Process-structure-property relations for the erosion durability of plasma spray-physical vapor deposition (PS-PVD) thermal barrier coatings

Schmitt, Michael P.; Harder, Bryan J.; Wolfe, Douglas E.

doi:10.1016/j.surfcoat.2016.04.029

Cited by 60 publications

(22 citation statements)

References 34 publications

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“…This process enables the formation of columnar structures, which is one of its main advantages [15,16]. However, it is possible to control the formation process by changing the parameters, and as a result, control the coating morphology [17]. Gao et al [18] described three types of coating structure formation during the PS-PVD process: dense, columnar, and hybrid.…”

Section: Introductionmentioning

confidence: 99%

Synthesis of Gd2Zr2O7 Coatings Using the Novel Reactive PS-PVD Process

et al. 2021

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Ceramic topcoats of thermal barrier coatings (TBCs) make it possible to increase the working temperature of the hot sections of jet engines. Yttria-stabilized zirconia oxide (YSZ) is usually used to protect the turbine blades and vanes against high temperature and oxidation. It is necessary to develop new materials which can operate at higher temperatures in a highly oxidizing gas atmosphere. Re2Zr2O7-type pyrochlores are promising YSZ replacements. Usually, they are produced by mixing pure oxides in the calcination process at higher temperatures. In a recent article, the new concept of pyrochlore synthesis during the deposition process was presented. The new technology, called reactive plasma spray physical vapor deposition (reactive PS-PVD), was developed and a Gd2Zr2O7 (GZO) coating was achieved. The reactive PS-PVD process allowed for the use of a mixture of untreated ZrO2 and Gd2O3 powders as reactants, instead of the commercially available gadolinium zirconate powders used in other types of processes. The results of microstructure observations revealed a columnar microstructure in the produced ceramic layer. The phase composition indicated the presence of gadolinium zirconate. Thermal analysis showed a decrease in the thermal conductivity in the range of 700 to 1200 °C of the produced layers, as compared to the layer made of the currently used conventional YSZ.

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Section: Introductionmentioning

confidence: 99%

Synthesis of Gd2Zr2O7 Coatings Using the Novel Reactive PS-PVD Process

et al. 2021

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“…Since LZ has a lower KIC than 8YSZ, low erosion resistance of LZ in the erosion test is expected [71].…”

Section: Erosion Testmentioning

confidence: 99%

Lanthanum zirconate based thermal barrier coatings: A review

Zhang

Guo

Jung

et al. 2017

Surface and Coatings Technology

192

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This review article summarizes the latest information about the manufacturing techniques of lanthanum zirconate (La2Zr2O7, LZ) powder and La2Zr2O7 based thermal barrier coatings (TBCs). Lanthanum zirconate is a promising candidate material for TBC applications, due to its lower thermal conductivity and higher thermal stability compared to other traditional TBC systems. In this work, the physical, thermal, and mechanical properties of the powder and coatings are evaluated. The durability experiments of the TBCs in various thermal, mechanical, and corrosive conditions is also reviewed. In addition, theoretical studies on the powder and coatings properties are presented. Finally, future research directions of lanthanum zirconate as TBC applications are proposed.

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“…It also benefits from the high deposition rate of plasma spraying. Because of the very low chamber pressure in PS-PVD [10], the plasma jet may extend up to 2 m in length and 200-400 mm in diameter. However, under such pressures the momentum and heat transfer between the plasma flow and particles is reduced due to the rarefaction effect.…”

Section: Introductionmentioning

confidence: 99%

Numerical Analysis of the Interactions between Plasma Jet and Powder Particles in PS-PVD Conditions

et al. 2021

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Plasma spray-physical vapor deposition (PS-PVD) refers to a very low-pressure (~100 Pa) deposition process in which a powder is injected in a high-enthalpy plasma jet, and mostly vaporized and recondensed onto a substrate to form a coating with a specific microstructure (e.g., columnar). A key issue is the selection of the powder particle size that could be evaporated under specific spray conditions. Powder evaporation takes place, first, in the plasma torch between the injection location and nozzle exit and, then, in the deposition chamber from the nozzle exit to the substrate location. This work aims to calculate the size of the particles that can be evaporated in both stages of the process. It deals with an yttria-stabilized zirconia powder and two commercial plasma torches operated at different arc powers with gas mixtures of argon and helium or argon and hydrogen. First, it used computational fluid dynamics simulations to calculate the velocity and temperature fields of the plasma jets under very low-pressure plasma conditions. Then, it estimated the evaporation of the particles injected in both plasma jets assuming an isothermal evaporation process coupled with momentum and heat transfer plasma-particle models in a rarefied plasma. The calculations showed that, for different powers of the Ar–H2 and the Ar–He operating conditions of this study, the heat flux from the plasma jet to particles inside the torch is much higher than that transferred in the deposition chamber while the specific enthalpy transferred to particles is comparable. The argon-helium mixture is more efficient than the argon-hydrogen mixture to evaporate the particles. Particles less than 2 μm in diameter could be fully evaporated in the Ar–He plasma jet while they should be less than 1 µm in diameter in the Ar–H2 plasma jet.

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Process-structure-property relations for the erosion durability of plasma spray-physical vapor deposition (PS-PVD) thermal barrier coatings

Cited by 60 publications

References 34 publications

Synthesis of Gd2Zr2O7 Coatings Using the Novel Reactive PS-PVD Process

Synthesis of Gd2Zr2O7 Coatings Using the Novel Reactive PS-PVD Process

Lanthanum zirconate based thermal barrier coatings: A review

Numerical Analysis of the Interactions between Plasma Jet and Powder Particles in PS-PVD Conditions

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