Microstructure assessment of suspension plasma spraying coatings from multicomponent submicronic Y-TZP/Al2O3/SiC particles

In this research, Suspension Plasma Spraying (SPS) technique was used for the thermal deposition of a multicomponent mixture made up of an Y-TZP/Al₂O₃ matrix with SiC particles. Two suspensions of Y-TZP and Al₂O₃ with different SiC particles content (6?wt% and 12?wt%) were tested as feedstocks in the SPS process. Three stand-off distances were varied in order to assess coating microstructure and evaluate the presence of SiC in the final coatings. Coatings were characterised in terms of porosity, microstructure and phase distribution. The estimate of the amount of SiC in the coating was carried out by XRD technique.Findings showed typical cauliflower-like SPS microstructure which intensifies with stand-off distance. Coatings porosity varied significantly between 8% and 25% whereas minimum porosity was found for the intermedium stand-off distance of 40?mm.Microstructure analysis also revealed the presence of SiC particles in the coatings which was confirmed by EDX analysis, overall XRD tests as well as TG analysis. Finally, evaluation of SiC content in the final coatings by means of XRD analysis showed that most of SiC particles (c.a 80%) of the feedstocks were preserved in the final coatings.     

Challenging zircon coatings by suspension plasma spraying

Zircon is a ceramic material that decomposes at high temperature, limiting its use by conventional thermal spraying. In this work, it is intended to use thermal spraying from concentrated aqueous suspensions to evaluate the possibility of obtaining coatings in which a significant proportion of zircon could be preserved. For this purpose, stable concentrated suspensions of zircon have been prepared, which have been subsequently sprayed at two different spraying distances. The coatings were characterised in terms of microstructural features and the amount of zircon present in the coatings was quantified. All the coatings obtained display the typical microstructure derived from the deposition of liquid feedstocks by plasma spraying. In all cases, the XRD analysis demonstrates the partial decomposition of zircon into zirconia and residual silica, but also that a significant percentage (about 20%) is preserved without decomposing, which marks a strong difference with respect to reported data for atmospheric plasma spraying.     

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.     

Effect of fructose-containing feedstocks on the microstructure of multicomponent coatings deposited by suspension plasma spraying

This work addressed to investigate the use of fructose as an additive in the water-based suspension feedstock of a Y-TZP/Al₂O₃/SiC multicomponent coating manufactured by suspension plasma spraying. The effect of fructose on suspension rheology and surface tension and on the microstructure and thermal conductivity of the resulting coatings was assessed.It was observed that addition of fructose slightly affected the rheological behaviour of the suspensions while a strong decrease in the surface tension of water occurred. The fructose addition led to the development of columnar-like structures, probably associated with its effect on surface tension. X-ray diffraction patterns in the final coating displayed that crystallinity of tetragonal zirconia formed when fructose was added whereas silicon carbide crystalline phase was practically preserved. The determination of thermal conductivity showed that the formation of a controlled columnar structure along with inter-columnar porosity can be beneficial for thermal insulation.     

Effect of environmental pressure on the microstructure of YSZ thermal barrier coating via suspension plasma spraying

Suspension plasma spraying (SPS) as a potential technique to prepare thermal barrier coatings (TBCs) has been attracting more and more attention. However, most reports on SPS were carried out in the atmosphere. Given the unique features of in-flight particles and plasma jets under low pressure, the resulting coatings are expected to be different from those under atmospheric pressure. In this article, yttria-stabilized zirconia (YSZ) thermal barrier coatings were prepared using suspension plasma spraying under different environmental pressures. The results show that as the environmental pressure decreased, the column-like structural coating turned into a vertical crack segmented structure, as well as a dramatic decrease in surface roughness. More nanoparticle agglomerates were formed in the coating under lower environmental pressures. The real porosity of the coating increased with a decrease in environmental pressure.     

Taguchi optimization of YSZ/alumina/silica colloids for suspension plasma sprayed coating process

The stability of suspensions plays a key role in the water-based suspension plasma sprayed coating process. The effects of suspension parameters, such as the solid content and the type/content of dispersants on the suspension stability were studied in this work. In this regard, a Taguchi L9 array design of experiments was used to optimize submicron-sized YSZ/nano-sized alumina/silica additive suspensions with low viscosity, high steady-state turbidity, and inter-particle electrostatic charges. The optimal stable suspension with the viscosity of 4.2 cp, the zeta potential of 65 mV, and the Nephelometric Turbidity Units (NTU) of 3503 was used as the feedstock for suspension plasma spraying. Accordingly, a typical columnar coating morphology was obtained with the porosity of almost 19.3 vol%, which is a desirable feature for high-temperature applications. In conclusion, this study reflects the merit of the Taguchi design of experiments to optimize multicomponent thermal barrier coatings.     

The toughening design of multi-layer antioxidation coating on C/C matrix via SiC-SiCw transition layer grown in-situ

Poor antioxidant and thermal-shock capacities of C/C composites thermal barrier coating (TBC) caused by cracking and shedding of coatings has been a major obstacle blocking the development of C/C composites. Herein, in-situ growth of whisker reinforced silicon carbide transition layer and inter-embedding mechanism of multi-gradient coatings were brought into the design of TBC to enhance the antioxidant and thermal-shock capacities. A three-layer gradient coating SiC-SiC_w/ZrB₂-SiC/ZrSiO₄-aluminosilicate glass (ZAG) from inside to outside, in which ZrB₂-SiC/ZAG serve as oxygen barrier layers with self-healing ability and SiC-SiC_w provides thermal stress buffering and bonding against cracking and shedding of coatings, is designed. The ZAG mainly forms a dense oxygen blocking frontier with self-healing ability through fluidized glass, while the ZrB₂-SiC can react actively with infiltrated oxygen in a way of self-sacrifice, preventing oxygen erosion to C/C matrix and SiC-SiC_w transition layer. As a result, the collaborative work among layers endows this coating with excellent high temperature service performance. This work provides a new insight for the design of excellent TBC.     

Comparative study on thermal shock behavior of thick thermal barrier coatings fabricated with nano-based YSZ suspension and agglomerated particles

Two kinds of segmentation-crack structured YSZ thick thermal barrier coatings (TTBCs) were deposited by suspension plasma spraying (SPS) and atmospheric plasma spraying (APS) with nano-based suspension and agglomerated particles, respectively. The phase composition, microstructure evolution and failure behavior of both TBCs before and after thermal shock tests were systematically investigated. Microstructure of the APS coating exhibits typical segmentation-crack structure in the through-thickness direction, similar with the SPS coating. The densities of segmentation-crack in APS and SPS coatings were about 3 cracks mm⁻¹ and 4 cracks mm⁻¹_, respectively. The microstructure observation also showed that the columnar and equiaxed grains existed in the SPS coating. As for the thermal shock test, the spallation life of the APS TTBCs was 146 cycles, close to that of the SPS TTBCs (166 cycles). Failure of the APS coating is due to the spallation of fringe segments and splats.     

Effect of pre-oxidation and Al amount on the oxidation behavior of healing agents in YSZ-Mo(Si1-x,Alx)2 composite

Efficient and easy to produce self-healing agents have significant role on the development of self-healing composites. Herein, we report preoxidized Self-propagating high-temperature synthesis (SHS) synthesized Al-alloyed MoSi₂ for self-healing agent in thermal barrier coating system. The raw materials of Mo, Si and Al with molar aspect ratio of (1:1.6:0.4) and (1:1.2:0.8) were used to produce Mo(Si_1-x,Al_x) via SHS method. The healing agents were used to produce YSZ- Mo(Si_1-x,Al_x) composite by spark plasma sintering (SPS) method. Effect of peroxidation and Aluminum amount were studied after iso-thermal oxidation at 1050 °C with FE-SEM, EDX and XPS analysis. Oxide shell were grown on the surface of healing agent powders after preoxidizing. Oxide form of aluminum, silicon and molybdenum are available in oxide shell after preoxidation. Selective oxidation of Aluminum led to produce firm and continues Alumina oxide film on the surface of healing agents. Peroxidation is effective way to reserve the healing agent with molar aspect ratio of (1:1.2:0.8) by decreasing oxidation rates of them at working temperature and has not significant effect on healing agent with (1:1.6:0.4) molar aspect ratio. There is much prospect that this research will led to producing novel self-healing thermal barrier coatings by modification of healing agents composition in order to have the most appropriate properties at working condition.     

Gelcasting of concentrated aqueous silicon carbide suspension

Gelcasting of high concentrated aqueous silicon carbide suspension with 50 vol.% solids loading is discussed in this paper. It is found that SiC powder is suitable for being suspended in basic solution, provided that a proper pH value is chosen for it. The rheological property of SiC suspension is also affected by solids loading. When SiC slurry is cast at 70°C, reaction between free Si on the surface of SiC powder and an organic base used as dispersant gives out H₂ gas, which produces pores in green bodies. However, by vacuum pumping and controlling pH value of the suspensions, complicated shapes of uniform SiC green bodies without pores are prepared.     

Effects of h-BN/SiC ratios on oxidation mechanism and kinetics of C/C-BN-SiC composites

C/C-BN-SiC composite was prepared by ceramic slurry infiltration combined with resin impregnation and carbonization, and the matrix with continuous distributed self-healing phase was obtained. In this study, the kinetic characteristics and oxidation behavior of the composites with various h-BN/SiC ratios in the temperature range of 600～1300°C were studied by combining the isothermal oxidation test with the kinetic model. The optimal h-BN/SiC ratio balances the thermal stability and fluidity of the oxidized product, which not only has high thermal stability and low oxygen permeability to acts as an oxygen diffusion barrier but also has a certain fluidity to seal defects.     

Effect of silicon/graphite ratio and temperature on oxidation protective properties of SiC/ZrB2–SiC coatings prepared by pack cementation

To investigate the silicon/graphite ratio and temperature on preparation and properties of ZrB₂–SiC coatings, ZrB₂, silicon, and graphite powders were used as pack powders to prepare ZrB₂–SiC coatings on SiC coated graphite samples at different temperatures by pack cementation method. The composition, microstructure, thermal shock, and oxidation resistance of these coatings were characterized and assessed. High silicon/graphite ratio (in this case, 2) did not guarantee higher coating density, instead could be harmful to coating formation and led to the lump of pack powders, especially at temperatures of 2100 and 2200 °C. But residual silicon in the coating is beneficial for high density and oxidation protection ability. The SiC/ZrB₂–SiC (ZS50-2) coating prepared at 2000 °C showed excellent oxidation protective ability, owing to the residual silicon in the coating and dense coating structure. The weight loss of ZS50-2 after 15 thermal shocks between 1500 °C and room temperature, and oxidation for 19 h at 1500 °C are 6.5% and 2.9%, respectively.     

SiC modified self-healing ytterbium disilicate materials for potential environmental barrier coating application

Environmental barrier coatings (EBCs) are crucial to the reliability and durability of SiC_f/SiC composite components seeking applications in hot sections of next-generation advanced aero-engines. The cracks initiated and developed in EBCs owing to various reasons during service greatly undermine their lifespans. To address this problem, in this work, silicon carbide (SiC) in the forms of particles and whiskers with various amounts have been introduced to ytterbium disilicate (Yb₂Si₂O₇), the mainstream EBC topcoat materials, so as to gain some self-healing potential. The results reveal that, the SiC inclusions in Yb₂Si₂O₇ in the presence of ytterbium monosilicate (Yb₂SiO₅) can trigger the following reactions. Specifically, SiC self-healing agents are oxidized to form viscous SiO₂, which actively reacts with Yb₂SiO₅ upon encountering it, forming Yb₂Si₂O₇. This has brought twofold beneficial effects including ① silicon supplementation of disilicate topcoat, whose silicon element tends to be “dragged out” by water vapor, leading to the deterioration of thermal mismatch; as well as ② crack self-healing resulting from the volume expansion induced by the above reactions. Then the two aspects of self-healing agents, namely the “promptness” and “sustainability,” have been discussed in detail. The former is unveiled to be more pertinent to the repairing of large cracks, whilst the latter is more relevant to the self-healing of tiny cracks at initiation or early stage of propagation. The current work sheds some lights on the design and development of more durable and robust EBCs with self-healing capability.     

Experimental visualization of microstructure evolution during suspension plasma spraying of thermal barrier coatings

This paper investigates the evolution of microstructure of thermal barrier coatings (TBCs) produced by suspension plasma spraying (SPS) through a careful experimental study. Understanding the influence of different suspension characteristics such as type of solvent, solid load content and median particle size on the ensuing TBC microstructure, as well as visualizing the early stages of coating build-up leading to formation of a columnar microstructure or otherwise, was of specific interest. Several SPS TBCs with different suspensions were deposited under identical conditions (same substrate, bond coat and plasma spray parameters). The experimental study clearly revealed the important role of suspension characteristics, namely surface tension, density and viscosity, on the final microstructure, with study of its progressive evolution providing invaluable insights. Variations in suspension properties manifest in the form of differences in droplet momentum and trajectory, which are found to be key determinants governing the resulting microstructure (e.g., lamellar/vertically cracked or columnar).     

High temperature thermal physical performance of SiC/UO2 composites up to 1600 °C

SiC was introduced to UO₂ matrix by spark plasma sintering (SPS) to improve the thermal conductivity. The microstructure evolution and thermal physical properties up to 1600?°C were firstly reported. The grain growth and the formation of equiaxed grain structure were inhibited by the addition of SiC. The critical SPS sintering temperature, above which SiC was positive on improving thermal conductivity, was discovered to be 1300?°C. Two equations were proposed to calculate the thermal diffusivity and thermal conductivity of SiC/UO₂ sintering at 1500?°C. Each percent of SiC fraction brought about 3% increment in thermal conductivity. The coefficient of thermal expansion (CTE) was decreased after SiC addition. Such improvement in thermal conductivity and decrease in CTE were beneficial to the fuel safety in accident condition.     

Polymer-derived yttrium silicate coatings on 2D C/SiC composites

Yttrium silicate environmental barrier coatings (EBCs) on C/SiC composites were fabricated by using polysiloxanes-derived ceramic process. In order to reduce the free silica in the resultant ceramic coatings, Y₂O₃ was added as an active filler. The materials with different weight ratios of polysiloxanes to Y₂O₃ were synthesized. Their coefficient of thermal expansion (CTE) and water-vapor resistance were tested. The results indicated that the composition of 50% Y₂O₃–50% polysiloxanes (Y50) was suitable to be the EBCs for C/SiC composites. The C/SiC composites coated with Y50 were tested in the water-vapor environments at 1400 °C for 200 h. The results revealed that such a coating could effectively protect the C/SiC composites.     

Dispersion of TiO2 nanopowders to obtain homogeneous nanostructured granules by spray-drying

This work deals with the dispersion and stabilisation of nanosized TiO₂ particles in an aqueous medium as a first step in the preparation of spray-dried nanostructured powders.A colloidal route leading to the production of titania nanostructured feedstocks to obtain nanostructured powders was developed. The process was based on the production of homogeneous and concentrated TiO₂ nanosuspensions dispersed in deionised water with a suitable control of pH and the use of an appropriate anionic dispersant. Concentrated suspensions could be obtained by mixing with an ultrasounds probe at different times depending on the dispersing conditions.Homogeneous suspensions prepared were then reconstituted by spray drying into free-flowing powders with an adequate granule size distribution for diverse purposes, such as atmospheric plasma spraying coatings.     

On the preparation of organosilanized silicon carbide aqueous suspension

The functionalization of ceramic nanoparticles with organosilanes is commonly employed to improve the surface adhesion mechanism for specific applications, especially in polymer composites. However, this surface modification changes the behavior of the nanoparticles in suspension, which is important for applications that require preparation involving aqueous medium. In the present study the influence of organosilanization on the size and stability of SiC particles in aqueous medium was evaluated. Initially, SiC particles were organofunctionalized using (3-aminopropyl) triethoxysilane through two different reaction routes (SiC_{Sil I} and SiC_{Sil II}). XPS spectroscopy of solid particles showed higher content of nitrogen atoms arising from the organosilanization reaction in the SiC_{Sil II}, prepared in ethanol. Compared to the unmodified SiC aqueous suspension, the organosilanized SiC aqueous suspensions presented much higher particle sizes, with the largest particle size distribution, assigned mainly to the organosilanization of SiC agglomerates. Subsequently, polyethylenimine (PEI) was tested as a dispersant for the aqueous suspensions, aiming to increase the repulsion forces among the particles and induce their de-agglomeration. The addition of PEI to SiC and SiC_{Sil II} particle aqueous suspensions resulted in a drastic reduction in the particle size (up to 40% (D50) at pH 5.5) and narrowest particle size distribution over a wide pH range. This fact was attributed to the PEI electrosteric effect on aqueous suspensions containing SiC or SiC_{Sil II}, which was supported by dynamic laser scattering and zeta potential results.     

Review of suspension and solution precursor plasma sprayed thermal barrier coatings

As one of the promising methods that can be employed to fabricate high-performance thermal barrier coatings (TBCs), suspension plasma spraying (SPS) or solution precursor plasma spraying (SPPS) has received significant attention in academic research. Enhanced performances have been shown in the SPS-/SPPS-coatings due to their special microstructures, such as uniformly distributed micro-pores, vertical cracks or columnar structures. Since there are more complexities than conventional plasma spraying methods, many works have been devoted to study the mechanism and properties of SPS-/SPPS-coatings during the past decades. In this work, the latest development of SPS or SPPS is reviewed in order to discuss some key issues in terms of preparation of suspension or solution precursor, injection mode of liquid phase, interaction between liquid and plasma jet, microstructure of as-sprayed coatings and corresponding deposition mechanism. Meanwhile, the potential application of SPS or SPPS in some new-type TBCs is introduced at the end of this paper.     

Influence of SiC fiber on thermal cycling lifetime of SiC fibers /YSZ thermal barrier coatings by atmospheric plasma spraying

The initiation and propagation of cracks under thermal stresses easily is one of the problems limiting the thermal cycling lifetime of thermal barrier coatings (TBCs). In order to improve the thermal cycling lifetime, SiC fibers were introduced to yttria stabilized zirconia (YSZ) coating deposited on In738LC substrate by atmospheric plasma spray (APS). Phase composition, thermal cycling behaviors and fiber toughening mechanisms of coatings were systematically investigated by X-ray diffraction (XRD), scanning electron microscopy (SEM) and thermal cycling test. Results showed that the thermal cycling lifetime and fracture toughness of SiC fibers/YSZ coatings could reach 442?±?13 and 1.54?±?0.19?MPa $\sqrt{m}$ respectively, which were 1.6 times and 1.3 times higher than that of conventional TBCs. There are two stages of fiber reinforced during thermal cycling, and the first is crack deflection and termination, the second is fiber debonding, pull-out, breakage and bridging. Meanwhile, SiC fibers could prevent the stress-activated ZrO₂ martensitic transformation by reducing the stress in the lattice.