Low-pressure plasma-induced physical vapor deposition of advanced thermal barrier coatings: Microstructures, modelling and mechanisms

Liu, S.-H.; Trelles, Juan Pablo; Murphy, Anthony B.; He, Wenting; Shi, Jiancheng; Li, S.; Li, C.-J.; Guo, Hongbo

doi:10.1016/j.mtphys.2021.100481

Cited by 26 publications

(8 citation statements)

References 303 publications

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“…Until now, in the aerospace industry, ZrO 2 × 8Y 2 O 3 oxide powder with a smaller average particle diameter of D 50 = 10-12 µm (Metco-6700) has been used mainly in PS-PVD processes [33]. The results show that it is possible to deposit a ceramic coating with the radial powder feed method in the plasma stream (using an A60 single-electrode plasma torch) using a powder with small particles, Metco-6700.…”

Section: Thickness and Porosity Of Ceramic Coatingsmentioning

confidence: 99%

Influence of air plasma spraying process parameters on the thermal barrier coating deposited with micro- and nanopowders

Kubaszek

Góral

Pędrak

2022

Materials Science-Poland

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This study investigates the optimal conditions to deposit a thermal barrier coating using micro- and nanopowders in the air plasma spraying (APS) process. The influence of the APS process parameters on the thickness, porosity and hardness of the yttria-stabilized zirconia (YSZ; ZrO2 × 8Y2O3) coatings deposited with a single-electrode plasma gun was determined. The temperature and velocity of melted particles were determined by the DPV diagnostic system to decrease the number of experimental processes. The current and H2 flow rate were changed in this research. Metco-6700 YSZ micropowder has already been used in plasma spray physical vapor deposition. The results of this study suggest the possibility of using it for APS. The particles of this powder are characterized by high temperature (2,700°C–2,900°C) and high speed (>380 m/s). The highest thickness of the coating was obtained with 6 NLPM (normal liter per minute) H2 flow and 800 A current. Difficulties were observed with the feeding of the powder particles at higher H2 flow. The results showed that using APS, deposition of Metco-6609, a nanopowder normally used in suspension plasma spraying, is possible. In this research, this powder was fed using a carrier gas. The coatings were around 40 μm thick and had high porosity. The lowest porosity of the coating was obtained at a current of 600 A and H2 flow rate of 12 NLPM. In the coatings, unmelted spherical particles were also visible.

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Section: Thickness and Porosity Of Ceramic Coatingsmentioning

confidence: 99%

Influence of air plasma spraying process parameters on the thermal barrier coating deposited with micro- and nanopowders

Kubaszek

Góral

Pędrak

2022

Materials Science-Poland

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“…Usually, dense ceramic EBCs, which exhibit a columnar microstructure, are synthesized via electron beam-physical vapor deposition (EB-PVD), and Si is used as a bond coat (BC) to increase the bonding strength of the EBCs. [31][32][33] Ceramic TBCs are synthesized by air plasma spraying (APS) and they display lamellar microstructure. [34][35][36][37] EB-PVD coatings typically display higher relative densities than APS coatings.…”

Section: Introductionmentioning

confidence: 99%

“…Similarities can be observed in the microstructures of EBCs and TBCs, schematically detailed in Figure 3(a) and (b), respectively. Usually, dense ceramic EBCs, which exhibit a columnar microstructure, are synthesized via electron beam‐physical vapor deposition (EB‐PVD), and Si is used as a bond coat (BC) to increase the bonding strength of the EBCs 31–33 . Ceramic TBCs are synthesized by air plasma spraying (APS) and they display lamellar microstructure 34–37 .…”

Section: Introductionmentioning

confidence: 99%

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Ferroelastic rare‐earth tantalates for multifunctional thermal/environmental barrier coatings: A perspective

Chen,

Wang,

Zhang

et al. 2023

J Am Ceram Soc.

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This perspective outlines the research directions of ferroelastic rare‐earth (RE) tantalates (RETaO4), which have been studied as multifunctional thermal/environmental barrier coatings (T/EBCs) with working temperatures above 1600°C. Ferroelastic RETaO4 ceramics exhibit several distinct features, including the reversible second‐order ferroelastic phase transition, high toughness, low thermal conductivity, low oxygen ion conductivity, and adjustable thermal expansion coefficients. This perspective provides a concise summary of the research progress on tantalate coatings synthesized via air plasma spraying and electron beam physical vapor deposition. The service performance of tantalate coatings is typically evaluated through thermal fatigue and shock measurements. Uncovering the failure mechanisms and understanding influencing factors are key aspects for future studies. In this regard, establishing the synthesis‐structure‐property relationship of RETaO4 coatings is essential. This brief perspective can serve as a guide for future work on RETaO4 coatings and further advancements in their applications across various fields, including aviation engines and gas turbines.This article is protected by copyright. All rights reserved

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“…In order to assess and analyze recent review articles in this area, a Scopus search was conducted in April 2023 for the specific time frame of 2018–2023. This search resulted in 165 review articles on ceramic additive manufacturing or some subset of that topic 1,3–166 . Figure 1 shows a graphical representation of the number of review articles separated into five focus areas.…”

Section: Introductionmentioning

confidence: 99%

Future directions in ceramic additive manufacturing: Fiber reinforcements and artificial intelligence

Rueschhoff,

Baldwin,

Hardin

et al. 2023

J Am Ceram Soc.

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Research in the field of ceramic additive manufacturing (AM) has been rapidly accelerating, resulting in hundreds of publications and review articles in recent years. While strides have been made in forming near‐net and complex‐shaped ceramic components, challenges remain that inhibit more widespread implementation. In this perspective, we provide a meta‐analysis of recent review articles and highlight a deficiency in two areas of promising future directions to address remaining challenges. The first is incorporation of fiber reinforcements in printed parts to overcome the challenges of poor mechanical performance of monolithic ceramics. Recent work in the area has shown promise incorporating discrete fiber reinforcements as an easier use case given existing equipment limitations, but continuous fibers are needed to reach full toughness potential. Here, we overview some options and future directions bases on success in polymer composites. Second, artificial intelligence (AI) approaches, including machine learning (ML), are suggested in order to accelerate feedstock development and process optimization. While there has been very limited work to date in utilizing AI/ML techniques for ceramic AM, again inspiration and lessons learned are drawn from the polymer AM community.

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Low-pressure plasma-induced physical vapor deposition of advanced thermal barrier coatings: Microstructures, modelling and mechanisms

Cited by 26 publications

References 303 publications

Influence of air plasma spraying process parameters on the thermal barrier coating deposited with micro- and nanopowders

Influence of air plasma spraying process parameters on the thermal barrier coating deposited with micro- and nanopowders

Ferroelastic rare‐earth tantalates for multifunctional thermal/environmental barrier coatings: A perspective

Future directions in ceramic additive manufacturing: Fiber reinforcements and artificial intelligence

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