Review of New Developments in Suspension and Solution Precursor Thermal Spray Processes

Killinger, Andreas; Gadow, Rainer; Mauer, Georg; Guignard, Alexandre; Vaßen, Robert; Stöver, D.

doi:10.1007/s11666-011-9639-8

Cited by 167 publications

(81 citation statements)

References 91 publications

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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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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

View full text Add to dashboard Cite

show abstract

“…The droplets interact first with the outer part of the plasma region, which is colder than the plasma core. This injection method is useful for large droplet sizes which may penetrate easier into the jet [17,18,33]. The study of Michaux [34] demonstrated the formation of Ni-based cermets with YSZ by SPPS using radial injection.…”

Section: Injection Of Solution Feedstockmentioning

confidence: 99%

“…Since the beginning of 21st century, there has been rapid development in nanostructured coating deposition using the SPPS process as reflected by a number of published articles [15][16][17][18][19][20][21][22]. However, most of the accounted papers focus on the deposition of ceramic materials alone and only a few have been reported on SPPS coating deposition for cermets (ceramic-metal composite) because of the oxidation potential of the metal-ions in the solution precursor [10,15].…”

mentioning

confidence: 99%

Current Progress in Solution Precursor Plasma Spraying of Cermets: A Review

Unabia

Candidato

Pawłowski

2018

Metals

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Ceramic and metal composites, known also as cermets, may considerably improve many material properties with regards to that of initial components. Hence, cermets are frequently applied in many technological fields. Among many processes which can be employed for cermet manufacturing, thermal spraying is one of the most frequently used. Conventional plasma spraying of powders is a popular and cost-effective manufacturing process. One of its most recent innovations, called solution precursor plasma spraying (SPPS), is an emerging coating deposition method which uses homogeneously mixed solution precursors as a feedstock. The technique enables a single-step deposition avoiding the powder preparation procedures. The nanostructured coatings developed by SPPS increasingly find a place in the field of surface engineering. The present review shows the recent progress in the fabrication of cermets using SPPS. The influence of starting solution precursors, such as their chemistry, concentration, and solvents used, to the micro-structural characteristics of cermet coatings is discussed. The effect of the operational plasma spray process parameters such as solution injection mode to the deposition process and coatings' microstructure is also presented. Moreover, the advantages of the SPPS process and its drawbacks compared to the conventional powder plasma spraying process are discussed. Finally, some applications of SPPS cermet coatings are presented to understand the potential of the process.

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“…It has further been realized that, apart from the particles formed in-flight, any unpyrolyzed precursor impacting the preheated substrate is another crucial factor influencing the microstructure of the coating formed. The gradually improved understanding of the SPPS process in general has been well summarized in some excellent reviews that have periodically appeared in literature (Ref [49][50][51][52].…”

Section: Solution Precursor Sprayed Tbcmentioning

confidence: 99%

Liquid Feedstock Plasma Spraying: An Emerging Process for Advanced Thermal Barrier Coatings

et al. 2017

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Liquid feedstock plasma spraying (LFPS) involves deposition of ultrafine droplets of suspensions or solution precursors (typically ranging from nano-to submicron size) and permits production of coatings with unique microstructures that are promising for advanced thermal barrier coating (TBC) applications. This paper reviews the recent progress arising from efforts devoted to development of high-performance TBCs using the LFPS approach. Advancements in both suspension plasma spraying and solution precursor plasma spraying, which constitute the two main variants of LFPS, are presented. Results illustrating the different types of the microstructures that can be realized in LFPS through appropriate process parameter control, model-assisted assessment of influence of coating defects on thermo-mechanical properties and the complex interplay between pore coarsening, sintering and crystallite growth in governing thermal conductivity are summarized. The enhancement in functional performances/lifetime possible in LFPS TBCs with multilayered architectures and by incorporating new pyrochlore chemistries such as gadolinium zirconate, besides the conventional single 8 wt.% yttria-stabilized zirconia insulating ceramic layer, is specifically highlighted.

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Review of New Developments in Suspension and Solution Precursor Thermal Spray Processes

Cited by 167 publications

References 91 publications

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

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

Current Progress in Solution Precursor Plasma Spraying of Cermets: A Review

Liquid Feedstock Plasma Spraying: An Emerging Process for Advanced Thermal Barrier Coatings

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