Process-structure-property relations for the erosion durability of plasma spray-physical vapor deposition (PS-PVD) thermal barrier coatings

Michael P. Schmitt, Bryan J. Harder, Douglas Edward Wolfe

Research output: Contribution to journalArticle

21 Citations (Scopus)

Abstract

New thermal barrier coating (TBC) materials and microstructures are under development to increase gas turbine operating temperatures beyond the ~1200 °C threshold of standard 7 wt.% yttria stabilized zirconia (7YSZ). To deposit these advanced coatings, a new thermal spray deposition technique is used: Plasma Spray - Physical Vapor Deposition (PS-PVD). PS-PVD is capable of depositing from the vapor phase to yield strain tolerant columnar microstructures similar to Electron Beam - Physical Vapor Deposition (EB-PVD) or, alternatively, the traditional splat-like lamellar microstructure common to Air Plasma Spray (APS). This study investigates the process-structure relationships and resulting erosion response for plasma gas flow, amperage, and feed rate. It was found that in the selected design space, porosity and surface roughness vary from ~12-26% and ~5-10 μm, respectively. Erosion behavior is discussed and the mechanism is identified to be heavily dependent upon the intercolumnar spacing. The lowest erosion rates are similar to EB-PVD, while the highest erosion rates were closer to APS. This is attributed to the hybrid nature of the PS-PVD process and provides an opportunity to tailor coatings with a wide range of properties, and thus performance.

Original languageEnglish (US)
Pages (from-to)11-18
Number of pages8
JournalSurface and Coatings Technology
Volume297
DOIs
StatePublished - Jul 15 2016

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Thermal barrier coatings
Physical vapor deposition
durability
erosion
sprayers
Erosion
Durability
vapor deposition
Plasmas
coatings
Microstructure
Electron beams
microstructure
Plasma Gases
roughness
Coatings
electron beams
Yttria stabilized zirconia
Air
air

All Science Journal Classification (ASJC) codes

  • Chemistry(all)
  • Condensed Matter Physics
  • Surfaces and Interfaces
  • Surfaces, Coatings and Films
  • Materials Chemistry

Cite this

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abstract = "New thermal barrier coating (TBC) materials and microstructures are under development to increase gas turbine operating temperatures beyond the ~1200 °C threshold of standard 7 wt.{\%} yttria stabilized zirconia (7YSZ). To deposit these advanced coatings, a new thermal spray deposition technique is used: Plasma Spray - Physical Vapor Deposition (PS-PVD). PS-PVD is capable of depositing from the vapor phase to yield strain tolerant columnar microstructures similar to Electron Beam - Physical Vapor Deposition (EB-PVD) or, alternatively, the traditional splat-like lamellar microstructure common to Air Plasma Spray (APS). This study investigates the process-structure relationships and resulting erosion response for plasma gas flow, amperage, and feed rate. It was found that in the selected design space, porosity and surface roughness vary from ~12-26{\%} and ~5-10 μm, respectively. Erosion behavior is discussed and the mechanism is identified to be heavily dependent upon the intercolumnar spacing. The lowest erosion rates are similar to EB-PVD, while the highest erosion rates were closer to APS. This is attributed to the hybrid nature of the PS-PVD process and provides an opportunity to tailor coatings with a wide range of properties, and thus performance.",
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Process-structure-property relations for the erosion durability of plasma spray-physical vapor deposition (PS-PVD) thermal barrier coatings. / Schmitt, Michael P.; Harder, Bryan J.; Wolfe, Douglas Edward.

In: Surface and Coatings Technology, Vol. 297, 15.07.2016, p. 11-18.

Research output: Contribution to journalArticle

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