Residual Stress Evolution in Zirconia (Y8%) Coatings During Atmospheric Plasma Spraying for Substrates Under Rotating Ki

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Residual Stress Evolution in Zirconia (Y8%) Coatings During Atmospheric Plasma Spraying for Substrates Under Rotating Kinematic V. Lasseur1 • S. Goutier1 • V. Martinez Garcia2 • A. Denoirjean1 • E. Meillot3 G. Mariaux1 • J. Absi1 • A. Killinger2



Submitted: 14 November 2019 / in revised form: 21 May 2020  ASM International 2020

Abstract Ceramics coatings produced by atmospheric plasma spraying (APS) on steel alloys parts involve high residual stress level that can affect the coating properties and integrity. Most of the experimental studies were focused on the stress evaluation into APS-produced coatings onto static targets. However, these studies have not been extended to stresses induced on rotating samples. Indeed, the thermal background and the deposition way onto a static target is different from a rotating one, resulting in indifferent coating residual stresses. The aim of this work is to estimate and understand the real-time stress evolution from the sandblasting process to the coating formation while the substrate is fixed at a rotating support thanks to a new system developed in the laboratory. Three different sources of stresses are analyzed in this paper: stresses induced by sandblasting, substrate heating, and splat quenching followed by the cooling down of the coating/substrate composite. Resulting stresses

This article is part of a special topical focus in the Journal of Thermal Spray Technology on Advanced Residual Stress Analysis in Thermal Spray and Cold Spray Processes. This issue was organized by Dr. Vladimir Luzin, Australian Centre for Neutron Scattering; Dr. Seiji Kuroda, National Institute of Materials Science; Dr. Shuo Yin, Trinity College Dublin; and Dr. Andrew Ang, Swinburne University of Technology. & V. Lasseur [email protected] 1

Univ. Limoges, CNRS, IRCER, UMR 7315, 87000 Limoges, France

2

Univ. Stuttgart, IFKB, Allmandring 7b, 70569 Stuttgart, Germany

3

CEA-DAM, Le Ripault, 37260 Monts, France

measurements are compared with after test ones made by incremental hole drilling. Keywords atmospheric plasma spraying (APS)  residual stress  rotating kinematic  thermal barrier coating (TBC)  yttria-stabilized zirconia (YSZ)

Introduction Atmospheric plasma spraying (APS) is a widely used deposition process that allows to build ceramic or metallic thick coating by stacking of lamellas formed by crushing of molten and accelerated powder particles by a thermal plasma jet. These coatings are commonly used as thermal barriers, wear, oxidation or corrosion protection, surface reloading. (Those particles are propelled toward the substrate in order to build a deposit with adapted conditions depending on the final properties required.) Coatings lifetime is a research issue that has been proven to be affected by residual stresses (Ref 1). Sprayed coatings show internal stresses related to the deposition process history that can affect the coating integrity if the process is not well controlled (i.e., delamination effects) especially for thermal applications (Ref 2