Preparation and characterization of nanocrystalline ZrO₂-7%Y₂O₃ powders for thermal barrier coatings by high-energy ball milling

Abstract

High-energy ball milling is an effective method to produce nanocrystalline oxides. In this study, a conventional ZrO₂-7%Y₂O₃ spray powder was ball-milled to produce nanocrystalline powders with high levels of crystalline disorders for deposition of thermal barrier coatings. The powder was milled both with 100Cr6 steel balls and with ZrO₂-3%Y₂O₃ ceramic balls as grinding media. The milling time was varied in order to investigate the effect of the milling time on the crystallite size. The powders were investigated in terms of their crystallite sizes and morphologies by X-ray diffraction analysis (XRD), scanning electron microscopy (SEM) and transmission electron microscopy (TEM). The results show that under given milling conditions the powder was already nanostructured after 40 min milling. The crystallite size decreased significantly with increasing milling time within first 120 min. After that, a further increase of milling time did not lead to a significant reduction of the crystallite size. Ball-milling led to lattice microstrains. Milling with the steel balls resulted in finer nano-sized crystal grains, but caused the contamination of the powder. The nano-sized crystal grains coarsened during the heat-treatment at 1250°C.

Keywords

nanostrucured powders / yttria stabilized zirconia (YSZ) / high-energy ball milling / thermal barrier coatings

References

[1] Lima R S, Marple B R. Toward highly sintering-resistant nanostructured ZrO₂-7 wt % Y₂O₃ coatings for TBC applications by employing differential sintering. Journal of Thermal Spray Technology, 2008, 17(5-6): 846–852

[2] Lima R S, Marple B R. Thermal spray coatings engineered from nanostructured ceramic agglomerated powders for structural, thermal barrier and biomedical applications: A Review. Journal of Thermal Spray Technology, 2007, 16(1): 40–63

[3] Liang B, Ding C. Thermal shock resistancees of nanostructured and conventional zirconia coatings deposited by atmospheric plasma spraying. Surface and Coatings Technology, 2005, 197(2-3): 185–192

[4] Sainz M A, Carretero J, Serena S, Caballero A. Nanocrystalline cubic zirconia obtained from zirconia and dolomite activated by a high energy ball milling process. Key Engineering Materials, 2004, 264-268: 2351–2354

[5] Chadwick AV, Pooley M J, Rammutla K E, Savin S L P, Rougier A. Comparision of the extended X-ray absorption fine structure of nanocrystalline ZrO₂ prepared by high energy ball milling and other methods. Journal of Physics Condensed Matter, 2003, 15: 431–440

[6] Gateshki M, Petkov V, Williams G, Pradan S, Ren Y. Atomic-scale structure of nanocrystalline ZrO₂ prepared by high energy ball milling. Physical Review B: Condensed Matter and Materials Physics, 2005, 71: 224107

[7] Savin S, Chadwick A, O’Dell L, Smith M. Structural studies of nanocrystalline oxides. Solid State Ionics, 2006, 177(26-32): 2519–2526

[8] Williamson G, Hall W. X-ray line broadening from field aluminium and wolfram. Acta Metallurgica, 1953, 1(1): 22–31

Acknowledgments

The authors would like to thank the German Science Foundation (DFG) for financially supporting the research work within the scope of DFG project ZH205/2-1.

RIGHTS & PERMISSIONS

2014 Higher Education Press and Springer-Verlag Berlin Heidelberg