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Characterization of Thermal Barrier Coatings Produced by Various Thermal Spray Techniques Using Solid Powder, Suspension, and Solution Precursor Feedstock Material
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 Manufacturing Processes. (PTW)ORCID iD: 0000-0003-0209-1332
University West, Department of Engineering Science, Division of Manufacturing Processes. (PTW)ORCID iD: 0000-0002-9578-4076
International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI), 500005 Hyderabad, India.
2016 (English)In: International Journal of Applied CeramicTechnology, ISSN 1744-7402, Vol. 13, no 2, 324-332 p.Article in journal (Refereed) Published
Abstract [en]

Use of a liquid feedstock in thermal spraying (an alternative to the conventional solid powder feedstock) is receiving an increasing level of interest due to its capability to produce the advanced submicrometer/nanostructured coatings. Suspension plasma spraying (SPS) and solution precursor plasma spraying (SPPS) are those advanced thermal spraying techniques which help to feed this liquid feedstock. These techniques have shown to produce better performance thermal barrier coatings (TBCs) than conventional thermal spraying. In this work, a comparative study was performed between SPS- and SPPS-sprayed TBCs which then were also compared with the conventional atmospheric plasma-sprayed (APS) TBCs. Experimental characterization included SEM, porosity analysis using weight difference by water infiltration, thermal conductivity measurements using laser flash analysis, and lifetime assessment using thermo-cyclic fatigue test. It was concluded that SPS coatings can produce a microstructure with columnar type features (intermediary between the columnar and vertically cracked microstructure), whereas SPPS can produce vertically cracked microstructure. It was also shown that SPS coatings with particle size in suspension (D50) <3 μm were highly porous with lower thermal conductivity than SPPS and APS coatings. Furthermore, SPS coatings have also shown a relatively better thermal cyclic fatigue lifetime than SPPS.

Place, publisher, year, edition, pages
Wiley-Blackwell, 2016. Vol. 13, no 2, 324-332 p.
Keyword [en]
Thermal spraying, coating, spray techniques
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology; ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-8636DOI: 10.1111/ijac.12472ISI: 000372037300017Scopus ID: 2-s2.0-84960358653OAI: oai:DiVA.org:hv-8636DiVA: diva2:868573
Note

Article first published online:11 September 2015

Available from: 2015-11-11 Created: 2015-11-11 Last updated: 2016-12-16Bibliographically 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)
Opponent
Supervisors
Available from: 2016-02-11 Created: 2016-02-10 Last updated: 2016-02-12Bibliographically approved

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