Integrated Study of APS YSZ Coatings with Different Spray Angle
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JTTEE5 22:110–115 DOI: 10.1007/s11666-012-9841-3 1059-9630/$19.00 Ó ASM International
Integrated Study of APS YSZ Coatings with Different Spray Angle Yikai Chen, Yang Tan, Silvia Tessarini, and Sanjay Sampath (Submitted June 25, 2012; in revised form September 20, 2012) Spray parameters play an important role on the microstructure and properties of plasma-sprayed coatings. Parameters such as spray distance, plasma gas flow and current, raster speed, and spray angle all can be varied. In this paper, an integrated study to investigate the effects and influences of spray angle on properties of yttria-stabilized zirconia coatings was carried out with spray angles of 60°, 75°, and 90° (to the substrate surface). In situ coating property sensor based on beam curvature measurements was used to measure the evolving stress and elastic moduli of the resultant coatings and combined with other characterization tools for thermo-physical property and microstructure analysis, such as laser flash and scanning electron microscopy. The results indicate that the coating with 60° spray angle had the lowest thermal conductivity and more compliant structure. This study seeks to understand the mechanism for this effect and will provide important insight into parametric sensitivities on complex spray parts.
Keywords
APS, modulus, spray angle, thermal conductivity, YSZ
1. Introduction Thermal barrier coatings (TBCs) are widely used on the surfaces of high temperature components in gas turbine engines and diesel engines (Ref 1-9). The primary function of a TBC is to provide a low thermal conductivity barrier to heat transfer from the hot gas in the engine to the surface of coated alloy components (Ref 10), and this function can increase operating temperature and efficiency of the engine with life extension of components, and reduce cooling requirements (Ref 8, 10, 11). A number of ceramic coatings have been investigated as TBC materials, but yttria-stabilized zirconia (YSZ) coating is the only material widely used, owing to its low thermal conductivity, chemical and thermal stability, and relatively high coefficient of thermal expansion (Ref 3, 4, 12-16).
This article is an invited paper selected from presentations at the 2012 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Thermal Spray 2012: Proceedings of the International Thermal Spray Conference, Air, Land, Water, and the Human Body: Thermal Spray Science and Applications, Houston, Texas, USA, May 21-24, 2012, Basil R. Marple, Arvind Agarwal, Laura Filofteia-Toma, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Andre´ McDonald, Ed., ASM International, Materials Park, OH, 2012. Yikai Chen, Yang Tan, Silvia Tessarini, and Sanjay Sampath, Department of Materials Science and Engineering, Center for Thermal Spray Research (CTSR), Stony Brook University, Stony Brook, NY. Contact e-mail: [email protected].
110—Volume 22(2-3) March 2013
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