Abstract
Ceramic matrix composites (CMCs) have become important structural materials of aero-engines under elevated operating temperature while the abradable ceramic coatings matched with CMCs are seldom reported. In this work, the atmospheric plasma spray (APS) technique was used to fabricate and design Yb2Si2O7-based coatings with various contents of CaF2. The phase composition and microstructure of the coatings, as well as Rockwell hardness, were characterized. The wear and abradable behaviors of the coatings including friction coefficients and volume wear rates were evaluated at room temperature and 900 °C, respectively. The results show that the Rockwell hardness and friction coefficients decreased, and the volume wear rates of the coatings at room temperature significantly raised with the increase of CaF2 content. The coatings exhibited quite different behaviors at 900 °C compared with those at room temperature owing to the lubricant effect of CaF2. The morphologies of the coatings after the wear tests were characterized and the possible failure mechanisms were analyzed, and this study may provide guidelines for the application of the abradable coatings suitable for CMCs.
Similar content being viewed by others
Reference
H.I. Faraoun, J.L. Seichepine, C. Coddet, H. Aourag, J. Zwick, N. Hopkins, D. Sporer, and M. Hertter, Modelling Route for Abradable Coatings, Surf. Coat., 2006, 200(22–23), p 6578-6582.
M. Bounazefa, S. Guessasmab, and E.A. Bediaa, Blade Protection and Efficiency Preservation of a Turbine by a Sacrificial Material Coating, Adv. Powder Technol., 2007, 18(2), p 123-133.
E. Irissou, A. Dadouche, and R.S. Lima, Tribological Characterization of Plasma-Sprayed CoNiCrAlY-BN Abradable Coatings, J. Therm. Spray Technol., 2013, 23(1–2), p 252-261.
P. Dowson, M.S. Walker, and A.P. Watson, Development of Abradable and Rub-Tolerant Seal Materials for Application in Centrifugal Compressors and Steam Turbines, Seal. Technol., 2004, 2004(12), p 5-10.
R. Rajendran, Gas Turbine Coatings–An Overview, Eng. Fail. Anal., 2012, 26, p 355-369.
X. Ma and A. Matthews, Investigation of Abradable Seal Coating Performance Using Scratch Testing, Surf. Coat. Technol., 2007, 202(4–7), p 1214-1220.
X. Cheng, Y. Yu, D. Zhang, T. Liu, J. Liu, and J. Shen, Preparation and Performance of an Abradable NiCrFeAlBN-YSZ-NiCrAl Layered Seal Coating for Aircraft Engines, J. Therm. Spray Technol., 2020, 29(7), p 1804-1814.
R. Soltani, M. Heydarzadeh-Sohi, M. Ansari, F. Afsari, and Z. Valefi, Effect of APS Process Parameters on High-Temperature Wear Behavior of Nickel–Graphite Abradable Seal Coatings, Surf. Coat. Technol., 2017, 321, p 403-408.
M. Yi, J. He, B. Huang, and H. Zhou, Friction and Wear Behaviour and Abradability of Abradable Seal Coating, Wear, 1999, 231(1), p 47-53.
R.E. Johnston, Mechanical Characterisation of AlSi-hBN, NiCrAl-Bentonite, and NiCrAl-Bentonite-hBN Freestanding Abradable Coatings, Surf. Coat. Technol., 2011, 205(10), p 3268-3273.
H.I. Faraoun, T. Grosdidier, J.L. Seichepine, D. Goran, H. Aourag, C. Coddet, J. Zwick, and N. Hopkins, Improvement of Thermally Sprayed Abradable Coating by Microstructure Control, Surf. Coat. Technol., 2006, 201(6), p 2303-2312.
N.P. Padture, Advanced Structural Ceramics in Aerospace Propulsion, Nat. Mater., 2016, 15(8), p 804-809.
M. Belmonte, Advanced Ceramic Materials for High Temperature Applications, Adv. Eng. Mater., 2006, 8(8), p 693-703.
R. Naslain, SiC-matrix Composites: Nonbrittle Ceramics for Thermo-structural Application, Int. J. Appl. Ceram. Technol., 2005, 2(2), p 75-84.
T. Zhu, Y. Niu, X. Zhong, J. Zhao, Y. Zeng, X. Zheng, and C. Ding, Influence of Phase Composition on Microstructure and Thermal Properties of Ytterbium Silicate Coatings Deposited by Atmospheric Plasma Spray, J. Eur. Ceram. Soc., 2018, 38(11), p 3974-3985.
Y. Wang, Y. Niu, X. Zhong, M. Shi, F. Mao, L. Zhang, Q. Li, and X. Zheng, Water Vapor Corrosion Behaviors of Plasma Sprayed RE2SiO5 (RE = Gd, Y, Er) Coatings, Corros. Sci., 2020, 167, p 108529-108537.
D. Qin, Y. Niu, H. Li, X. Zhong, X. Zheng, and J. Sun, Fabrication and Characterization of Yb2Si2O7-based Composites as Novel Abradable Sealing Coatings, Ceram. Int., 2021, 47(16), p 23153-23161.
R. Ali, T. Huang, P. Song, D. Zhang, S. Ali, M. Arif, S. Awais, D. Hanifi, and J. Lu, Tribological Performance and Phase Transition of MAX-phase/YSZ Abradable Seal Coating Produced by Air Plasma Spraying, Ceram. Int., 2022, 48(3), p 4188-4199.
X.M. Sun, L.Z. Du, H. Lan, H.F. Zhang, R.Y. Liu, Z.G. Wang, S.G. Fang, C.B. Huang, Z.A. Liu, and W.G. Zhang, Study on Thermal Shock Behavior of YSZ Abradable Sealing Coating Prepared by Mixed Solution Precursor Plasma Spraying, Surf. Coat. Technol., 2020, 397, p 126045-126053.
X.Q. Cao, R. Vassen, and D. Stoever, Ceramic Materials for Thermal Barrier Coatings, J. Eur. Ceram. Soc., 2004, 24(1), p 1-10.
D.R. Clarke, M. Oechsner, and N.P. Padture, Thermal-Barrier Coatings for More Efficient Gas-Turbine Engines, MRS Bull., 2012, 37(10), p 891-898.
A.G. Evans, D.R. Clarke, and C.G. Levi, The Influence of Oxides on the Performance of Advanced gas Turbines, J. Eur. Ceram. Soc., 2008, 28(7), p 1405-1419.
X. Zhang, Q. Yang, L. Chen, P. Song, and J. Feng, Fabrication and Characterization of 8YSZ Ceramic Based Abradable Seal Coatings by Atmospheric Plasma Spraying, Ceram. Int., 2020, 46(17), p 26530-26538.
C. Lamuta, G. Di Girolamo, and L. Pagnotta, Microstructural, Mechanical and Tribological Properties of Nanostructured YSZ Coatings Produced with Different APS Process Parameters, Ceram. Int., 2015, 41(7), p 8904-8914.
B. Saruhan, P. Francois, K. Fritscher, and U. Schulz, EB-PVD Processing of Pyrochlore-Structured La2Zr2O7-Based TBCs, Surf. Coat. Technol., 2004, 182(2–3), p 175-183.
Z. Shen, Z. Liu, Z. Huang, R. Mu, L. He, and G. Liu, Thermal Shock Life and Failure Behaviors of La2Zr2O7/YSZ, La2Ce2O7/YSZ and Gd2Zr2O7/YSZ DCL TBCs by EB-PVD, Mater Charact, 2021, 173, p 110923-110931.
R. Vaßen, M.O. Jarligo, T. Steinke, D.E. Mack, and D. Stöver, Overview on Advanced Thermal Barrier Coatings, Surf. Coat. Technol., 2010, 205(4), p 938-942.
X. Zhong, Y. Niu, L. Huang, H. Li, X. Zheng, C. Ding, and J. Sun, Microstructure and Thermal Properties of Atmospheric Plasma-Sprayed Yb2Si2O7 Coating, J. Therm. Spray Technol., 2016, 26(1–2), p 203-210.
Y. Wang, Y. Niu, X. Zhong, M. Shi, F. Mao, L. Zhang, Q. Li, and X. Zheng, Water Vapor Corrosion Behaviors of Plasma Sprayed Ytterbium Silicate Coatings, Ceram. Int., 2020, 46(18), p 28237-28243.
J. Deng, L. Liu, X. Yang, J. Liu, J. Sun, and J. Zhao, Self-Lubrication of Al2O3/TiC/CaF2 Ceramic Composites in Sliding Wear Tests and in Machining Processes, Mater. Des., 2007, 28(3), p 757-764.
W. Zhao, W. Zhao, Z. Huang, G. Liu, and B. Wu, Tribological Performances of Epoxy Resin Composite Coatings Using Hexagonal Boron Nitride and Cubic Boron Nitride Nanoparticles as Additives, Chem. Phys. Lett., 2019, 732, p 136646-136655.
C. Huang, L. Du, and W. Zhang, Preparation and Characterization of Atmospheric Plasma-Sprayed NiCr/Cr3C2-BaF2·CaF2 Composite Coating, Surf. Coat. Technol., 2009, 203(20-21), p 3058-3065.
Acknowledgments
This work was supported by the National Key R&D Program of China (2018YFB0704400) and Shanghai Technical Platform for testing on inorganic materials (19DZ2290700).
Author information
Authors and Affiliations
Corresponding authors
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Supplementary Information
Below is the link to the electronic supplementary material.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Wang, J., Hong, D., Zhong, X. et al. High-Temperature Wear and Abradable Behaviors of Yb2Si2O7-CaF2 Composite Coatings Fabricated by Atmospheric Plasma Spray. J Therm Spray Tech 33, 113–121 (2024). https://doi.org/10.1007/s11666-023-01666-3
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11666-023-01666-3