Highly Segmented Thermal Barrier Coatings Deposited by Suspension Plasma Spray: Effects of Spray Process on Microstructure

Xiaolong Chen, Hiroshi Honda, Seiji Kuroda, Hiroshi Araki, Hideyuki Murakami, Makoto Watanabe, Yoshio Sakka

Research output: Contribution to journalArticle

7 Citations (Scopus)

Abstract

Effects of the ceramic powder size used for suspension as well as several processing parameters in suspension plasma spraying of YSZ were investigated experimentally, aiming to fabricate highly segmented microstructures for thermal barrier coating (TBC) applications. Particle image velocimetry (PIV) was used to observe the atomization process and the velocity distribution of atomized droplets and ceramic particles travelling toward the substrates. The tested parameters included the secondary plasma gas (He versus H2), suspension injection flow rate, and substrate surface roughness. Results indicated that a plasma jet with a relatively higher content of He or H2 as the secondary plasma gas was critical to produce highly segmented YSZ TBCs with a crack density up to ~12 cracks/mm. The optimized suspension flow rate played an important role to realize coatings with a reduced porosity level and improved adhesion. An increased powder size and higher operation power level were beneficial for the formation of highly segmented coatings onto substrates with a wider range of surface roughness.

Original languageEnglish
Pages (from-to)1638-1649
Number of pages12
JournalJournal of Thermal Spray Technology
Volume25
Issue number8
DOIs
Publication statusPublished - 2016 Dec 1
Externally publishedYes

Keywords

  • segmentation cracks
  • suspension plasma spray
  • thermal barrier coating
  • yttria-stabilized zirconia (YSZ)

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Surfaces, Coatings and Films
  • Materials Chemistry

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