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

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Abstract

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.

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Acknowledgment

The authors would like to acknowledge gratefully Mr. Karl-Heinz Rauwald, Mr. Ralf Laufs, and Mr. Frank Vondahlen for their help in the manufacture of the sprayed samples. They thank Mr. Mark Kappertz for his support in metallographic preparations, Dr. Doris Sebold for SEM investigations, Mrs. Nicole Adels for thermal cycling tests, Mrs. Sigrid Schwartz-Lückge for mercury porosimetry measurements, Mrs. Hiltrud Moitroux for photographs of specimens (all Forschungszentrum Jülich GmbH, IEK-1), and Mr. Mirko Ziegner for XRD analysis (Forschungszentrum Jülich GmbH, IEK-2). The help of Dr. Robert Mücke (Forschungszentrum Jülich GmbH, IEK-1) in the determination of the Young’s modulus is also gratefully acknowledged.

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Authors and Affiliations

  1. Institut für Energie- und Klimaforschung (IEK-1), Forschungszentrum Jülich GmbH, Jülich, Germany

    Alexandre Guignard, Georg Mauer, Robert Vaßen & Detlev Stöver

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  1. Alexandre Guignard
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  2. Georg Mauer
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  3. Robert Vaßen
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  4. Detlev Stöver
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Corresponding author

Correspondence to Alexandre Guignard.

Additional information

This article is an invited paper selected from presentations at the 2011 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Thermal Spray 2011: Proceedings of the International Thermal Spray Conference, Hamburg, Germany, September 27-29, 2011, Basil R. Marple, Arvind Agarwal, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and André McDonald, Ed., ASM International, Materials Park, OH, 2011.

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Guignard, A., Mauer, G., Vaßen, R. et al. Deposition and Characteristics of Submicrometer-Structured Thermal Barrier Coatings by Suspension Plasma Spraying. J Therm Spray Tech 21, 416–424 (2012). https://doi.org/10.1007/s11666-012-9762-1

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  • DOI: https://doi.org/10.1007/s11666-012-9762-1

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