Method and Process Development of Advanced Atmospheric Plasma Spraying for Thermal Barrier Coatings

Over the last few years, global economic growth has triggered a dramatic increase in the demand for resources, resulting in steady rise in prices for energy and raw materials. In the gas turbine manufacturing sector, process optimizations of cost-intensive production steps involve a heightened potential of savings and form the basis for securing future competitive advantages in the market. In this context, the atmospheric plasma spraying (APS) process for thermal barrier coatings (TBC) has been optimized. A constraint for the optimization of the APS coating process is the use of the existing coating equipment. Furthermore, the current coating quality and characteristics must not change so as to avoid new qualification and testing. Using experience in APS and empirically gained data, the process optimization plan included the variation of e.g. the plasma gas composition and flow-rate, the electrical power, the arrangement and angle of the powder injectors in relation to the plasma jet, the grain size distribution of the spray powder and the plasma torch movement procedures such as spray distance, offset and iteration. In particular, plasma properties (enthalpy, velocity and temperature), powder injection conditions (injection point, injection speed, grain size and distribution) and the coating lamination (coating pattern and spraying distance) are examined. The optimized process and resulting coating were compared to the current situation using several diagnostic methods. The improved process significantly reduces costs and achieves the requirement of comparable coating quality. Furthermore, a contribution was made towards better comprehension of the APS of ceramics and the definition of a better method for future process developments.     

Deposition and Characteristics of Submicrometer-Structured Thermal Barrier Coatings by Suspension Plasma Spraying

In the field of thermal barrier coatings (TBCs) for gas turbines, suspension plasma sprayed (SPS) submicrometer-structured coatings often show unique mechanical, thermal, and optical properties compared to conventional atmospheric plasma sprayed ones. They have thus the potential of providing increased TBC performances under severe thermo-mechanical loading. Experimental results showed the capability of SPS to obtain yttria stabilized zirconia coatings with very fine porosity and high density of vertical segmentation cracks, yielding high strain tolerance, and low Young??s modulus. The evolution of the coating microstructure and properties during thermal cycling test at very high surface temperature (1400?°C) in our burner rigs and under isothermal annealing was investigated. Results showed that, while segmentation cracks survive, sintering occurs quickly during the first hours of exposure, leading to pore coarsening and stiffening of the coating. In-situ measurements at 1400?°C of the elastic modulus were performed to investigate in more detail the sintering-related stiffening.     

Recovering precious metals from electronic scrap

This article characterizes electronic scrap in terms of origin and composition and describes the steps in preliminary processing: sorting, calcination, combustion, shredding, and sampling. Hydrometallurgical and pyrometallurgical process technologies for the concentration and recovery of precious-metals values in scrap are reviewed, and some downstream processing options are outlined. The article concludes with some caveats concerning the risky but potentially profitable business of recovery of precious metals from electronic scrap.     

Suspension Plasma Spraying: Process Characteristics and Applications

Suspension plasma spraying (SPS) offers the manufacture of unique microstructures which are not possible with conventional powdery feedstock. Due to the considerably smaller size of the droplets and also the further fragmentation of these in the plasma jet, the attainable microstructural features like splat and pore sizes can be downsized to the nanometer range. Our present understanding of the deposition process including injection, suspension plasma plume interaction, and deposition will be outlined. The drawn conclusions are based on analysis of the coating microstructures in combination with particle temperature and velocity measurements as well as enthalpy probe investigations. The last measurements with the water cooled stagnation probe gives valuable information on the interaction of the carrier fluid with the plasma plume. Meanwhile, different areas of application of SPS coatings are known. In this paper, the focus will be on coatings for energy systems. Thermal barrier coatings (TBCs) for modern gas turbines are one important application field. SPS coatings offer the manufacture of strain-tolerant, segmented TBCs with low thermal conductivity. In addition, highly reflective coatings, which reduce the thermal load of the parts from radiation, can be produced. Further applications of SPS coatings as cathode layers in solid oxide fuel cells (SOFC) and for photovoltaic (PV) applications will be presented.     

Oxide scale formation of modified FeCrAl coatings exposed to liquid lead

Modified FeCrAl coatings were studied with respect to their capability to form a thin protective oxide scale in liquid lead environment. They were manufactured by low pressure plasma spraying and GESA surface melting, thereby tuning the Al content. The specimens were exposed for 900 h to liquid lead containing 10^?6 and 10^?8 wt.% oxygen, respectively, at various temperatures from 400 to 550 °C. Threshold values for an Al content that guarantees the formation of thin protective Al-rich oxide scales are determined, dependent on the respective chromium content, on the presence of yttrium in the modified coating, and on the exposure conditions.     

Room-Temperature Solubility Behavior of Barium Titanate in Aqueous Media

In the present study, the incongruent dissolution of barium from barium titanate (BaTiO₃) has been studied as a function of dispersion pH and powder volume fraction for two different BaTiO₃ powders. In alkaline dispersions, the barium solubility strongly increases as the pH increases, as suggested by thermodynamic considerations. At pH <7, the barium solubility reaches a plateau, the height of which is dependent on the surface area of the powder and the solids loading of the slip. The BaTiO₃ surface is completely depleted of barium in this region.     

Wax esters and triglycerides as storage substances in seeds of Buxus sempervirens

The seeds of the evergreen Buxus‐tree, Buxus sempervirens, contain a yellowish oil which represents up to 42% of the dry weight. The oil consists, in comparison to the lipids of jojoba fruits (Simmondsia chinensis), of only 3.6% wax esters. 95% of the oil consist of triglycerides, the typical storage substances of oil fruits. Phospholipids occur with 0.4% and glycolipids with 0.13%. The fatty acid patterns of these lipids correspond to the typical fatty acid compositions of the respective lipid classes. In the wax esters monoenoic fatty acids and saturated fatty acids with 16 and 18 carbon atoms prevail. The glycolipid and phospholipid fractions are characterized by a high portion of dienoic and monoenoic as well as saturated fatty acids having 16 and 18 carbon acids.     

MgAl2O4-Spinel Synthesized by High-Energy Ball Milling and Reaction Sintering

A new way to prepare magnesia-alumina-spinel was investigated making use of a mixed powder system of MgO and metallic Al-3 wt% Mg. Intensive ball milling was applied which provides the formation of new powder particles as composite of both components in intimate contact. The new configuration of the particles had a significant impact on the reaction sintering behavior leading to single phase spinel microstructures at moderate temperatures below 1400°C. Optimized milling of the powder mixture was therefore required providing reduced crystallite sizes and strongly enlarged interfacial area shared by the reacting components. The optimal milling time was identified by the complete reaction of the starting powders to spinel during sintering. Shorter milling times led to incomplete reactions and longer milling times contaminated the milling product by debris from the milling tools. The amount of interfaces generated by the intimate mixing dominated the sintering reaction kinetics whereas the specific surfaces area was of secondary importance.