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Performance of Atmospheric Plasma-Sprayed Thermal Barrier Coatings on Additively Manufactured Super Alloy Substrates
University West, Department of Engineering Science, Division of mechanical engineering. (KAMPT)ORCID iD: 0000-0003-4141-4886
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. University West, Department of Engineering Science, Division of mechanical engineering.ORCID iD: 0000-0003-1732-6544
Siemens Energy AB, Finspang (SWE).
Hoganas AB, Hoganas (SWE).
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2024 (English)In: Coatings, ISSN 2079-6412, Vol. 14, no 5, article id 626Article in journal (Refereed) Published
Abstract [en]

This work represents a preliminary study of atmospheric plasma-sprayed (APS) YttriaStabilized Zirconia (YSZ)-based thermal barrier coatings (TBCs) deposited on forged and additivemanufactured (AM) HAYNES®282® (H282) superalloy substrates. The effect of different feedstockmorphologies and spray gun designs with radial and axial injection on APS-deposited YSZ layercharacteristics such as microstructure, porosity content, roughness, etc., has been investigated. Theperformance of TBCs in terms of thermal cycling fatigue (TCF) lifetime and erosion behaviour werealso comprehensively investigated. In view of the high surface roughness of as-built AM surfacescompared to forged substrates, two different types of NiCoCrAlY bond coats were examined: oneinvolved high-velocity air fuel (HVAF) spraying of a finer powder, and the other involved APSdeposition of a coarser feedstock. Despite the process and feedstock differences, the above two routesyielded comparable bond coat surface roughness on both types of substrates. Variation in porositylevel in the APS topcoat was observed when deposited using different YSZ feedstock powdersemploying axial or radial injection. However, the resultant TBCs on AM-derived substrates wereobserved to possess similar microstructures and functional properties as TBCs deposited on reference(forged) substrates for any given YSZ deposition process and feedstock. 

Place, publisher, year, edition, pages
MDPI, 2024. Vol. 14, no 5, article id 626
Keywords [en]
additive manufacturing; thermal barrier coatings; superalloys; microstructural characterization; thermal cycling; erosion testing
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-21648DOI: 10.3390/coatings14050626OAI: oai:DiVA.org:hv-21648DiVA, id: diva2:1860651
Funder
Knowledge Foundation, 20200007
Note

CC-BY 4.0

Financial support from the Knowledge Foundation, Sweden, for the project Engineeredcoatings for next generation gas turbine components (EcoGATE) (Dnr. 2020007), as a part of whichthe present work was carried out, is gratefully acknowledged

Available from: 2024-05-24 Created: 2024-05-24 Last updated: 2024-05-24

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Bellippady, MadhuraBjörklund, StefanJoshi, Shrikant V.Markocsan, Nicolaie

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