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Characterization of Microstructure and Thermal Properties of YSZ Coatings Obtained by Axial Suspension Plasma Spraying (ASPS)
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 Manufacturing Processes. (PTW)ORCID iD: 0000-0003-1181-0415
University West, Department of Engineering Science, Division of Manufacturing Processes. (PTW)ORCID iD: 0000-0002-9578-4076
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2015 (English)In: Journal of thermal spray technology (Print), ISSN 1059-9630, E-ISSN 1544-1016, Vol. 24, no 7, 1195-1204 p.Article in journal (Refereed) Published
Abstract [en]

The paper aims at demonstrating various microstructures which can be obtained using the suspension spraying technique and their respective significance in enhancing the thermal insulation property of a thermal barrier coating. Three different types of coating microstructures are discussed which were produced by the Axial Suspension Plasma Spraying. Detailed characterization of coatings was then performed. Optical and scanning electron microscopy were utilized for microstructure evaluations; x-ray diffraction for phase analysis; water impregnation, image analysis, and mercury intrusion porosimetry for porosity analysis, and laser flash analysis for thermal diffusivity measurements were used. The results showed that Axial Suspension Plasma Spraying can generate vertically cracked, porous, and feathery columnar-type microstructures. Pore size distribution was found in micron, submicron, and nanometer range. Higher overall porosity, the lower density of vertical cracks or inter-column spacing, and higher inter-pass porosity favored thermal insulation property of the coating. Significant increase in thermal diffusivity and conductivity was found at higher temperature, which is believed to be due to the pore rearrangement (sintering and pore coarsening). Thermal conductivity values for these coatings were also compared with electron beam physical vapor deposition (EBPVD) thermal barrier coatings from the literature and found to be much lower. © 2015 ASM International

Place, publisher, year, edition, pages
2015. Vol. 24, no 7, 1195-1204 p.
Keyword [en]
Coatings; Cracks; Diffusion; Diffusion barriers; Microstructure; Physical vapor deposition; Plasma jets; Plasma spraying; Pore size; Porosity; Scanning electron microscopy; Sintering; Thermal conductivity; Thermal diffusivity; Thermal insulation; Thermal spraying; X ray diffraction; Yttria stabilized zirconia, Axial injections; Columnar microstructures; Nanometer pores; Suspension plasma spraying; Vertical crack, Thermal barrier coatings
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering; Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-7886DOI: 10.1007/s11666-015-0263-xISI: 000363038600008Scopus ID: 2-s2.0-8494427946OAI: oai:DiVA.org:hv-7886DiVA: diva2:845768
Available from: 2015-08-13 Created: 2015-08-12 Last updated: 2017-12-04Bibliographically 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. 58 p.
Series
Licentiate Thesis: University West, 9
Keyword
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)
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Supervisors
Available from: 2016-02-11 Created: 2016-02-10 Last updated: 2016-02-12Bibliographically approved

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Ganvir, AshishCurry, NicholasBjörklund, StefanMarkocsan, NicolaieNylén, Per

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