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Influence of Microstructure on Thermal Properties of Axial Suspension Plasma-Sprayed YSZ Thermal Barrier Coatings
University West, Department of Engineering Science, Division of Manufacturing Processes. (PTW)ORCID iD: 0000-0003-1897-0171
University West, Department of Engineering Science, Division of Mechanical Engineering. (PTW)ORCID iD: 0000-0003-0209-1332
University West, Department of Engineering Science, Division of Production Engineering. (PTW)ORCID iD: 0000-0002-9578-4076
University West, Department of Engineering Science, Division of Production Engineering. (PTW)ORCID iD: 0000-0001-7787-5444
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2016 (English)In: Journal of thermal spray technology (Print), ISSN 1059-9630, E-ISSN 1544-1016, Vol. 25, no 1-2, p. 202-212Article in journal (Refereed) Published
Abstract [en]

Suspension plasma spraying is a relatively new thermal spaying technique to produce advanced thermal barrier coatings (TBCs) and enables production of coatings with a variety of structures—highly dense, highly porous, segmented, or columnar. This work investigates suspension plasma-sprayed TBCs produced using axial injection with different process parameters. The influence of coating microstructure on thermal properties was of specific interest. Tests carried out included microstructural analysis, phase analysis, determination of porosity, and pore size distribution, as well as thermal diffusivity/conductivity measurements. Results showed that axial suspension plasma spraying process makes it possible to produce various columnar-type coatings under different processing conditions. Significant influence of microstructural features on thermal properties of the coatings was noted. In particular, the process parameter-dependent microstructural attributes, such as porosity, column density, and crystallite size, were shown to govern the thermal diffusivity and thermal conductivity of the coating.

Place, publisher, year, edition, pages
2016. Vol. 25, no 1-2, p. 202-212
Keywords [en]
axial injection, columnar microstructure, porosity, suspension plasma spraying, thermal conductivity, thermal diffusivity
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering; Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-8737DOI: 10.1007/s11666-015-0355-7ISI: 000374268000021Scopus ID: 2-s2.0-84953637268OAI: oai:DiVA.org:hv-8737DiVA, id: diva2:875496
Available from: 2015-12-01 Created: 2015-12-01 Last updated: 2018-05-23Bibliographically approved
In thesis
1. Microstructure and Thermal Conductivity of Liquid Feedstock Plasma Sprayed Thermal Barrier Coatings
Open this publication in new window or tab >>Microstructure and Thermal Conductivity of Liquid Feedstock Plasma Sprayed Thermal Barrier Coatings
2016 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Thermal barrier coating (TBC) systems are widely used on gas turbine components to provide thermal insulation and oxidation protection. TBCs, incombination with advanced cooling, can enable the gas turbine to operate at significantly higher temperatures even above the melting temperature of the metallic materials. There is a permanent need mainly of environmental reasons to increase the combustion turbine temperature, hence new TBC solutions are needed.By using a liquid feedstock in thermal spraying, new types of TBCs can be produced. Suspension plasma/flame or solution precursor plasma spraying are examples of techniques that can be utilized for liquid feedstock thermal spraying.This approach of using suspension and solution feedstock, which is an alternative to the conventional solid powder feed stock spraying, is gaining increasing research interest, since it has been shown to be capable of producing coatings with superior coating performance.The objective of this research work was to explore relationships between process parameters, coating microstructure, thermal diffusivity and thermal conductivity in liquid feedstock thermal sprayed TBCs. A further aim was to utilize this knowledge to produce a TBC with lower thermal diffusivity and lower thermal conductivity compared to state-of-the-art in industry today, i.e. solid feed stock plasma spraying. Different spraying techniques, suspension high velocity oxy fuel,solution precursor plasma and suspension plasma spraying (with axial and radialfeeding) were explored and compared with solid feedstock plasma spraying.A variety of microstructures, such as highly porous, vertically cracked and columnar, were obtained. It was shown that there are strong relationships between the microstructures and the thermal properties of the coatings.Specifically axial suspension plasma spraying was shown as a very promising technique to produce various microstructures as well as low thermal diffusivity and low thermal conductivity coatings.

Place, publisher, year, edition, pages
Trollhättan: University West, 2016. p. 58
Series
Licentiate Thesis: University West ; 9
Keywords
Microstructure, Thermal Barrier Coating; Axial Injection; Suspension Plasma Spraying; Suspension High Velocity Oxy Fuel Spraying; Solution Precursor Plasma Spraying; Porosity; Thermal Diffusivity; Thermal Conductivity
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
urn:nbn:se:hv:diva-9061 (URN)978-91-87531-18-7 (ISBN)978-91-87531-19-4 (ISBN)
Opponent
Supervisors
Available from: 2016-02-11 Created: 2016-02-10 Last updated: 2016-02-12Bibliographically approved
2. Design of Suspension Plasma Sprayed Thermal Barrier Coatings
Open this publication in new window or tab >>Design of Suspension Plasma Sprayed Thermal Barrier Coatings
2018 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Thermal barrier coatings (TBCs) are widely used on gas turbine components to provide thermal insulation, which in combination with advanced cooling, can enable the gas turbine to operate at significantly higher temperatures even above the melting temperature of the metallic components. There is a permanent need,mainly due to environmental reasons, to increase the combustion temperature inturbines, hence new TBC solutions are needed. By using a liquid feedstock in thermal spraying, new types of TBCs can be produced. Suspension plasma/flame or solution precursor plasma spraying are examples of techniques that can be utilized for liquid feedstock thermal spraying. This approach of using suspension and solution feedstock, which is an alternative to the conventional solid powder feedstock spraying, is gaining increasing research interest since it has been shown to be capable of producing coatings withsuperior performance. The objective of this research work was to identify relationships between process parameters, coating microstructure, thermal conductivity and lifetime in suspension plasma sprayed TBCs. A further objective was to utilize these relationships to enable tailoring of the TBC microstructure for superior performance compared to state-of-the-art TBC used in industry today, i.e. solid feedstock plasma sprayed TBCs. Different spraying techniques, namely suspension high velocity oxy fuel, solution precursor plasma and suspension plasma spraying (with axial and radial feeding) were explored and compared to solid feedstock plasma spraying. A variety of microstructures, such as highly porous, vertically cracked and columnar, were produced and investigated. It was shown that there are strong relationships between microstructure, thermo-mechanical properties and performance of the coatings. Specifically, axial suspension plasma spraying wasshown as a very promising technique to produce various microstructures as wellas highly durable coatings. Based on the experimental results, a tailored columnar microstructure design for a superior TBC performance is also proposed.

Place, publisher, year, edition, pages
Trollhättan: University West, 2018. p. 96
Series
PhD Thesis: University West ; 20
Keywords
Microstructure; Thermal Barrier Coatings; Axial Injection; Suspension Plasma Spraying; Porosity; Thermal Conductivity; Fracture Toughness; Lifetime
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology; ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-12336 (URN)978-91-87531-92-7 (ISBN)978-91-87531-91-0 (ISBN)
Public defence
2018-06-15, F104, University West, Trollhättan, 10:15 (English)
Opponent
Supervisors
Available from: 2018-05-25 Created: 2018-05-23 Last updated: 2018-05-25

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Ganvir, AshishCurry, NicholasMarkocsan, NicolaieNylén, PerJoshi, Shrikant

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