Experimental visualization of microstructure evolution during suspension plasma spraying of thermal barrier coatings

Ganvir, Ashish; Calinas, R.; Markocsan, Nicolaie; Curry, Nicholas; Joshi, Shrikant V.

doi:10.1016/j.jeurceramsoc.2018.09.023

Cited by 61 publications

(62 citation statements)

References 42 publications

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“…It was observed that the center and bottom of the substrate had a higher deposition, since the coatings were thicker at those locations. The center of the deposition also presented denser coatings, which is in accordance with the work carried out by Ganvir et al [19].…”

Section: Discussionsupporting

confidence: 92%

“…Some of those conclusions showed that coating microstructure and performance are related to the suspension characteristics [18]. Ganvir et al [19] studied the evolution of the coating microstructure during spray. This work showed the importance of suspension characteristics, such as surface tension, density and viscosity, on the resulting coating microstructure.…”

Section: Introductionmentioning

confidence: 99%

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Influence of Substrate Shape and Roughness on Coating Microstructure in Suspension Plasma Spray

Caio

Moreau

2019

Coatings

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This study investigated the influence of the substrate shape and roughness on the microstructure of suspension plasma spray (SPS) coatings. For this purpose, an yttria-stabilized zirconia (YSZ) suspension was sprayed on flat and curved stainless-steel substrates by SPS. The suspension was composed of 20 wt.% YSZ particles in ethanol. After spraying, the morphology of the coatings was characterized by scanning electron microscopy (SEM). The results showed that the substrate shape influences the amount of coating material deposited and microstructural features of the coating. The amount of coating material deposited was seen to decrease as the radius of curvature decreased. Finally, the roughness was found to influence the formation of columnar structure.

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Section: Discussionsupporting

confidence: 92%

Section: Introductionmentioning

confidence: 99%

Influence of Substrate Shape and Roughness on Coating Microstructure in Suspension Plasma Spray

Caio

Moreau

2019

Coatings

View full text Add to dashboard Cite

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“…On the other hand, the particles in suspension C2 are roughly 2-3 times larger, mainly presenting angular/faceted shapes. As all spray parameters are almost identical for all suspensions and as their rheological properties do not correlate well with the observed microstructures, one can speculate that the different observed structures are linked with the actual 100µm 100µm 100µm 100µm As seen in Figure 9, the microstructural changes that were observed with the different suspensions do not correlate in a straightforward manner with the different viscosities and surface tensions of the investigated suspensions in opposition to the results that were observed with the radial injection ( Figure 8) and the literature using Axial III torch [22]. In the axial injection torch, the suspension undergoes two successive atomization steps.…”

Section: Coatings Microstructuresmentioning

confidence: 67%

A Comparative Study of YSZ Suspensions and Coatings

et al. 2019

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The demand for suspensions that are used in thermal spray processes is expanding from research labs using the lab-prepared suspensions toward actual coating production in different industrial sectors. Industrial applications dictate the reduced production time and effort, which may in turn justify the development of the market for ready-to-use commercial suspensions. To this end, some of the powder suppliers have already taken steps forward by introducing, to the market, suspensions of some of the most used materials, such as yttria-stabilized zirconia (YSZ), alumina, and titania. However, there is a need to compare the suspension characteristics over time and the resultant coatings when using these suspensions when compared with the freshly prepared homemade suspensions. In this work, such a comparison is done using YSZ suspensions of the sub-micron to a few micron powders. In addition, some changes in the suspensions’ formula were performed as a tool to vary the coatings’ microstructures in a more predictable way, without any variation of the spray parameters. The coatings were generated while using both radial and axial injection of the suspensions into Oerlikon-Metco 3MB and Mettech Axial III plasma spray torches, respectively. A clear effect of suspension viscosity on the coating microstructure was observed using the 3MB torch with a radial injection of suspension (i.e., cross flow atomization). However, the viscosity role was not dominant when using the Axial III torch with an axial feed injection system (i.e., coaxial flow atomization).

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“…Prior to the coating deposition, the substrates were grit-blasted using Alumina grit, resulting in surface roughness of R a 3-4 µm. The process parameters used in this work, based on extensive prior experimentation conducted by our group in depositing 8YSZ coatings for TBC (Thermal Barrier Coating) applications using SPS [6,15], are tabulated in Table 1. It is important to point out that the Mettech Axial III plasma torch consists of three electrodes.…”

Section: Experimental Workmentioning

confidence: 99%

A Facile Approach to Deposit Graphenaceous Composite Coatings by Suspension Plasma Spraying

et al. 2019

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This paper demonstrates, for the first time ever, the deposition of graphenaceous composite coatings using an easy, yet robust, suspension plasma spraying (SPS) process. As a case study, a composite coating comprising 8 wt.% of yttria-stabilized-zirconia (8YSZ) and reinforced with graphene oxide (GO) was deposited on a steel substrate. The coatings were sprayed using an 8YSZ-GO mixed suspension with varied plasma spray parameters. Establishing the possibility of retaining the graphene in a ceramic matrix using SPS was of specific interest. Electron microscopy and Raman spectroscopy confirmed the presence of graphenaceous material distributed throughout the coating in the 8YSZ matrix. The experimental results discussed in this work confirm that SPS is an immensely attractive pathway to incorporate a graphenaceous material into virtually any matrix material and can potentially have major implications in enabling the deposition of large-area graphene-containing coatings for diverse functional applications.

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Experimental visualization of microstructure evolution during suspension plasma spraying of thermal barrier coatings

Cited by 61 publications

References 42 publications

Influence of Substrate Shape and Roughness on Coating Microstructure in Suspension Plasma Spray

Influence of Substrate Shape and Roughness on Coating Microstructure in Suspension Plasma Spray

A Comparative Study of YSZ Suspensions and Coatings

A Facile Approach to Deposit Graphenaceous Composite Coatings by Suspension Plasma Spraying

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