A Novel Plasma-Sprayed Durable Thermal Barrier Coating with a Well-Bonded YSZ Interlayer Between Porous YSZ and Bond Coat

Li, Chang‐Jiu; Li, Yong

doi:10.1007/s11666-012-9771-0

Cited by 47 publications

(14 citation statements)

References 26 publications

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“…More than two fold improvement in FCT life has been observed in some cases (B6 and B7), which concurrently are also coatings with highest interfacial toughness layer, since the porous second layer is constant in all the coatings. These results are consistent with the bilayer coating results of Li et al ., where only one parameter was varied namely the deposition temperature of the first layer. They attributed the enhancement in durability to enhanced toughness and adhesion of the near‐interface layer, achieved at high deposition temperatures.…”

Section: Resultssupporting

confidence: 91%

“…APS process with appropriate processing control is ideally suited to assemble such a microstructure. There is preliminary evidence in the literature that such hybrid microstructurally engineered coatings are more durable than single layer TBCs, although the operative mechanisms are not fully elaborated …”

Section: Introductionmentioning

confidence: 99%

“…There is preliminary evidence in the literature that such hybrid microstructurally engineered coatings are more durable than single layer TBCs, although the operative mechanisms are not fully elaborated. 21,22 In this study, we seek to systematically engineer TBC microstructure through optimization of sprayed layers based on the knowledge of process-toughness and process-modulus relations derived from prior studies. 20,23,24 The goal here is to employ processing strategies that will impart high density and thus high toughness in the near bond-coat regions (within the first 50-100 lm of the interface), followed by porous low modulus top-coat to provide compliance and low sintering propensity.…”

Section: Introductionmentioning

confidence: 99%

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Engineered Multilayer Thermal Barrier Coatings for Enhanced Durability and Functional Performance

2014

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The durability of plasma sprayed thermal barrier coatings (TBCs) has been of significant interest ever since their introduction in gas turbine engine components. Of particular importance is the role of coating processing, microstructure and ensuing properties on their thermal cycle life. Among the coating properties of the ceramic top coat that have shown strong correlations with durability include the elastic modulus (i.e., compliance) and the fracture toughness, both of which are influenced by processing as well as thermal aging during service. In this article, we have systematically investigated furnace cycle durability of plasma sprayed TBCs produced from controlled processing conditions, yielding differences in both modulus and toughness. Following performance assessment and mechanistic insights obtained from single layer ceramic coatings, novel bilayer architectures have been proposed and fabricated, in an effort to improve furnace cycle durability. The bilayer approach targets coating properties based on location, by providing dense, high toughness coating at regions prone to delamination failure (near‐interface), while allowing for the majority of the coating to contain high porosity, resulting in reduced overall modulus. Such improved bilayers simultaneously display both high durability and low thermal conductivity enabling a promising approach for functionally optimized coatings. The plasma spray process together with its ability to dynamically change process parameters enables the fabrication of these novel architectures.

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Section: Resultssupporting

confidence: 91%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Engineered Multilayer Thermal Barrier Coatings for Enhanced Durability and Functional Performance

2014

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“…[18][19][20] Taking account of the fact that the cracks leading to the failure of plasma sprayed TBCs usually propagate within YSZ near the YSZ/bond coat interface, it was proposed to introduce a well bonded YSZ layer of high fracture toughness between the bond layer and porous YSZ layer to construct YSZ double layered TBCs to improve local crack propagation resistance and thus thermal cyclic lifetime of TBCs. 21 The test result showed that by the proposed double layer TBC design the thermal cycling life of TBCs can be significantly improved. 2 When the combination of conventional YSZ and low thermal conductivity TBC materials is employed as the multiple layers or at least double layers design, the lamellar structure feature of APS coating will limit the fracture toughness of YSZ near YSZ/bond coat and that of APS LZO near the YSZ/LZO interface.…”

Section: Introductionmentioning

confidence: 97%

Splat interface bonding formation during plasma spraying of LZO coating

Liu

Yang

et al. 2014

Materials Research Innovations

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Plasma sprayed ceramic coatings of low thermal conductivity are becoming important candidates for next generation thermal barrier coatings. The rare earth ceramic materials are regarded as promising materials which can be applied by plasma spraying. However, the lower mechanical strength of these materials compared with YSZ limits their performance during thermal cycling. The interlamellar bonding of plasma sprayed ceramic coatings dominates their mechanical properties. In this study, the rare earth ceramic LZO splats were deposited on both YSZ and LZO surfaces at different surface temperatures to reveal the effect of the deposition temperature on the splat interface bonding formation. The bonding conditions between splat and different substrates were examined from the cross-sections by fracturing the splats. It is confirmed that at low surface temperature no effective splat bonding formed between the splat and the substrate surface. It is also observed that there was a critical surface temperature over which the interface bonding begins to form. The present results will benefit the control of splat interface bonding, and thus the properties of the coatings.

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“…There are several methods of spraying TC layer such as plasma spray (PS), high-velocity oxygen fuel (HVOF), flame spraying, cold spraying etc. Among these air plasma spray method is well known for its cost-efficiency and high productivity [6,7]. BC layer plays a crucial role in a TBC system by providing a strong adhesion of TC to the substrate.…”

Section: Introductionmentioning

confidence: 99%

Air Plasma Sprayed Bond Coat Oxidation Behavior and its Resistance to Isothermal and Thermal Shock Loading

2019

IJE

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A B S T R A C TAn experimental investigation was conducted to find the effect of spraying method of coating of Thermal Barrier Coatings (TBCs) on their oxidation behaviour and resistance to various thermal loading. Isothermal and thermal shock tests were performed in order to study oxidation behaviour of air plasma sprayed Bond Coat (BC) and assess its effect on TBCs lifetime under the stated loadings. Specimens, after loading were investigated using Field Emission Scanning Electron Microscopy (FE-SEM). Results showed in spite of forming various oxide layers within the BC its oxidation in Bond Coat/Top Coat interface behave the same as samples coated by other methods and no failure was observed at substrate/BC interface or within the BC.

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A Novel Plasma-Sprayed Durable Thermal Barrier Coating with a Well-Bonded YSZ Interlayer Between Porous YSZ and Bond Coat

Cited by 47 publications

References 26 publications

Engineered Multilayer Thermal Barrier Coatings for Enhanced Durability and Functional Performance

Engineered Multilayer Thermal Barrier Coatings for Enhanced Durability and Functional Performance

Splat interface bonding formation during plasma spraying of LZO coating

Air Plasma Sprayed Bond Coat Oxidation Behavior and its Resistance to Isothermal and Thermal Shock Loading

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