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Columnar-Structured Mg-Al-Spinel Thermal Barrier Coatings (TBCs) by Suspension Plasma Spraying (SPS)

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Abstract

The suspension plasma spraying (SPS) process has been developed to permit the feeding of sub-micrometer-sized powder into the plasma plume. In contrast to electron beam-physical vapor deposition and plasma spray-physical vapor deposition, SPS enables the cost-efficient deposition of columnar-structured coatings. Due to their strain tolerance, these coatings play an important role in the field of thermal barrier coatings (TBCs). In addition to the cost-efficient process, attention was turned to the TBC material. Nowadays, yttria partially stabilized zirconia (YSZ) is used as standard TBC material. However, its long-term application at temperatures higher than 1200 °C is problematic. At these high temperatures, phase transitions and sintering effects lead to the degradation of the TBC system. To overcome those deficits of YSZ, Mg-Al-spinel was chosen as TBC material. Even though it has a lower melting point (~2135 °C) and a higher thermal conductivity (~2.5 W/m/K) than YSZ, Mg-Al-spinel provides phase stability at high temperatures in contrast to YSZ. The Mg-Al-spinel deposition by SPS resulted in columnar-structured coatings, which have been tested for their thermal cycling lifetime. Furthermore, the influence of substrate cooling during the spraying process on thermal cycling behavior, phase composition, and stoichiometry of the Mg-Al-spinel has been investigated.

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Acknowledgments

The authors kindly thank Mr. Karl-Heinz Rauwald, Mr. Ralf Laufs, and Mr. Frank Vondahlen for their support in the manufacturing of the sprayed samples. They acknowledge gratefully Dr. Doris Sebold for her SEM- and EDS-investigations, Dr. Yoo Jung Sohn for x-ray analysis, Mrs. Andrea Hilgers for the measurement of the particle-sizes and the viscosity, Mrs. Michaela Andreas for the powder preparation, and Mrs. Hiltrud Moitroux for the photographs of the specimens. Furthermore, they thank Mrs. Nicole Adels for the thermal cycling tests.

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Author notes

  1. S. Ebert

    Present address: CeramTec-ETEC, Lohmar, Germany

Authors and Affiliations

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

    N. Schlegel, S. Ebert, G. Mauer & R. Vaßen

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  1. N. Schlegel
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  2. S. Ebert
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  3. G. Mauer
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  4. R. Vaßen
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Correspondence to N. Schlegel.

Additional information

This article is an invited paper selected from presentations at the 2014 International Thermal Spray Conference, held May 21-23, 2014, in Barcelona, Spain, and has been expanded from the original presentation.

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Schlegel, N., Ebert, S., Mauer, G. et al. Columnar-Structured Mg-Al-Spinel Thermal Barrier Coatings (TBCs) by Suspension Plasma Spraying (SPS). J Therm Spray Tech 24, 144–151 (2015). https://doi.org/10.1007/s11666-014-0138-6

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  • DOI: https://doi.org/10.1007/s11666-014-0138-6

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