Influence of Process Parameters on the Aerosol Deposition (AD) of Yttria-Stabilized Zirconia Particles
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Influence of Process Parameters on the Aerosol Deposition (AD) of Yttria-Stabilized Zirconia Particles Tarini Prasad Mishra1 • Reeti Singh1 • Robert Mu¨cke1 • Ju¨rgen Malzbender2 Martin Bram1 • Olivier Guillon1,3 • Robert Vaßen1
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Submitted: 15 April 2020 / in revised form: 11 September 2020 / Accepted: 14 September 2020 ASM International 2020
Abstract Aerosol deposition (AD) is a novel deposition process for the fabrication of dense and rather thick oxide films at room temperature. The bonding of the deposited ceramic particles is based on a shock-loading consolidation, resulting from the impact of the ceramic particles on the substrate. However, the deposition mechanism is not fully understood. In addition, many technical challenges have been observed for achieving a successful deposition of the oxides with higher efficiency. In this work, the influence of different processing parameters on the properties of the deposited layer is studied. Proof of concept was done using 8 mol.% yttria-stabilized zirconia (8YSZ) powder as starting material. The window of deposition with respect to carrier gas flows for successful deposition was identified. The influence of this carrier gas flow, the substrate materials and the carrier gas species on the coating thickness, interface quality and coating microstructure was systematically investigated. The derived mechanical characteristics revealed an unexpected behavior related to a This article is part of a special topical focus in the Journal of Thermal Spray Technology on Aerosol Deposition and Kinetic Spray Processes. This issue was organized by Dr. Kentaro Shinoda, National Institute of Advanced Industrial Science and Technology (AIST); Dr. Frank Gaertner, Helmut-Schmidt University; Prof. Changhee Lee, Hanyang University; Prof. Ali Dolatabadi, Concordia University; and Dr. Scooter Johnson, Naval Research Laboratory. & Tarini Prasad Mishra [email protected] 1
Forschungszentrum Ju¨lich GmbH, Institute of Energy and Climate Research, IEK-1, 52428 Ju¨lich, Germany
2
Forschungszentrum Ju¨lich GmbH, Institute of Energy and Climate Research. IEK-2, 52428 Ju¨lich, Germany
3
Ju¨lich Aachen Research Alliance, JARA-Energy, Ju¨lich 52425, Germany
gradient microstructure. This study supports understanding of the mechanism of room-temperature impact consolidation and its effect on the mechanical properties of the deposited layer. Keywords aerosol deposition process carrier gas coating hardness room-temperature impact consolidation (RTIC) 8 mol.% Yttria-stabilized zirconia (8YSZ) coating
Introduction Coating technologies are essential to provide surface protection, decorative finishes and numerous special applications (Ref 1). Many everyday products are only rendered usable because of their surface treatments. Ceramics coatings are used in particular to improve the resistance to sharp contact, wear and erosion (Ref 2). Also, they often improve the resistance to substrate oxidation because the coating separates the substrate from direct exposure to pote
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