Effect of Thermal Treatment on the Grain Growth of Nanostructured YSZ Thermal Barrier Coating Prepared by Air Plasma Spraying

A nanostructured thermal barrier coating is prepared by air plasma spraying using the 8wt% Y_2O_3 partially stabilized zirconia nano-powder with an average grain size of 40 nm. The microstructure and phase composition of feedstock nano-powder and coating are investigated using SEM, TEM and XRD. It is found that the as-sprayed zirconia coating has an average grain size of 67 nm and mainly consistes of metastable tetragonal phase, together with some monoclinic phase and tetragonal phase. Thermal treatment results show that the grains of the nanostructured coating grow slightly below 900℃, whereas over 1000℃ the gains grow rapidly and monoclinic phase noticeably appeares.

Oxidation Performance of Ytterbium Disilicate/Silicon Environmental Barrier Coating via Optimized Air Plasma Spraying

Environmental barrier coatings (EBCs) play a critical role in mitigating the degradation of SiCf/SiC ceramic matrix composites (CMCs) in complex combustion environment, and improve the service life of thermal engine components. In this paper, by adjusting the parameters of atmospheric plasma spraying (APS), the spraying process of ytterbium disilicate (Yb2Si2O7) under a lower power has been optimized. A two-layer EBC system consisting of ytterbium disilicate and silicon is prepared on the SiCf/SiC composite substrate by using optimized technological parameters. The thermal resistance and water oxygen corrosion resistance of such two-layer EBC system are investigated. The results indicate that the current ytterbium disilicate/silicon EBC system exhibits good phase stability, excellent water vapor and oxygen corrosion resistance. However, the exposed silicon bonding layer tends to generate an excessive thermal growth oxide (TGO) layer known as SiO2, leading to an early spallation of the coating.

Effects of Heat-treatment on Crystallization and Wear Property of Plasma Sprayed Fe-based Amorphous Coatings

The Fe-based amorphous coatings were produced by air plasma spraying. The as-sprayed coatings were heat-treated at the temperature of 573, 873, and 1 023 K, respectively. The crystallization and wear behavior of the heat-treated amorphous coatings were investigated. It was found that the amorphous- nanocrystalline transformation appeared when the as-sprayed coatings were treated at 853 K. The crystallization process had completed and a coating with microcrystallines was formed when the treatment temperature reached 1 023 K. The resultant amorphous and nanocrystalline composite coatings exhibited superior wear resistance compared to crystalline coating. It is attributed to fine grain strengthening of formed nanocrystallines.

Air plasma-sprayed high-entropy (Y_(0.2)Yb_(0.2)Lu_(0.2)Eu_(0.2)Er_(0.2))_(3)Al_(5)O_(12) coating with high thermal protection performance

High-entropy rare-earth aluminate(Y_(0.2)Yb_(0.2)Lu_(0.2)Eu_(0.2)Er_(0.2))_(3)Al_(5)O_(12)(HE-RE_(3)Al_(5)O_(12))has been considered as a promising thermal protection coating(TPC)material based on its low thermal conductivity and close thermal expansion coefficient to that of Al2O3.However,such a coating has not been experimentally prepared,and its thermal protection performance has not been evaluated.To prove the feasibility of utilizing HE-RE_(3)Al_(5)O_(12) as a TPC,HE-RE_(3)Al_(5)O_(12) coating was deposited on a nickelbased superalloy for the first time using the atmospheric plasma spraying technique.The stability,surface,and cross-sectional morphologies,as well as the fracture surface of the HE-RE_(3)Al_(5)O_(12) coating were investigated,and the thermal shock resistance was evaluated using the oxyacetylene flame test.The results show that the HE-RE_(3)Al_(5)O_(12) coating can remain intact after 50 cycles at 1200℃ for 200 s,while the edge peeling phenomenon occurs after 10 cycles at 1400℃ for 200 s.This study clearly demonstrates that HE-RE_(3)Al_(5)O_(12) coating is effective for protecting the nickel-based superalloy,and the atmospheric plasma spraying is a suitable method for preparing this kind of coatings.

Tailoring sintering-resistant thermal barrier coatings by considering critical healing width of two-dimensional interlamellar pores

Large degradation in thermal insulation and strain tolerance is a main headache and a primary cause of the failure for plasma-sprayed thermal barrier coatings(TBCs)during service.One mechanism behind such degradation is the healing of interlamellar pores formed by multiple connections between edges of a pore,which significantly speeds up healing during thermal exposure.The objective of this study is to obtain sintering-resistant TBCs by tailoring the width of interlamellar pores to avoid multiple connections.Firstly,the mechanism responsible for the multiple connections was revealed.The splat surfaces before and after thermal treatments were characterized via an atomic force microscope(AFM).The roughening of the pore surface occurs during thermal exposure,along with the grain growth inside the splats.Consequently,the local surface height increases,which causes multiple connections and healing of the interlamellar pores.Secondly,critical widths of the interlamellar pores for avoiding the multiple connections during thermal exposure are established by correlating the extent of surface roughening with the growth of individual grains.The height increase of the splat surface and the growth of the grain size(D)were found to increase with the exposure temperature and duration.A relationship linking the height increase and the growth of the grain size induced by thermal exposure in plasma-sprayed ceramic splats was obtained.Finally,composite TBCs were prepared to form wide interlamellar pores in the coatings.Using this design,the increases in the thermal conductivity(λ)and the elastic modulus(E)can be prevented to a large extent.Thus,sintering-resistant TBCs that maintain high thermal insulation and strain tolerance,even afer long thermal exposure,can be created.

Microstructure modification of Y2O3 stabilized ZrO2 thermal barrier coatings by laser glazing and the effects on the hot corrosion resistance

Y2O3 stabilized ZrO2(YSZ)thermal barrier coatings(TBCs)are prone to hot corrosion by molten salts.In this study,the microstructure of atmospheric plasma spraying YSZ TBCs is modified by laser glazing in order to improve the corrosion resistance.By optimizing the laser parameters,a^18μm smooth glazed layer with some vertical cracks was produced on the coating surfaces.The as-sprayed and modified coatings were both exposed to hot corrosion tests at 700 and 1000℃for 4 h in V2O5 molten salt,and the results revealed that the modified one had improved corrosion resistance.After hot corrosion,the glazed layer kept structural integrity,with little evidence of dissolution.However,the vertical cracks in the glazed layer acted as the paths for molten salt penetration,accelerating the corrosion of the non-modified coating.Further optimization of the glazed layer is needed in the future work.

Failure Behavior of Thermal Barrier Coatings on Cylindrical Superalloy Tube Under Thermomechanical Fatigue

Failure behavior of thermal barrier coatings on cylindrical superalloy tube was investigated under thermome- chanical fatigue （TMF）. Two types of TMF tests, i.e. in phase （IP） and out of phase （OP）, were performed in the temperature range of 450-850℃. All tests were carried out under mechanical strain control at a given period of 300 s. The bond coat NiCrAIY was produced by high velocity oxygen fuel （HVOF）, and the top coat 7%Y203-ZrO2 was deposited by air plasma spraying （APS）. The testing results showed that the OP TMF life was longer than the IP TMF one under the same mechanical strain amplitude. Observations of the fractured specimens revealed that the interface damage and cracking behavior in the two phasing conditions were different. In OP loading, the top coat was cracked and detached from the bond coat while no spallation was found in the IP loading.