Abstract
Additively manufactured nickel-based superalloys are now being considered as a replacement for traditionally manufactured components on commercial and military aircraft. While the potential of additive manufacturing for gas turbine engines is promising, the quality and performance of additive manufactured components still need extensive study. Coupon-sized test specimens comprised of as-printed additively and traditionally manufactured Inconel 718 with and without yttria-stabilized zirconia thermal barrier coating were tested under simulated isothermal and thermal cycling combustion conditions that were representative of gas turbine environments. Pre-test scanning electron microscopy indicated that traditionally manufactured coupons had a smooth surface finish with minor imperfections while additive manufactured coupons had a rough surface finish. Post-test scanning electron microscopy exhibited differences in oxide scale between the isothermal and thermal cycling conditions. The thermal cycling condition increased the amount of oxide scale for both additively manufactured and traditionally manufactured Inconel 718. The size of the oxide islands on traditionally manufactured coupons was significantly larger than the additively manufactured coupons. The results indicated that differences in surface roughness may affect the growth of the oxidation scale in a high-temperature combustion environment. The benefits of yttria-stabilized zirconia thermal barrier coating were characterized. The substrate of the coupons experienced little to no formation of oxide scales compared to the uncoated additive and traditionally manufactured coupons. The results further suggested that yttria-stabilized zirconia thermal barrier coating can be utilized to provide both insulation and oxidation protection when desired. Post-test energy-dispersive X-ray spectrometry results corresponded well with known elemental compositions and oxidation mechanisms.
