Thermal Shock Resistance of Stabilized Zirconia/Metal Coat on Polymer Matrix Composites by Thermal Spraying Process
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JTTEE5 23:1312–1322 DOI: 10.1007/s11666-014-0144-8 1059-9630/$19.00 Ó ASM International
Thermal Shock Resistance of Stabilized Zirconia/Metal Coat on Polymer Matrix Composites by Thermal Spraying Process Ling Zhu, Wenzhi Huang, Haifeng Cheng, and Xueqiang Cao (Submitted March 3, 2014; in revised form July 6, 2014) Stabilized zirconia/metal coating systems were deposited on the polymer matrix composites by a combined thermal spray process. Effects of the thicknesses of metal layers and ceramic layer on thermal shock resistance of the coating systems were investigated. According to the results of thermal shock lifetime, the coating system consisting of 20 lm Zn and 125 lm 8YSZ exhibited the best thermal shock resistance. Based on microstructure evolution, failure modes and failure mechanism of the coating systems were proposed. The main failure modes were the formation of vertical cracks and delamination in the outlayer of substrate, and the appearance of coating spallation. The residual stress, thermal stress and oxidation of substrate near the substrate/metal layer interface were responsible for coating failure, while the oxidation of substrate near the substrate/coating interface was the dominant one.
Keywords
failure, HVOF spray, polymers, thermal shock resistance
1. Introduction In recent years, polymer matrix composites (PMCs) perform successfully in the airframes and the gas flow path of advanced turbine engines, and are used as the materials of fan blades, outlet guide vanes, nose cone spinners, core engine fairings, variable vane rings and cowl doors in the aircraft engines (Ref 1). In order to increase the thrust– weight ratio, the PMCs with lighter weight and higher strength-to-weight ratio are employed to replace the metallic parts of aerocraft. However, the further substitution of metallic parts with PMCs in the application of aero-propulsion is still limited by weak abrasion resistance, weak oxidation resistance and relatively low operation temperature (Ref 2). As reported in the research (Ref 3, 4), a typical thermal barrier coating system (TBC) consisting of a metallic bond layer and a ceramic top layer provided a temperature drop of 100–200 °C and highLing Zhu, School of Chemistry and Biological Engineering, Changsha University of Science and Technology, Changsha 410114, Hunan, P.R. China; Wenzhi Huang and Haifeng Cheng, Science and Technology on Advanced Ceramic Fibers and Composites Laboratory, National University of Defense Technology, Changsha 410073, Hunan, P.R. China; and Xueqiang Cao, School of Chemistry and Biological Engineering, Changsha University of Science and Technology, Changsha 410114, Hunan, P.R. China and State Key Laboratory of Rare Earth Resources Utilization, Changchun Institute of Applied Chemistry, Chinese Academy of Sciences, Changchun 130022, Jilin, P.R. China. Contact e-mails: [email protected] and [email protected].
1312—Volume 23(8) December 2014
temperature oxidation resistance for the materials. Some surface modification technologies, such as high velocity oxy-f
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