Preparation of long-lifetime thermal barrier coatings and toughening mechanism by using hierarchy structured zirconia-based microspheres |
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| Authors: | Ruiji Zhang Xing Zhang Chen Xing Li Hu Fangwei Guo Xin Wang Xiaofeng Zhao |
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| Affiliation: | 1. School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China;2. Shanghai Key Laboratory of Advanced High-temperature Materials and Precision Forming, Shanghai Jiao Tong University, Shanghai, 200240, China;3. Aerospace System Engineering of Shanghai, Shanghai, 201108, China;4. Konca Solar Cell Co., Ltd., Wuxi 214174, China |
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| Abstract: | The thermal cycling lifetime of thermal barrier coatings was doubled when deposited by electro-sprayed (ESP) microspheres instead of by commercial hollow spherical powders. It was believed that partial-molten nodules with featured microstructures inherited from the feedstock microspheres were the main contributor for prolonged thermal cycling durability due to improved fracture toughness and strain tolerance. The maximum lifetime was observed on samples with 20?30 vol.% of partial-molten microspheres. The hierarchy pores may both slow down the crack propagation by triggering multi-deflecting and promote cracking by reducing the tendency of interfacial deflection, the net effect depends on situation. The ESP coatings exhibited bimodal Weibull moduli upon indentation, which was regarded as originated from the hierarchy porous structure. Finally, the criterion was verified by micro-indentation and residual stain-stress evaluation by Raman spectroscopy. |
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| Keywords: | Thermal barrier coatings Yttria stabilized zirconia Air plasma spray Electro-sprayed Microstructure |
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