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Preparation of SrZrO3 Thermal Barrier Coating by Solution Precursor Plasma Spray

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Abstract

The solution precursor plasma spray (SPPS) process is capable of depositing highly durable thermal barrier coatings (TBCs). In this study, an aqueous chemical precursor feedstock was injected into the plasma jet to deposit SrZrO3 thermal barrier coating on metal substrate. Taguchi design of experiments was employed to optimize the SPPS process. The thermal characteristics and phase evolution of the SrZrO3 precursor, as well as the influence of various spray parameters on the coating deposition rate, microhardness, microstructure, and phase stability, were investigated. The experimental results showed that, at given spray distance, feedstock flow rate, and atomization pressure, the optimized spray parameters were arc current of 600 A, argon flow rate of 40 L/min, and hydrogen flow rate of 10 L/min. The SrZrO3 coating prepared using the optimized spray parameters had single-pass thickness of 6.0 μm, porosity of ~18%, and microhardness of 6.8 ± 0.1 GPa. Phase stability studies indicated that the as-sprayed SrZrO3 coating had good phase stability in the temperature range from room temperature to 1400 °C, gradually exhibiting a phase transition from t′-ZrO2 to m-ZrO2 in the SrZrO3 coating at 1450 °C with increasing time, while the SrZrO3 phase did not change.

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Acknowledgments

The authors gratefully acknowledge financial support from the National Natural Science Foundation of China (Nos. 51462026, 51672136), the Inner Mongolia Natural Science Foundation (No. 2014MS0509), and Shanghai technical platform for testing and characterization on inorganic materials (No. 14DZ2292900). The authors would also like to thank Prof. E. Jordan from University of Connecticut for valuable discussion.

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Authors and Affiliations

  1. School of Materials Science and Engineering, Inner Mongolia University of Technology, Hohhot, 010051, China

    Xinhui Li, Wen Ma, Jing Wen, Yu Bai, Li Sun & Baodong Chen

  2. Inner Mongolia Key Laboratory of Thin Film and Coatings Technology, Hohhot, 010051, China

    Xinhui Li, Wen Ma, Jing Wen, Yu Bai, Li Sun, Baodong Chen, Hongying Dong & Yingchai Shuang

  3. School of Chemical Engineering, Inner Mongolia University of Technology, Hohhot, 010051, China

    Hongying Dong & Yingchai Shuang

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  1. Xinhui Li
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  2. Wen Ma
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  3. Jing Wen
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  4. Yu Bai
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  5. Li Sun
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  7. Hongying Dong
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  8. Yingchai Shuang
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Correspondence to Wen Ma.

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Li, X., Ma, W., Wen, J. et al. Preparation of SrZrO3 Thermal Barrier Coating by Solution Precursor Plasma Spray. J Therm Spray Tech 26, 371–377 (2017). https://doi.org/10.1007/s11666-017-0527-8

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  • DOI: https://doi.org/10.1007/s11666-017-0527-8

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