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Bilayer Suspension Plasma-Sprayed Thermal Barrier Coatings with Enhanced Thermal Cyclic Lifetime: Experiments and Modeling
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.ORCID iD: 0000-0002-2857-0975
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.ORCID iD: 0000-0002-4087-6467
University West, Department of Engineering Science, Research Enviroment Production Technology West. University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.ORCID iD: 0000-0001-7787-5444
2017 (English)In: Journal of thermal spray technology (Print), ISSN 1059-9630, E-ISSN 1544-1016, Vol. 26, no 6, 1038-1051 p.Article in journal (Refereed) Published
Abstract [en]

Suspension plasma spraying (SPS) has been shown as a promising process to produce porous columnar strain tolerant coatings for thermal barrier coatings (TBCs) in gas turbine engines. However, the highly porous structure is vulnerable to crack propagation, especially near the topcoat-bondcoat interface where high stresses are generated due to thermal cycling. A topcoat layer with high toughness near the topcoat-bondcoat interface could be beneficial to enhance thermal cyclic lifetime of SPS TBCs. In this work, a bilayer coating system consisting of first a dense layer near the topcoat-bondcoat interface followed by a porous columnar layer was fabricated by SPS using Yttria-stabilised zirconia suspension. The objective of this work was to investigate if the bilayer topcoat architecture could enhance the thermal cyclic lifetime of SPS TBCs through experiments and to understand the effect of the column gaps/vertical cracks and the dense layer on the generated stresses in the TBC during thermal cyclic loading through finite element modeling. The experimental results show that the bilayer TBC had significantly higher lifetime than the single-layer TBC. The modeling results show that the dense layer and vertical cracks are beneficial as they reduce the thermally induced stresses which thus increase the lifetime.

Place, publisher, year, edition, pages
SPRINGER , 2017. Vol. 26, no 6, 1038-1051 p.
Keyword [en]
bilayer coating system; finite element modeling; lifetime; suspension plasma spraying; stresses; thermal barrier coatings
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-11411DOI: 10.1007/s11666-017-0595-9ISI: 000407335200005Scopus ID: 2-s2.0-8502200231OAI: oai:DiVA.org:hv-11411DiVA: diva2:1142655
Available from: 2017-09-19 Created: 2017-09-19 Last updated: 2017-09-21Bibliographically approved

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