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Systematic Investigation on the Influence of Spray Parameters on the Mechanical Properties of Atmospheric Plasma-Sprayed YSZ Coatings

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Abstract

In the atmospheric plasma spray (APS) process, micro-sized ceramic powder is injected into a thermal plasma where it is rapidly heated and propelled toward the substrate. The coating formation is characterized by the subsequent impingement of a large number of more or less molten particles forming the so-called splats and eventually the coating. In this study, a systematic investigation on the influence of selected spray parameters on the coating microstructure and the coating properties was conducted. The investigation thereby comprised the coating porosity, the elastic modulus, and the residual stress evolution within the coating. The melting status of the particles at the impingement on the substrate in combination with the substrate surface condition is crucial for the coating formation. Single splats were collected on mirror-polished substrates for selected spray conditions and evaluated by identifying different types of splats (ideal, distorted, weakly bonded, and partially molten) and their relative fractions. In a previous study, these splat types were evaluated in terms of their effect on the above-mentioned coating properties. The particle melting status, which serves as a measure for the particle spreading behavior, was determined by in-flight particle temperature measurements and correlated to the coating properties. It was found that the gun power and the spray distance have a strong effect on the investigated coating properties, whereas the feed rate and the cooling show minor influence.

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Acknowledgments

The authors gratefully acknowledge the German Research Foundation (DFG) for funding this Project (VA163/6-1). Furthermore, we gratefully acknowledge the assistance of Karl-Heinz Rauwald for the experimental support, and Mark Kappertz for his help with metallographic sample preparations.

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Authors and Affiliations

  1. Forschungszentrum Jülich GmbH, Institute of Energy and Climate Research, Materials Synthesis and Processing (IEK-1), 52425, Jülich, Germany

    Markus Mutter, Georg Mauer, Robert Mücke, Olivier Guillon & Robert Vaßen

  2. Jülich Aachen Research Alliance: JARA-Energy, Jülich, Germany

    Olivier Guillon

Authors
  1. Markus Mutter
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  2. Georg Mauer
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  3. Robert Mücke
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  4. Olivier Guillon
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  5. Robert Vaßen
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Correspondence to Markus Mutter.

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Mutter, M., Mauer, G., Mücke, R. et al. Systematic Investigation on the Influence of Spray Parameters on the Mechanical Properties of Atmospheric Plasma-Sprayed YSZ Coatings. J Therm Spray Tech 27, 566–580 (2018). https://doi.org/10.1007/s11666-018-0697-z

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  • DOI: https://doi.org/10.1007/s11666-018-0697-z

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