Characterization of functionally graded ZrO₂ thermal barrier coatings sprayed by supersonic plasma spray with dual powder feed ports

Abstract

The functionally graded thermal barrier coatings (FG-TBCs) with 80% ZrO₂-13%CeO₂-7%Y₂O₃ (CYSZ)/NiCoCrAlY were prepared using a recently developed supersonic plasma spraying (S-PS) with dual powder feed ports system. The thermal shock experiment of FG-TBCs specimens was carried out by means of the automatic thermal cycle device, in which the samples were heated to 1 200 °C by oxygen-acetylene flame jet then water-quenched to ambient temperature. The temperature—time curves of specimens and photographs can be watched online and recorded by a computer during the test. The results show that the totally 1 mm-thick FG-TBCs have excellent thermal shock resistance due to the fact that the coatings have no any peeling-off after 200 thermal cycles. The microstructures and morphologies of FG-TBCs were characterized and analyzed by SEM.

Keywords

supersonic plasma spray (S-PS) / dual powder feed ports / functionally graded thermal barrier coatings (FG-TBCs) / thermal shock

References

[1] SharafatS, KobayashiA, ChenY, et al.. Plasma spraying of micro-composite thermal barrier coatings [J]. Vacuum, 2002, 65: 415-425

[2] WangY P, SampathS, PrasadV, et al.. An advanced model for plasma spraying of functionally graded materials [J]. Journal of Materials Processing Technology, 2003, 137: 110-116

[3] ZhuDong-ming, ChoiS R, MillerR A. Development and thermal fatigue testing of ceramic thermal barrier coatings [J]. Surface & Coatings Technology, 2004, 188–189: 146-152

[4] ParkS Y, KimJ H, KimM C, et al.. Microscopic observation of degradation behavior in yttria and ceria stabilized zirconia thermal barrier coatings under hot corrosion [J]. Surface & Coatings Technology, 2005, 190: 357-365

[5] PomeroyM J. Coatings for gas turbine materials and long term stability issues [J]. Materials and Design, 2005, 26: 223-231

[6] PanatP, ZhangS L, HsiaK J. Bond coat surface rumpling in thermal barrier coatings [J]. Acta Materialia, 2003, 51: 239-249

[7] Marek-JerzyP, AboudiJ, ArnoldS M. Analysis of spallation mechanism in thermal barrier coatings with graded bond coats using the higher-order theory for FGMs [J]. Engineering Fracture Mechanics, 2002, 69: 1587-1606

[8] VaßenR, CzechN, MallenerW, et al.. Influence of impurity content and porosity of plasma-sprayed yttriastabilized zirconia layers on the sintering behaviour [J]. Surface and Coatings Technology, 2001, 141: 135-140

[9] KimJ H, KimM C, ParkC G. Evaluation of functionally graded thermal barrier coatings fabricated by detonation gun spray technique [J]. Surface and Coatings Technology, 2003, 168: 275-280

[10] HutchinsonJ W, EvansA G. On the delamination of thermal barrier coatings in a thermal gradient [J]. Surface and Coatings Technology, 2002, 149: 179-184

[11] TolpygoV K, ClarkeD R. Morphological evolution of thermal barrier coatings induced by cyclic oxidation [J]. Surface and Coatings Technology, 2003, 163–164: 81-86

[12] MesratiN, SaifQ, TreheuxD, et al.. Characterization of thermal fatigue damage of thermal barrier produced by atmospheric plasma spraying [J]. Surface & Coatings Technology, 2004, 187: 185-193

[13] CarimA H, DobbinsT A, GiannuzziL A, et al.. Phase distribution in, and origin of interfacial protrusions in Ni-Cr-Al-Y/ZrO₂ thermal barrier coatings [J]. Materials Science and Engineering, 2002, A334: 65-72

[14] KokiniK, DeJongeJ, RangarajS, et al.. Thermal shock of functionally graded thermal barrier coatings with similar thermal resistance [J]. Surface and Coatings Technology, 2002, 154: 223-232