Superior thermal barrier coatings using solution precursor plasma spray |
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Authors: | E H Jordan L Xie M Gell N P Padture B Cetegen A Ozturk X Ma J Roth T D Xiao P E C Bryant |
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Affiliation: | (1) University of Connecticut, 06269-3137 Storrs, CT;(2) Inframat Inc., 06032 Farmington, CT |
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Abstract: | A novel process, solution precursor plasma spray (SPPS), is presented for depositing thermal barrier coatings (TBCs), in which
aqueous chemical precursors are injected into a standard direct current plasma spray system. The resulting coatings microstructure
has three unique features: (1) ultra fine splats (1 μm), (2) nanometer and micron-sized interconnected porosity, and (3) closely
spaced, through-thickness cracks. Coatings over 3 mm thick can be readily deposited using the SPPS process. Coating durability
is excellent, with SPPS coatings showing, in furnace cycling tests, 2.5 times the spallation life of air plasma coatings (APS)
and 1.5 times the life of electron beam physical vapor deposited (EB-PVD) coatings. The conductivity of SPPS coatings is lower
than EB-PVD coatings and higher than the best APS coatings. Manufacturing cost is expected to be similar to APS coatings and
much lower than EB-PVD coatings. The SPPS deposition process includes droplet break-up and material arriving at the deposition
surface in various physical states ranging from aqueous solution, gel phase, to fully-molten ceramic. The relation between
the arrival state of the material and the microstructure is described. |
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Keywords: | solution precursor plasma spray thermal barrier coatings |
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