Solid particle erosion of thermal spray and physical vapour deposition thermal barrier coatings

Cernuschi, F.; Lorenzoni, L.; Capelli, S.; Guardamagna, C.; Karger, M.; Vaßen, Robert; Niessen, Konstantin von; Markocsan, Nicolaie; Menuey, Justine; Giolli, C.

doi:10.1016/j.wear.2011.06.013

Cited by 99 publications

(48 citation statements)

References 32 publications

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“…The microstructure of the coating A3 suggests it to be the most porous of the SPS coatings investigated here; thus, it is feasible that a denser SPS coating could have an erosion rate on par with a DVC coating. Cernuschi et al [30] conducted a more detailed study comparing DVC structured APS coatings with EB-PVD coatings. Their work suggests that the erosion rates of EB-PVD and DVC structures are similar.…”

Section: Erosion Test Resultsmentioning

confidence: 99%

Thermal Conductivity Analysis and Lifetime Testing of Suspension Plasma-Sprayed Thermal Barrier Coatings

Curry

VanEvery²,

Snyder³

et al. 2014

Coatings

117

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Suspension plasma spraying (SPS) has become an interesting method for the production of thermal barrier coatings for gas turbine components. The development of the SPS process has led to structures with segmented vertical cracks or column-like structures that can imitate strain-tolerant air plasma spraying (APS) or electron beam physical vapor deposition (EB-PVD) coatings. Additionally, SPS coatings can have lower thermal conductivity than EB-PVD coatings, while also being easier to produce. The combination of similar or improved properties with a potential for lower production costs makes SPS of great interest to the gas turbine industry. This study compares a number of SPS thermal barrier coatings (TBCs) with vertical cracks or column-like structures with the reference of segmented APS coatings. The primary focus has been on lifetime testing of these new coating systems. Samples were tested in thermo-cyclic fatigue at temperatures of 1100 °C for 1 h cycles. Additional testing was performed to assess thermal shock performance and erosion resistance. Thermal conductivity was also assessed for samples in their as-sprayed state, and the microstructures were investigated using SEM.

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Section: Erosion Test Resultsmentioning

confidence: 99%

Thermal Conductivity Analysis and Lifetime Testing of Suspension Plasma-Sprayed Thermal Barrier Coatings

Curry

VanEvery²,

Snyder³

et al. 2014

Coatings

117

View full text Add to dashboard Cite

show abstract

“…To understand the erosion mechanism for PS-PVD it is first helpful to examine what is known for EB-PVD and APS erosion as these mechanisms have been heavily covered in the literature [18,28,[30][31][32][33][34] while erosion of PS-PVD has seen minimal investigation [20,35]. The velocities and particle sizes used in this study fit into the Mode I regime as described by…”

Section: Erosion Mechanismmentioning

confidence: 99%

“…For instance, the characteristic columnar microstructure of Electron Beam -Physical Vapor Deposition (EB-PVD) typically offers an order of magnitude improvement in erosion durability compared to a standard lamellar Air Plasma Spray (APS) coating [18]. Recent work has investigated methods to improve the durability of APS coatings via dense vertical cracking and deposition from small particle suspensions or precursor solutions [19,20]. The common factor in each of these methods is the formation of a vertically oriented porosity that inhibits lateral cracking and promotes strain tolerance, yielding erosion rates approaching EB-PVD.…”

Section: Introductionmentioning

confidence: 99%

Process-structure-property relations for the erosion durability of plasma spray-physical vapor deposition (PS-PVD) thermal barrier coatings

Schmitt

Harder

Wolfe

2016

Surface and Coatings Technology

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New thermal barrier coating (TBC) materials and microstructures are under development to increase gas turbine operating temperatures beyond the ~1200°C threshold of standard 7 wt. % yttria stabilized zirconia (7YSZ). To deposit these advanced coatings, a new thermal spray deposition technique is used: Plasma Spray -Physical Vapor Deposition (PS-PVD). PS-PVD is capable of depositing from the vapor phase to yield strain tolerant columnar microstructures similar to Electron Beam -Physical Vapor Deposition (EB-PVD) or, alternatively, the traditional splat-like lamellar microstructure common to Air Plasma Spray (APS). This study investigates the process-structure relationships and resulting erosion response for plasma gas flow, amperage, and feed rate. It was found that in the selected design space, porosity and surface roughness vary © 2016. This manuscript version is made available under the Elsevier user license http://www.elsevier.com/open-access/userlicense/1.0/ from ~12-26% and ~5-10 µm, respectively. Erosion behavior is discussed and the mechanism is identified to be heavily dependent upon the intercolumnar spacing. The lowest erosion rates are similar to EB-PVD, while the highest erosion rates were closer to APS. This is attributed to the hybrid nature of the PS-PVD process and provides an opportunity to tailor coatings with a wide range of properties, and thus performance.

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“…A number of researchers have also studied the solid particle erosion wear of plasma sprayed traditional ceramic coatings. [16][17][18][19][20][21][22][23][24][25] Branco et al 16 examined solid particle erosion of zirconia and alumina based ceramic coatings with different levels of porosity and concluded that there was a strong relationship between erosion rate and porosity. Westergård et al 20 studied the influence of different spraying conditions on the erosion resistance of plasma sprayed alumina coatings.…”

Section: Introductionmentioning

confidence: 99%

Solid Particle Erosion Behaviour of Plasma-Sprayed Conventional and Nanostructured Al₂O₃-13 wt% TiO₂Ceramic Coatings

Wang

Tian

Wang

et al. 2015

Transactions of the Indian Ceramic Society

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In this study, conventional and nanostructured Al 2 O 3 -13 wt% TiO 2 coatings were fabricated by plasma spraying. The microstructural characteristics, bonding strength and solid particle erosion behaviours of the two types of coatings were compared. Results indicated that the traditional coating has a typical laminated structure. The nanostructured coating exhibited a bimodal microstructure consisting of fully melted regions and partially melted regions. The bonding strength and erosion wear resistance of the nanostructured coating were considerably better than those of the conventional one due to compact microstructure and nanoparticles of partially melted regions. Erosion failure analysis showed that the conventional coating was dominated by brittle erosion, whereas the nanostructured coating was dominated by brittle erosion as well as some ductile erosion.[Keywords: Plasma spraying, Nanostructured coatings, Al 2 O 3 -13 wt% TiO 2 , Solid particle erosion] Trans. Ind. Ceram. Soc., vol. 74, no. 2, pp. 90-96 (2015).

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Solid particle erosion of thermal spray and physical vapour deposition thermal barrier coatings

Cited by 99 publications

References 32 publications

Thermal Conductivity Analysis and Lifetime Testing of Suspension Plasma-Sprayed Thermal Barrier Coatings

Thermal Conductivity Analysis and Lifetime Testing of Suspension Plasma-Sprayed Thermal Barrier Coatings

Process-structure-property relations for the erosion durability of plasma spray-physical vapor deposition (PS-PVD) thermal barrier coatings

Solid Particle Erosion Behaviour of Plasma-Sprayed Conventional and Nanostructured Al₂O₃-13 wt% TiO₂Ceramic Coatings

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Solid particle erosion of thermal spray and physical vapour deposition thermal barrier coatings

Cited by 99 publications

References 32 publications

Thermal Conductivity Analysis and Lifetime Testing of Suspension Plasma-Sprayed Thermal Barrier Coatings

Thermal Conductivity Analysis and Lifetime Testing of Suspension Plasma-Sprayed Thermal Barrier Coatings

Process-structure-property relations for the erosion durability of plasma spray-physical vapor deposition (PS-PVD) thermal barrier coatings

Solid Particle Erosion Behaviour of Plasma-Sprayed Conventional and Nanostructured Al2O3-13 wt% TiO2Ceramic Coatings

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Solid Particle Erosion Behaviour of Plasma-Sprayed Conventional and Nanostructured Al₂O₃-13 wt% TiO₂Ceramic Coatings