Combined thermal power plants, which account for a portion of domestic and foreign power generation capaticy, are composed of combination of a steam turbine and a gas turbine. Gas turbines used in these power plants contain various high-alloy and super-alloy materials and are designed to have suffic...
Combined thermal power plants, which account for a portion of domestic and foreign power generation capaticy, are composed of combination of a steam turbine and a gas turbine. Gas turbines used in these power plants contain various high-alloy and super-alloy materials and are designed to have sufficient heat resistance and corrosion resistance to operate in harsh environments of high pressure and high temperature. The operating temperature of gas turbines must be increased to increase the power-generation efficiency, but this requires materials with excellent heat resistance. To increase the heat resistance of gas-turbine materials, they must be coated with a ceramic thermal barrier coating (TBC). For example, 8 wt% yttria-stabilized zirconia (8YSZ) is widely used as a commercial TBC material because of its excellent thermal properties, such as a high melting point, low thermal conductivity, and mechanical properties that are compatible with metal substrates. However, 8YSZ is not stable for use above 1200 °C because it undergoes a phase change with a corresponding volume change that damages the coating. Accordingly, next-generation TBC materials such as lantanium zirconate (LZO) and gadolinium zirconate (GZO) with excellent phase stability are attracting attention, but their application is challenging because of their insufficient mechanical properties and low thermal conductivity. Therefore, it is necessary to develop new TBC materials to overcome these limitations. In this study, to achieve the ultimate increase in power-generation efficiency and lifespan of gas turbines, an LZO@8YSZ powder with a core-shell structure was synthesized; LZO with excellent phase stability is used as the core and 8YSZ with excellent mechanical and thermal conductivity properties is used as the shell.
Meanwhile, a generator that converts the kinetic energy of the gas turbine into electrical energy and a transformer that transforms the generated electricity are composed of an iron core and wire windings. The iron core is a silicon steel plate, and ceramic coatings such as forsterite (MgSiO4) and phosphates are applied to prevent iron loss and increase conversion efficiency. To increase the efficiency and lifespan of the transformer, it is necessary to further improve its corrosion resistance and insulation properties by developing new coating agents. Therefore, in this study, a ceramic coating agent was developed to increase the efficiency of gas turbines and transformers. First, to improve the insulating properties of a MgO coating material prepared as the precursor of a forsterite coating, a transition metal M (Ni, Co, Mn) was added to synthesize Mg1-xMxO binary powder to form a multi-component forsterite coating. Second, organic–inorganic hybrid coatings that combine organic groups with excellent adhesion and inorganic materials with excellent insulating properties were developed to improve the insulation, corrosion resistance, and bond strength of the ceramic coatings. These research results are expected to greatly contribute to the future power-generation industry.
Combined thermal power plants, which account for a portion of domestic and foreign power generation capaticy, are composed of combination of a steam turbine and a gas turbine. Gas turbines used in these power plants contain various high-alloy and super-alloy materials and are designed to have sufficient heat resistance and corrosion resistance to operate in harsh environments of high pressure and high temperature. The operating temperature of gas turbines must be increased to increase the power-generation efficiency, but this requires materials with excellent heat resistance. To increase the heat resistance of gas-turbine materials, they must be coated with a ceramic thermal barrier coating (TBC). For example, 8 wt% yttria-stabilized zirconia (8YSZ) is widely used as a commercial TBC material because of its excellent thermal properties, such as a high melting point, low thermal conductivity, and mechanical properties that are compatible with metal substrates. However, 8YSZ is not stable for use above 1200 °C because it undergoes a phase change with a corresponding volume change that damages the coating. Accordingly, next-generation TBC materials such as lantanium zirconate (LZO) and gadolinium zirconate (GZO) with excellent phase stability are attracting attention, but their application is challenging because of their insufficient mechanical properties and low thermal conductivity. Therefore, it is necessary to develop new TBC materials to overcome these limitations. In this study, to achieve the ultimate increase in power-generation efficiency and lifespan of gas turbines, an LZO@8YSZ powder with a core-shell structure was synthesized; LZO with excellent phase stability is used as the core and 8YSZ with excellent mechanical and thermal conductivity properties is used as the shell.
Meanwhile, a generator that converts the kinetic energy of the gas turbine into electrical energy and a transformer that transforms the generated electricity are composed of an iron core and wire windings. The iron core is a silicon steel plate, and ceramic coatings such as forsterite (MgSiO4) and phosphates are applied to prevent iron loss and increase conversion efficiency. To increase the efficiency and lifespan of the transformer, it is necessary to further improve its corrosion resistance and insulation properties by developing new coating agents. Therefore, in this study, a ceramic coating agent was developed to increase the efficiency of gas turbines and transformers. First, to improve the insulating properties of a MgO coating material prepared as the precursor of a forsterite coating, a transition metal M (Ni, Co, Mn) was added to synthesize Mg1-xMxO binary powder to form a multi-component forsterite coating. Second, organic–inorganic hybrid coatings that combine organic groups with excellent adhesion and inorganic materials with excellent insulating properties were developed to improve the insulation, corrosion resistance, and bond strength of the ceramic coatings. These research results are expected to greatly contribute to the future power-generation industry.
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