Characterization and processing of spray-dried zirconia powders for plasma spray application |
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| Authors: | P. Pei S. G. Malghan S. J. Dapkunas P. H. Zajchowski |
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| Affiliation: | (1) Ceramics Division, MSEL, National Institute of Standards and Technology, Rm. 256/Bldg. 223, 20899 Gaithersburg, MD, USA;(2) Pratt and Whitney, United Technologies, 400 Main Street, M/S 165-34, 06108 East Hartford, CT, USA |
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| Abstract: | The correlation between the performance of plasma spray coatings and feedstock powder properties is not fully understood. To demonstrate this correlation, eight spray-dried zirconia powders containing a mass fraction of 20% Y2O3 (yttria) were characterized with respect to their physical, bulk chemical, and surface chemical properties. The same powders were plasma spray deposited as coatings, and their relative performance was evaluated using a thermal rupture test developed by Pratt and Whitney. The specific powder properties studied were chemical composition, binder content, particle size distribution, powder morphology, interface chemistry, thermogravimetry, phase composition, and specific surface area. Among the characterization data, the binder-related properties of the powder correlated most strongly with the thermal rupture test data. Specifically, higher binder contents were associated with poor thermal rupture test performance. |
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| Keywords: | binder content plasma spray powder characterization powder performance correlation thermal rupture test yttria-stabilized zirconia powder zirconia-based thermal barrier coatings |
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