Effect of increased water vapor levels on TBC lifetime with Pt-containing bond coatings

To investigate the effect of increased water vapor levels on thermal barrier coating (TBC) lifetime, furnace cycle tests were performed at 1150 °C in air with 10 vol.% water vapor (similar to natural gas combustion) and 90 vol.%. Either Pt diffusion or Pt-modified aluminide bond coatings were applied to specimens from the same batch of a commercial second-generation single-crystal superalloy and commercial vapor-deposited yttria-stabilized zirconia (YSZ) top coats were applied. Three coatings of each type were furnace cycled to failure to compare the average lifetimes obtained in dry O2, using the same superalloy batch and coating types. Average lifetimes with Pt diffusion coatings were unaffected by the addition of water vapor. In contrast, the average lifetime of Pt-modified aluminide coatings was reduced by more than 50% with 10% water vapor but only slightly reduced by 90% water vapor. Based on roughness measurements from similar specimens without a YSZ coating, the addition of 10% water vapor increased the rate of coating roughening more than 90% water vapor. Qualitatively, the amount of β-phase depletion in the coatings exposed in 10% water vapor did not appear to be accelerated.