Suspensions Plasma Spraying of Ceramics with Hybrid Water-Stabilized Plasma Technology

Mušálek, Radek; Medřický, Jan; Tesař, Tomáš; Kotlan, Jiří; Pala, Zdeněk; Lukáč, František; Chráska, Tomáš; Curry, Nicholas

doi:10.1007/s11666-016-0493-6

Cited by 16 publications

(7 citation statements)

References 26 publications

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“…Deposition of individual sublayers consisted of several deposition cycles (each consisting of 3 up and down torch strokes) interrupted by cooling periods to prevent overheating of the samples. Further details on deposition procedure are provided in Ref 12 , 13 , 15 . Spraying parameters are surveyed in Table 1 .…”

Section: Methodsmentioning

confidence: 99%

“…It was recently demonstrated that hybrid water/argon-stabilized plasma (WSP-H) technology can be used for cost-effective large-throughput deposition of TBC-relevant materials not only from dry coarse powders but also from liquid feedstocks (Ref 12 – 14 ). Due to the high plasma enthalpy, considerable feed rates (more than 100 mL of liquid per minute) may be processed with high deposition efficiency (DE).…”

Section: Introductionmentioning

confidence: 99%

“…Due to the high plasma enthalpy, considerable feed rates (more than 100 mL of liquid per minute) may be processed with high deposition efficiency (DE). For example, at ~ 100 mL/min feed rates, DE of around 55-60% is commonly achieved by WSP-H torch for YSZ spraying from suspension or solution and around 75% for spraying of YAG from suspension (Ref 12 , 13 ). TBCs with both NiCrAlY bond-coat and single-layer YSZ or GZO top-coats were already successfully deposited from powder, suspension, and solution and benchmarked by thermal cycling fatigue (TCF) test repeatedly exposing coatings to 1100 °C for 1 h. Please note that this test is in the literature also denoted as furnace cycle test (acronym FCT) and due to its relatively low cost, simplicity, and high throughput is often used for initial screening of thermal fatigue resistance of newly developed TBCs.…”

Section: Introductionmentioning

confidence: 99%

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High-Temperature Cycling of Plasma Sprayed Multilayered NiCrAlY/YSZ/GZO/YAG Thermal Barrier Coatings Prepared from Liquid Feedstocks

et al. 2020

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High-enthalpy hybrid water/argon-stabilized plasma (WSP-H) torch may be used for efficient deposition of coatings from dry powders, suspensions, and solutions. WSP-H torch was used to deposit two complete thermal barrier coatings (TBCs) with multilayered top-coat. NiCrAlY was used as bond - coat and deposited on nickel-based superalloy substrates. Top-coat consisted of up to three sublayers: (i) yttria-stabilized zirconia (ZrO 2 -8 wt.%Y 2 O 3 -YSZ) deposited from solution, (ii) gadolinium zirconate (Gd 2 Zr 2 O 7 -GZO) deposited from suspension, and (iii) optional yttrium aluminum garnet (Y 3 Al 5 O 12 -YAG) overlayer deposited from suspension. Each of the sublayers was intended to provide different functionalities, namely improved fracture toughness, low thermal conductivity, and high erosion resistance, respectively. High-temperature performance and thermal shock resistance of the deposited coatings were tested by thermal cycling fatigue “TCF” test (maximum temperature 1100 °C, 1 h dwell per cycle) and “laser-rig” test (maximum temperature ~ 1530 °C, 5 min dwell per cycle) exposing samples to isothermal and gradient thermal conditions, respectively. In both tests, coatings endured around 800 test cycles which shows great potential for further development of these layers and their application in demanding thermal conditions. Analysis of the samples after the test showed microstructural changes and identified reason of ultimate coating failure.

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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High-Temperature Cycling of Plasma Sprayed Multilayered NiCrAlY/YSZ/GZO/YAG Thermal Barrier Coatings Prepared from Liquid Feedstocks

et al. 2020

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“…More details on the deposition with WSP-H are provided e.g. in [4,5] or papers referenced for each coating example.…”

Section: Experimentalsmentioning

confidence: 99%

Composite coatings containing nanometric constituents prepared by plasma spraying with liquid feedstocks

Mušálek

Tesař

Medřický

et al. 2021

NANOCON 2021 Conference Proeedings

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Plasma spraying of liquid feedstocks allows deposition of materials with novel microstructures. Due to the combination of a liquid carrier and ultrafine powders (in case of suspensions) or in-situ formation of the final material in the plasma jet (in case of solutions), preparation of ultrafine composites is possible, typically in a form of coatings on the substrates. Moreover, both suspension and solution spraying routes can be easily combined, either together or even with conventional plasma spraying of coarse dry powders, thus merging benefits of "nanometric" and "micrometric" constituents in the final composite microstructure. As a consequence, liquid feedstock plasma spraying represents an industrially-relevant deposition process with wide variability, providing coatings with properties tailored for various applications ranging from compact wearresistant layers, porous thermal barrier coatings, bio-compatible medical coatings, catalyst carriers, fuel-cells, etc. The paper introduces several examples of such ultrafine coatings recently deposited at IPP CAS using hybrid water-stabilized plasma torch.

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“…Three coatings were prepared on grit-blasted steel coupons (20 × 30 × 2.5 mm 3 ) by hybrid waterstabilized plasma (WSP-H) torch WSP-H 500 (Pro-jectSoft HK, a.s., Czechia 1. For details, see [10][11][12].…”

Section: Experimentalsmentioning

confidence: 99%

Evaluation of Internal Cohesion of Multiphase Plasma-Sprayed Coatings by Cavitation Test: Feasibility Study

Mušálek

Nardozza

Tesař

et al. 2020

APP

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Mechanical characterization of plasma-sprayed coatings at microscopic level represents a major challenge due to the presence of numerous inherent microstructural features such as cracks, pores, or splat boundaries, which complicate coatings characterization by conventional testing methods. Need for reliable testing of structural integrity of newly developed multiphase plasma-sprayed coatings introduced even more complexity to the testing. In this study, applicability of indirect vibratory cavitation test (adapted from ASTM G32 standard) for such testing was evaluated. Three plasmasprayed coatings having distinctive microstructures were tested: i) conventional alumina coating deposited from coarse powder, ii) hybrid coating deposited by co-spraying of coarse alumina powder and fine yttria-stabilized zirconia (YSZ) suspension, and iii) compact alumina coating deposited from fine ethanol-based suspension. Differences in the coatings internal cohesion were reflected in different failure mechanisms observed within the cavitation crater by scanning electron microscopy and mean erosion rates being i) 280 μm/hour, ii) 97 μm/hour and iii) 14 μm/hour, respectively.

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Suspensions Plasma Spraying of Ceramics with Hybrid Water-Stabilized Plasma Technology

Cited by 16 publications

References 26 publications

High-Temperature Cycling of Plasma Sprayed Multilayered NiCrAlY/YSZ/GZO/YAG Thermal Barrier Coatings Prepared from Liquid Feedstocks

High-Temperature Cycling of Plasma Sprayed Multilayered NiCrAlY/YSZ/GZO/YAG Thermal Barrier Coatings Prepared from Liquid Feedstocks

Composite coatings containing nanometric constituents prepared by plasma spraying with liquid feedstocks

Evaluation of Internal Cohesion of Multiphase Plasma-Sprayed Coatings by Cavitation Test: Feasibility Study

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