Application of Suspension Plasma Spraying (SPS) for Manufacture of Ceramic Coatings

Kaßner, H.; Siegert, R.; Hathiramani, D.; Vaßen, Robert; Stoever, D.

doi:10.1007/s11666-007-9144-2

Cited by 167 publications

(84 citation statements)

References 15 publications

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“…On the one hand porosity values seem to be lower than those expected when compared with reported data obtained by other techniques [3,18]. This is probably due to the limitations associated to the assessment methodology by SEM, in particular for very small voids as mentioned earlier [14,18].…”

Section: Resultsmentioning

confidence: 64%

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Effect of particle size distribution of suspension feedstock on the microstructure and mechanical properties of suspension plasma spraying YSZ coatings

Carpio

Bannier

Salvador

et al. 2015

Surface and Coatings Technology

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Estimation of the length of the manuscript (the pages of the manuscript should be numbered) Number of words Please fill outPlease fill out Length of the text 1) (using "word count") 3716 Number of Tables 1 × 150 3) Total number of words: 4000 words for a contributed paper (oral and posters), 8000 words for an invited paper and plenary paper. Manuscripts exceeding these word limits will not be considered for publication in the Proceedings volume. These too long papers could be submitted to the Editor of the journal for publication as regular papers. AbstractIn this work, aqueous suspensions feedstocks with different particle size distribution from submicron-and nano-sized YSZ powders were prepared. A previous colloidal characterisation allowed concentrated suspensions (~40 wt%) to be prepared. These suspensions were then successfully deposited by suspension plasma spraying (SPS) onto stainless steel substrates at different spraying distances. Coatings were characterised in terms of microstructure and mechanical properties (hardness and elastic modulus) by nanoindentation.All coatings displayed a two-zones microstructure formed by partially molten melted areas containing nanometer or submicrometer-sized particles surrounded by fully molten melted areas. These partially molten melted areas strongly increased as standoff distance lengthened. Mechanical properties worsened with spraying distance increase.The finer the feedstock particle size the more the spraying distance effect was. A clear correlation between mechanical properties and amount of partially molten melted areas has been proved. Thus the use of a mixture of nano/submicron-sized particles as a SPS feedstock can represent a good balance between suspension processability and final coating performance.

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Section: Resultsmentioning

confidence: 64%

“…[1][2][3]. Nevertheless the properties of the resulting coatings are very dependent on the feedstock suspension properties [4,5].…”

Section: Introductionmentioning

confidence: 99%

Effect of particle size distribution of suspension feedstock on the microstructure and mechanical properties of suspension plasma spraying YSZ coatings

Carpio

Bannier

Salvador

et al. 2015

Surface and Coatings Technology

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“…3a); signicantly smaller than those from conventional thermal spraying processes (30-80 mm). 33 Good contact between splats and substrate is a prerequisite for good coating adhesion. 34 The well-molten splats in Fig.…”

Section: Coating Formation Mechanismmentioning

confidence: 99%

Wettability of hierarchically-textured ceramic coatings produced by suspension HVOF spraying

et al. 2015

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A novel but simple path for the preparation of superhydrophobic and superhydrophilic coatings has been demonstrated via a recently developed technology, namely suspension high velocity oxy-fuel spraying.Potential uses for robust superhydrophobic coatings include antifouling applications such as aeroplane wings, ship hulls, offshore wind turbine blades, or the above-deck structures on ice breaker vessels.Several fabrication techniques have been reported for preparing inorganic superhydrophobic surfaces, but existing coatings either lack the necessary robustness for engineering applications and/or their deposition methods are not suitable for industrial scale-up. In this work, the industrially established HVOF coating process was adapted to use a liquid suspension of commercially available nano-particles (titania-TiO 2 , and hexagonal boron nitride-h-BN) as feedstock to produce nanostructured suspension HVOF TiO 2 /h-BN coatings for the first time on stainless steel. Results indicate that agglomerates in the nano-feedstock can be dispersed by h-BN due to poor mutual wettability between h-BN and molten TiO 2 . It also inhibits the anatase-to-rutile transformation of TiO 2 during coating deposition by inhibiting sintering of TiO 2 in the HVOF flame. The resultant coating becomes superhydrophobic when the addition of h-BN reaches 10 wt% due to the presence of hierarchical nano-texture on the surface. The superhydrophobicity (contact angle of 163-170 ) is maintained over a long period of time (>13 months, test still ongoing) and remains stable after exposure to light and tape test. A potential route for industrial preparation of robust water-repellent coatings is therefore highlighted by the study.

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“…Suspension plasma spraying has become a promising contender for the production of high performance thermal barrier coating systems, as vertically cracked [14,15], columnar [16] or highly porous coatings [17] are possible to manufacture. Suspension plasma spraying (SPS) coatings can be produced with high levels of porosity that are not normally achievable with APS or EB-PVD coatings [18].…”

Section: Introductionmentioning

confidence: 99%

Thermal Conductivity Analysis and Lifetime Testing of Suspension Plasma-Sprayed Thermal Barrier Coatings

Curry

VanEvery²,

Snyder³

et al. 2014

Coatings

117

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Suspension plasma spraying (SPS) has become an interesting method for the production of thermal barrier coatings for gas turbine components. The development of the SPS process has led to structures with segmented vertical cracks or column-like structures that can imitate strain-tolerant air plasma spraying (APS) or electron beam physical vapor deposition (EB-PVD) coatings. Additionally, SPS coatings can have lower thermal conductivity than EB-PVD coatings, while also being easier to produce. The combination of similar or improved properties with a potential for lower production costs makes SPS of great interest to the gas turbine industry. This study compares a number of SPS thermal barrier coatings (TBCs) with vertical cracks or column-like structures with the reference of segmented APS coatings. The primary focus has been on lifetime testing of these new coating systems. Samples were tested in thermo-cyclic fatigue at temperatures of 1100 °C for 1 h cycles. Additional testing was performed to assess thermal shock performance and erosion resistance. Thermal conductivity was also assessed for samples in their as-sprayed state, and the microstructures were investigated using SEM.

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Application of Suspension Plasma Spraying (SPS) for Manufacture of Ceramic Coatings

Cited by 167 publications

References 15 publications

Effect of particle size distribution of suspension feedstock on the microstructure and mechanical properties of suspension plasma spraying YSZ coatings

Effect of particle size distribution of suspension feedstock on the microstructure and mechanical properties of suspension plasma spraying YSZ coatings

Wettability of hierarchically-textured ceramic coatings produced by suspension HVOF spraying

Thermal Conductivity Analysis and Lifetime Testing of Suspension Plasma-Sprayed Thermal Barrier Coatings

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