T. V., & Manjunath, A. N. (2023). Experimental and numerical study of temperature gradients, thermal stresses, and TGO in TBCs. International Journal of Research and Analytical Reviews (IJRAR), 10(3), P-ISSN 2349-5138.
[3]	shrestha, Bibhum and S, Sreenivas and Kulkarni, Anand and TV, Manjunath TV and CS, Girish, Characterization of Thermal Barrier Coatings (TBCs) (May 27, 2024). Available at http://dx.doi.org/10.2139/ssrn.4843425
[4]	Nagaraj B. S., et al. "Investigation of Thermal Barrier Coating and Bond Coat Thickness Effects on Temperature Profile and Thermal Stress." Journal of Thermal Spray Technology, vol. 20, no. 3, 2011, pp. 508–515.
[5]	Vaßen R., et al. "Thermal Barrier Coatings for Gas Turbine Engines: History and Future Challenges." Journal of Thermal Spray Technology, vol. 25, no. 4, 2016, pp. 656–675.
[6]	Khan T., et al. "Development of a Burner Rig for Thermal Barrier Coating Testing." International Journal of Aerospace Engineering, vol. 2017, 2017, pp. 1–8.
[7]	Li L., et al. "Numerical Study of the Influence of Porosity on the Thermal Conductivity of Thermal Barrier Coatings." Journal of Thermal Spray Technology, vol. 28, no. 3, 2019, pp. 471–480.
[8]	Zhu W., et al. "Evaluation of Thermal Barrier Coatings for Gas Turbine Applications Using a Burner Rig Test." Surface and Coatings Technology, vol. 349, 2018, pp. 514–523.
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[14]	Shi X., et al. "Effect of Topcoat Thickness on the Performance of Thermal Barrier Coatings." Surface and Coatings Technology, vol. 282, 2015, pp. 96–102.
[15]	Zhang Y., et al. "Durability Evaluation of Thermal Barrier Coatings for Aero-Engine Applications." Journal of Thermal Spray Technology, vol. 26, no. 6, 2017, pp. 1234–1245.
[16]	Lee J. H., et al. "Evaluation of Advanced Thermal Barrier Coatings Using a Burner Rig Test." Surface and Coatings Technology, vol. 358, 2019, pp. 247–256.
[17]	Liu S., et al. "Failure Mechanisms of Plasma-Sprayed Thermal Barrier Coatings Under Thermal-Mechanical Loading: A Review." Surface and Coatings Technology, vol. 361, 2019, pp. 184–198.
[18]	Srinivasan, M. P., et al. "Thermal Barrier Coatings for Gas Turbine Engine Applications: Current Status and Future Directions." Journal of Thermal Spray Technology, vol. 28, no. 7, 2019, pp. 1154-1184.
[19]	Wang, Z., & Zhang, W. (2020). A review of thermal barrier coatings for gas turbine engines. Journal of Thermal Spray Technology, 29(1-2), 77-98.
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APA Style

Shrestha, B., Subramaiah, S. (2024). Fabrication of Burner Rig and Testing of Thermal Barrier Coatings. International Journal of Mechanical Engineering and Applications, 12(6), 142-151. https://doi.org/10.11648/j.ijmea.20241206.12

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ACS Style

Shrestha, B.; Subramaiah, S. Fabrication of Burner Rig and Testing of Thermal Barrier Coatings. Int. J. Mech. Eng. Appl. 2024, 12(6), 142-151. doi: 10.11648/j.ijmea.20241206.12

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AMA Style

Shrestha B, Subramaiah S. Fabrication of Burner Rig and Testing of Thermal Barrier Coatings. Int J Mech Eng Appl. 2024;12(6):142-151. doi: 10.11648/j.ijmea.20241206.12

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@article{10.11648/j.ijmea.20241206.12,
  author = {Bibhum Shrestha and Sreenivas Subramaiah},
  title = {Fabrication of Burner Rig and Testing of Thermal Barrier Coatings
},
  journal = {International Journal of Mechanical Engineering and Applications},
  volume = {12},
  number = {6},
  pages = {142-151},
  doi = {10.11648/j.ijmea.20241206.12},
  url = {https://doi.org/10.11648/j.ijmea.20241206.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmea.20241206.12},
  abstract = {This research explores the design and fabrication of burner rig to test Thermal Barrier Coatings (TBCs) aimed at enhancing the longevity and performance of gas turbines. Gas turbines, commonly used in aviation and power generation, face extreme operating conditions with high temperatures and thermal gradients that can lead to significant component damage. TBCs, ceramic coatings applied to engine components, play a crucial role in providing thermal insulation and mitigating thermal fatigue, oxidation, and thermal shock. The study involved designing a burner rig, modeled in Solid Works and fabricated from mild steel, to replicate the high temperature environment of gas turbines. The experimental setup was enhanced by the precise machining of components like the aluminum alloy 6061 substrate, achieved through EDM wire cutting. The study demonstrates how factors such as material selection, bond coat and topcoat thickness, porosity, and thermal cycling significantly influence TBC performance. Testing with the burner rig showed that TBCs can greatly enhance engine efficiency and lifespan by providing robust thermal insulation. Advanced monitoring techniques, including infrared thermography and acoustic emission testing, were employed to evaluate the behavior of TBCs under thermal cycling. The findings underscore the need for balancing thermal insulation with thermal stress resistance to maximize coating performance. This research serves as a foundation for further advancements in TBC materials and testing methodologies, with the goal of enhancing the operational efficiency, longevity, and environmental sustainability of gas turbine engines.
},
 year = {2024}
}

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TY  - JOUR
T1  - Fabrication of Burner Rig and Testing of Thermal Barrier Coatings

AU  - Bibhum Shrestha
AU  - Sreenivas Subramaiah
Y1  - 2024/12/31
PY  - 2024
N1  - https://doi.org/10.11648/j.ijmea.20241206.12
DO  - 10.11648/j.ijmea.20241206.12
T2  - International Journal of Mechanical Engineering and Applications
JF  - International Journal of Mechanical Engineering and Applications
JO  - International Journal of Mechanical Engineering and Applications
SP  - 142
EP  - 151
PB  - Science Publishing Group
SN  - 2330-0248
UR  - https://doi.org/10.11648/j.ijmea.20241206.12
AB  - This research explores the design and fabrication of burner rig to test Thermal Barrier Coatings (TBCs) aimed at enhancing the longevity and performance of gas turbines. Gas turbines, commonly used in aviation and power generation, face extreme operating conditions with high temperatures and thermal gradients that can lead to significant component damage. TBCs, ceramic coatings applied to engine components, play a crucial role in providing thermal insulation and mitigating thermal fatigue, oxidation, and thermal shock. The study involved designing a burner rig, modeled in Solid Works and fabricated from mild steel, to replicate the high temperature environment of gas turbines. The experimental setup was enhanced by the precise machining of components like the aluminum alloy 6061 substrate, achieved through EDM wire cutting. The study demonstrates how factors such as material selection, bond coat and topcoat thickness, porosity, and thermal cycling significantly influence TBC performance. Testing with the burner rig showed that TBCs can greatly enhance engine efficiency and lifespan by providing robust thermal insulation. Advanced monitoring techniques, including infrared thermography and acoustic emission testing, were employed to evaluate the behavior of TBCs under thermal cycling. The findings underscore the need for balancing thermal insulation with thermal stress resistance to maximize coating performance. This research serves as a foundation for further advancements in TBC materials and testing methodologies, with the goal of enhancing the operational efficiency, longevity, and environmental sustainability of gas turbine engines.

VL  - 12
IS  - 6
ER  -

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Author Information

Bibhum Shrestha

Department of Mechanical Engineering, Cambridge Institute of Science and Technology, Bengaluru, India

Contact Email

http://orcid.org/0009-0002-3618-0907
Sreenivas Subramaiah

Department of Mechanical Engineering, Cambridge Institute of Science and Technology, Bengaluru, India

http://orcid.org/0000-0002-0472-8600

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Plain Text BibTeX RIS

APA Style

Shrestha, B., Subramaiah, S. (2024). Fabrication of Burner Rig and Testing of Thermal Barrier Coatings. International Journal of Mechanical Engineering and Applications, 12(6), 142-151. https://doi.org/10.11648/j.ijmea.20241206.12

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ACS Style

Shrestha, B.; Subramaiah, S. Fabrication of Burner Rig and Testing of Thermal Barrier Coatings. Int. J. Mech. Eng. Appl. 2024, 12(6), 142-151. doi: 10.11648/j.ijmea.20241206.12

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AMA Style

Shrestha B, Subramaiah S. Fabrication of Burner Rig and Testing of Thermal Barrier Coatings. Int J Mech Eng Appl. 2024;12(6):142-151. doi: 10.11648/j.ijmea.20241206.12

Copy | Download

@article{10.11648/j.ijmea.20241206.12,
  author = {Bibhum Shrestha and Sreenivas Subramaiah},
  title = {Fabrication of Burner Rig and Testing of Thermal Barrier Coatings
},
  journal = {International Journal of Mechanical Engineering and Applications},
  volume = {12},
  number = {6},
  pages = {142-151},
  doi = {10.11648/j.ijmea.20241206.12},
  url = {https://doi.org/10.11648/j.ijmea.20241206.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmea.20241206.12},
  abstract = {This research explores the design and fabrication of burner rig to test Thermal Barrier Coatings (TBCs) aimed at enhancing the longevity and performance of gas turbines. Gas turbines, commonly used in aviation and power generation, face extreme operating conditions with high temperatures and thermal gradients that can lead to significant component damage. TBCs, ceramic coatings applied to engine components, play a crucial role in providing thermal insulation and mitigating thermal fatigue, oxidation, and thermal shock. The study involved designing a burner rig, modeled in Solid Works and fabricated from mild steel, to replicate the high temperature environment of gas turbines. The experimental setup was enhanced by the precise machining of components like the aluminum alloy 6061 substrate, achieved through EDM wire cutting. The study demonstrates how factors such as material selection, bond coat and topcoat thickness, porosity, and thermal cycling significantly influence TBC performance. Testing with the burner rig showed that TBCs can greatly enhance engine efficiency and lifespan by providing robust thermal insulation. Advanced monitoring techniques, including infrared thermography and acoustic emission testing, were employed to evaluate the behavior of TBCs under thermal cycling. The findings underscore the need for balancing thermal insulation with thermal stress resistance to maximize coating performance. This research serves as a foundation for further advancements in TBC materials and testing methodologies, with the goal of enhancing the operational efficiency, longevity, and environmental sustainability of gas turbine engines.
},
 year = {2024}
}

Copy | Download

TY  - JOUR
T1  - Fabrication of Burner Rig and Testing of Thermal Barrier Coatings

AU  - Bibhum Shrestha
AU  - Sreenivas Subramaiah
Y1  - 2024/12/31
PY  - 2024
N1  - https://doi.org/10.11648/j.ijmea.20241206.12
DO  - 10.11648/j.ijmea.20241206.12
T2  - International Journal of Mechanical Engineering and Applications
JF  - International Journal of Mechanical Engineering and Applications
JO  - International Journal of Mechanical Engineering and Applications
SP  - 142
EP  - 151
PB  - Science Publishing Group
SN  - 2330-0248
UR  - https://doi.org/10.11648/j.ijmea.20241206.12
AB  - This research explores the design and fabrication of burner rig to test Thermal Barrier Coatings (TBCs) aimed at enhancing the longevity and performance of gas turbines. Gas turbines, commonly used in aviation and power generation, face extreme operating conditions with high temperatures and thermal gradients that can lead to significant component damage. TBCs, ceramic coatings applied to engine components, play a crucial role in providing thermal insulation and mitigating thermal fatigue, oxidation, and thermal shock. The study involved designing a burner rig, modeled in Solid Works and fabricated from mild steel, to replicate the high temperature environment of gas turbines. The experimental setup was enhanced by the precise machining of components like the aluminum alloy 6061 substrate, achieved through EDM wire cutting. The study demonstrates how factors such as material selection, bond coat and topcoat thickness, porosity, and thermal cycling significantly influence TBC performance. Testing with the burner rig showed that TBCs can greatly enhance engine efficiency and lifespan by providing robust thermal insulation. Advanced monitoring techniques, including infrared thermography and acoustic emission testing, were employed to evaluate the behavior of TBCs under thermal cycling. The findings underscore the need for balancing thermal insulation with thermal stress resistance to maximize coating performance. This research serves as a foundation for further advancements in TBC materials and testing methodologies, with the goal of enhancing the operational efficiency, longevity, and environmental sustainability of gas turbine engines.

VL  - 12
IS  - 6
ER  -

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