Deposition of hydroxyapatite coatings by axial plasma spraying: Influence of feedstock characteristics on coating microstructure,phase content and mechanical properties

Axial plasma spray is one of the thermal spray techniques to deposit multifunctional advanced coatings. The present work explores the use of this process to deposit thin, continuous, and adherent Ca₅ (PO₄)₃OH (hydroxyapatite, HAp) coatings and characterize its microstructure, phases, hardness and adhesion strength. Three different suspension-deposited HAp coatings were investigated and compared with powder-deposited HAp coating on a Ti6Al4V substrate. The effect of mean solute particle size and solid-loading in the suspension has been explored on the evolution of microstructure, phase content and mechanical properties of axial suspension plasma sprayed (ASPS) coatings. Phase-characterization has shown retention of hydroxyapatite phase and coating crystallinity in the deposited coatings, whereas the adhesion strength of the HAp coating decreased from ～40 MPa to ～13 MPa when bioglass was added to the feedstock material. The lower solid load content and lower mean solute particle size in the suspension were found to be beneficial in achieving porous, rougher, and well-adhering coatings. This work concludes that ASPS can potentially deposit thin HAp coatings (< 50 μm) with high adhesion strength.     

MAX-phase coatings produced by thermal spraying

This paper presents a comparative study on the Ti₂AlC coatings produced by different thermal spray methods, as Ti₂AlC is one of the most studied materials from the MAX-phase family. Microstructural analysis of coatings produced by High Velocity Air Fuel (HVAF), Cold Spray and High Velocity Oxygen Fuel (HVOF) has been carried out by means of the scanning electron microscopy equipped with an energy dispersive spectrometer (EDS). The volume fraction of porosity was determined using the ASTM standard E562. The phase characterization of the as-received powder and as-sprayed coatings was conducted using the X-ray diffraction with CrKα radiation. Impact of the spray parameters on the porosity and the mechanical properties of the coatings are discussed. The results show that the spraying temperature and velocity play a crucial role in coatings characteristics.     

Effect of suspension characteristics on the performance of thermal barrier coatings deposited by suspension plasma spray

This paper investigates the influence of suspension characteristics on microstructure and performance of suspensions plasma sprayed (SPS) thermal barrier coatings (TBCs). Five suspensions were produced using various suspension characteristics, namely, type of solvent and solid load content, and the resultant suspensions were utilized to deposit five different TBCs under identical processing conditions. The produced TBCs were evaluated for their performance i.e. thermal conductivity, thermal cyclic fatigue (TCF) and thermal shock (TS) lifetime. This experimental study revealed that the differences in the microstructure of SPS TBCs produced using varied suspensions resulted in a wide-ranging overall TBC performance. All TBCs exhibited thermal conductivity lower than 1 W/(m. K) except water-ethanol mixed suspension produced TBC. The TS lifetime was also affected to a large extent where 10 wt % solid loaded ethanol and 25 wt % solid loaded water suspensions produced TBCs exhibited the highest and the lowest lifetime, respectively. On the contrary, TCF lifetime was not as significantly affected as thermal conductivity and TS lifetime, and all ethanol suspensions showed marginally better TCF lifetime than water and ethanol-water mixed suspensions deposited TBCs.     

Recent Activities in the Field of Thermal Barrier Coatings Including Burner Rig Testing in the European Union

Although thermal barrier coatings are used in industry for several decades there is still considerable demand for a further improvement of this coating system. Present research projects are for example dealing with the improvement of temperature capability and lifetime, developing of lifetime models, new processing technologies, or incorporating of additional functional properties in the coating. The present paper tries to give an overview on these recent research activities. In addition, it will also try to describe the different burner rig test facilities in Europe, which serve as an important test bed of thermal barrier coating systems.     

High-aspect-ratio nanoporous membranes made by reactive ion etching and e-beam and interference lithography

Nanoporous membranes engineered to mimic natural filtration systems can be used in “smart” implantable drug delivery systems, hemodialysis membranes, bio-artificial organs, and other novel nano-enabled medical devices. Conventional membranes exhibit several limitations, including broad pore size distributions and low pore densities. To overcome these problems, lithographic approaches were used to develop porous silicon, silicon nitride, ultrananocrystalline diamond (UNCD), and polymer film membranes. Here we report processing of high porosity, high-aspect-ratio membranes by two techniques: UNCD fabricated by reactive ion etching after e-beam lithography and epoxy fabricated by interference lithography.     

Study of gradual porous metallic membranes obtained by powder sedimentation

In our preliminary studies the possibility of obtaining sintered porous materials with gradual structure by sedimentation of metallic powder was demonstrated. In this paper we continued our studies on the influencing factors of the sedimentation of metallic powders. Irregular and spherical nickel particles were used having a grain size in the 2–90 μm range measured by the laser scattering particle size analyzer. The particles with irregular shape and larger diameter can sediment faster than the spherical and the smaller diameter particles. The sedimentation rate is also influenced by the sedimentation medium and the quantity of the dispersant agent. Deviations from Stokes law was observed in the case of the irregular particles. The gradual structure is influenced by the sintering regime and the powders characteristics too. The obtained structures were characterized by scanning electron microscopy and mercury porosimetry. The permeability and the filtration fineness were also determined.     

Characterization of Gradual Porous Ceramic Structures Obtained by Powder Sedimentation

Asymmetric membranes present better separation and service characteristics than the symmetric ones. In our preliminary studies the possibility of obtaining sintered porous materials with gradual structure by sedimentation of metallic and ceramic powders was demonstrated. Zirconium silicate (ZrSiO4) particles were used for the manufacturing of the porous supports, and mullite powder was deposited by sedimentation in order to achieve the active layer with pores size gradient. The used powders and the obtained structures were characterized by laser scattering particle size analyzer, scanning electron microscopy and mercury porosimetry. The permeability and the filtration fineness of the structures were also determined. By using a thin active layer made of small particles deposited onto a macro-porous support, one can achieve membranes with high flow rates and filtration fineness in the microfiltration area.     

Evaluation of the Lifetime and Thermal Conductivity of Dysprosia-Stabilized Thermal Barrier Coating Systems

The aim of this study was the further development of dysprosia-stabilized zirconia coatings for gas turbine applications. The target for these coatings was a longer lifetime and higher insulating performance compared to today’s industrial standard thermal barrier coating. Two morphologies of ceramic top coat were studied: one using a dual-layer system and the second using a polymer to generate porosity. Evaluations were carried out using a laser flash technique to measure thermal properties. Lifetime testing was conducted using thermo-cyclic fatigue testing. Microstructure was assessed with SEM and Image analysis was used to characterize porosity content. The results show that coatings with an engineered microstructure give performance twice that of the present reference coating.