Suspension plasma-sprayed coatings are produced using fine-grained feedstock. This allows to control the porosity and to achieve low thermal conductivity which makes the coatings attractive as topcoats in thermal barrier coatings (TBCs). Used in gas turbine applications, TBCs are exposed to high temperature exhaust gases which lead to microstructure alterations. In order to obtain coatings with optimized thermomechanical properties, microstructure alterations like closing of pores and opening of cracks have to be taken into account. Hence, in this study, TBC topcoats consisting of 4 mol.% yttria-stabilized zirconia were heat-treated in air at 1150°C and thereafter the coating porosity was investigated using image analysis (IA) and nuclear magnetic resonance (NMR) cryoporometry. Both IA and NMR cryoporometry showed that the porosity changed as a result of the heat treatment for all investigated coatings. In fact, both techniques showed that the fine porosity decreased as a result of the heat treatment, while IA also showed an increase in the coarse porosity. When studying the coatings using scanning electron microscopy, it was noticed that finer pores and cracks disappeared and larger pores grew slightly and achieved a more distinct shape as the material seemed to become more compact.
High temperature polymer membrane fuel cells (HTPEMFCs) are promising devices for future mobile applications. To minimize phosphoric acid migration from the membranes and to reduce the total stack weight and size metallic bipolar plates are a promising alternative. So far only very few published results are available on the use of metallic bipolar plates in HTPEMFCs. During this work a single test cell was equipped with metallic endplates to investigate the possibility of using metallic bipolar plates in HTPEMFC stacks. Furthermore we tried to simulate the environments present in an HTPEMFC by furnace exposures in an attempt to develop a simplified test method for accelerated corrosion of bipolar plate materials. It was found that the performance of the HTPEM test cell decreased by about 15 µV h−1. More corrosion products were seen on the cathode side samples, whereas on the anode side sample the corrosion attack of the steel was more severe. These results were successfully replicated in simulated furnace experiments.
Suspension plasma spraying (SPS) is a new, innovative plasma spray technique using a feedstock consisting of fine powder particles suspended in a liquid. Using SPS, ceramic coatings with columnar microstructures have been produced which are used as topcoats in thermal barrier coatings. The microstructure contains a wide pore size range consisting of inter-columnar spacings, micro-pores and nano-pores. Hence, determination of total porosity and pore size distribution is a challenge. Here, x-ray microscopy (XRM) has been applied for describing the complex pore space of the coatings because of its capability to image the (local) porosity within the coating in 3D at a resolution down to 50 nm. The possibility to quantitatively segment the analyzed volume allows analysis of both open and closed porosity. For an yttria-stabilized zirconia coating with feathery microstructure, both open and closed porosity were determined and it could be revealed that 11% of the pore volumes (1.4% of the total volume) are closed pores. The analyzed volume was reconstructed to illustrate the distribution of open and closed pores in 3D. Moreover, pore widths and pore volumes were determined. The results on the complex pore space obtained by XRM are discussed in connection with other porosimetry techniques.
A large variety of coatings are used to protect structural engineering materials from corrosion, wear, and erosion, and to provide thermal insulation. In this work, yttria-stabilized zirconia coatings produced by suspension plasma spraying were investigated with respect to their microstructure and especially their porosity, as the porosity affects the thermal insulation of the underlying component. To determine porosity, pore size distribution, and pore shape, the coatings were investigated using novel advanced characterization techniques like NMR cryoporometry and X-ray microscopy. In general, the porosity is inhomogeneously distributed and the coatings showed a large variety of pore sizes ranging from a few nanometers to micrometers.
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