Architecture designs for extending thermal cycling lifetime of suspension plasma sprayed thermal barrier coatings |
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| Affiliation: | 1. Forschungszentrum Jülich GmbH, Institute of Energy and Climate Research, Materials Synthesis and Processing (IEK-1), 52425, Jülich, Germany;2. Forschungszentrum Jülich GmbH, Institute of Energy and Climate Research, Plasma Physics (IEK-4), 52425, Jülich, Germany;3. Jülich Aachen Research Alliance: JARA-Energy, Germany;1. Forschungszentrum Jülich GmbH, Institute of Energy and Climate Research, Materials Synthesis and Processing (IEK-1), 52425 Jülich, Germany;2. Fraunhofer Institute for Ceramic Technologies and Systems, Fraunhofer IKTS, Winterbergstr. 28, 01277 Dresden, Germany;1. CEA-DAM Le Ripault, BP 16, 37260 Monts, France;2. Safran-Snecma, Rue Maryse Bastié, BP 129, 86101 Châtellerault, France;3. Safran, Pôle Matériaux et Procédés, Rue de Jeunes Bois, Châteaufort, CS 80112, 78772 Magny-Les-Hameaux, France;4. LEMTA, 2 Avenue de la forêt de Haye, BP 160, 54504 Vandoeuvre-Lès-Nancy, France;1. Materials Synthesis and Processing (IEK-1), Institute of Energy and Climate Research, Forschungszentrum Jülich GmbH, 52425, Jülich, Germany;2. State Key Laboratory for Strength and Vibration of Mechanical Structures, School of Aerospace Engineering, Xi’an Jiaotong University, Xi’an, 710049, China;3. Jülich Aachen Research Alliance, JARA Energy, Jülich, Germany;1. University West, 46186, Trollhättan, Sweden;2. Innovnano Materials, Coimbra, Portugal;3. Treibacher Industries AG, Althofen, Austria |
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| Abstract: | Suspension plasma spraying (SPS) as a relatively new spraying technology has great potential on depositing high performance thermal barrier coatings (TBCs). In some cases, however, columnar SPS TBCs show premature failure in thermal cycling test. To explain the reasons of such failure, a failure mechanism for columnar SPS TBCs was proposed in this work. The premature failure of TBCs might be related to the radial stresses in the vicinity of top coat/bond coat interface. These radial stresses were introduced by the thermal misfit and the roughness of bond coat. According to this mechanism, two architecture designs of SPS TBCs were applied to improve the thermal cycling lifetime. One was a double layered top coat design with a lamellar atmospheric plasma sprayed (APS) sub-layer and a columnar SPS top-layer. The other one was a low roughness bond coat design with a columnar SPS top coat deposited on a low roughness bond coat which was grinded before the spraying. With both designs, lifetimes of SPS TBCs were significantly extended. Especially, a lifetime even better than conventional APS TBCs was achieved with the double layered design. |
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| Keywords: | Suspension plasma spray Thermal barrier coatings Thermal cycling Architecture design Lifetime |
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