High-power hybrid plasma spraying of large yttria-stabilized zirconia powder |
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Authors: | Heji Huang Keisuke Eguchi Toyonobu Yoshida |
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Affiliation: | (1) Department of Materials Engineering, the University of Tokyo, Hongo, 7-3-1, Bunkyoku, 113-8656 Tokyo, Japan |
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Abstract: | To testify to the advantage of large ceramic powder spraying, numerical simulations and experimental studies on the behavior
of large yttria-stabilized zirconia (YSZ) powder in a high-power hybrid plasma spraying process have been carried out. Numeric
predictions and experimental results showed that, with the high radio frequency (RF) input power of 100 kW, the most refractory
YSZ powder with particle sizes as large as 88 μm could be fully melted and well-flattened splats could be formed. A large
degree of flattening (ξ) of 4.7 has been achieved. The improved adhesive strength between the large splat and the substrate
was confirmed based on the measurement of the crack density inside of the splats. A thick YSZ coating >300 μm was successfully
deposited on a large CoNiCrAlY-coated Inconel substrate (50×50×4 mm in size). The ultradense microstructure without clear
boundaries between the splats and the clean and crack-free interface between the top-coat and the bond-coat also indicate
the good adhesion. These results showed that highpower hybrid plasma spraying of large ceramic powder is a very promising
process for deposition of highquality coatings, especially in the application of thermal barrier coatings (TBCs). |
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Keywords: | crack density flattening degree hybrid plasma large powder spraying single-splat deformation thermal barrier coatings thermal plasma spray |
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