Microstructures and Thermal Cycling Properties of Thermal Barrier Coatings Deposited by Hybrid Water-Stabilized Plasma Torch

Hybrid water-stabilized plasma (WSP-H) torches provide high-enthalpy plasma which may be utilized for high-throughput and yet economical spraying of coatings from powders, suspensions, and solutions. It was previously demonstrated that microstructures and functional properties of the WSP-H coatings...

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Bibliographic Details
Published in:Journal of thermal spray technology 2020-02, Vol.29 (3), p.444-461
Main Authors: Musalek, Radek, Tesar, Tomas, Medricky, Jan, Lukac, Frantisek, Chraska, Tomas, Gupta, Mohit
Format: Article
Language:English
Subjects:
Analytical Chemistry
Characterization and Evaluation of Materials
Chemistry and Materials Science
coatings
Corrosion and Coatings
Machines
Manufacturing
Manufacturing and materials engineering
Materials Science
Microstructures
Peer Reviewed
plasma
Processes
Production Technology
Produktions- och materialteknik
Produktionsteknik
Surfaces and Interfaces
Thin Films
Tribology
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Summary:Hybrid water-stabilized plasma (WSP-H) torches provide high-enthalpy plasma which may be utilized for high-throughput and yet economical spraying of coatings from powders, suspensions, and solutions. It was previously demonstrated that microstructures and functional properties of the WSP-H coatings may be tailored to a wide extent for new applications, namely those requiring high coating thickness and/or coating of large components. In this study, applicability potential of WSP-H technology for spraying of novel thermal barrier coatings (TBCs) is demonstrated. WSP-H technology was used for spraying of yttria-stabilized zirconia (YSZ) top-coats from powder, suspension, and solution. Yttria content in the top-coat feedstock was 7-8 wt.%. In addition, gadolinium zirconate (Gd 2 Zr 2 O 7 -GZO) was sprayed from suspension for comparison. NiCrAlY bond-coat was also deposited by WSP-H, and Hastelloy-X alloy was used as substrate material. Microstructure, phase composition, and endurance of the deposited coatings in thermal cycling fatigue (TCF) test and during high-temperature short-term annealing were evaluated. All coatings showed excellent high-temperature stability and TCF resistance withstanding more than 650 cycles, surpassing some of the currently commercially used TBCs. Lifetime of the TBC with columnar top-coat deposited from YSZ suspension exceeded even more than 900 cycles.
ISSN:1059-9630
1544-1016
1544-1016
DOI:10.1007/s11666-020-00990-2