Fabrication of Burner Rig and Testing of Thermal Barrier Coatings

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.