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Suspensions Plasma Spraying of Ceramics with Hybrid Water-Stabilized Plasma Technology

Abstract

Technology of water-stabilized plasma torch was recently substantially updated through introduction of a so-called hybrid concept that combines benefits of water stabilization and gas stabilization principles. The high-enthalpy plasma provided by the WSP-H (“hybrid”) torch may be used for thermal spraying of powders as well as liquid feedstocks with high feed rates. In this study, results from three selected experiments with suspension plasma spraying with WSP-H technology are presented. Possibility of deposition of coatings with controlled microstructures was demonstrated for three different ceramics (YSZ—yttria-stabilized zirconia, YAG—yttrium aluminum garnet and Al2O3) introduced into ethanol-based suspensions. Shadowgraphy was used for optimization of suspension injection and visualization of the liquid fragmentation in the plasma jet. Coatings were deposited onto substrates attached to the rotating carousel with integrated temperature monitoring and air cooling, which provided an excellent reproducibility of the deposition process. Deposition of columnar-like YSZ and dense YAG and Al2O3 coatings was successfully achieved. Deposition efficiency reached more than 50%, as evaluated according to EN ISO 17 836 standard.

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Acknowledgment

Financial support provided by Czech Science Foundation through Grant No. GA15-12145S (Physical aspects of plasma spray deposition from liquid feedstock) is gratefully acknowledged.

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Correspondence to Radek Musalek.

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This article is an invited paper selected from presentations at the 2016 International Thermal Spray Conference, held May 10-12, 2016, in Shanghai, P. R. China, and has been expanded from the original presentation.

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Musalek, R., Medricky, J., Tesar, T. et al. Suspensions Plasma Spraying of Ceramics with Hybrid Water-Stabilized Plasma Technology. J Therm Spray Tech 26, 37–46 (2017). https://doi.org/10.1007/s11666-016-0493-6

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Keywords

  • alumina
  • ceramics
  • dense
  • hybrid plasma torch
  • suspension plasma spraying
  • water-stabilized plasma
  • yttria-stabilized zirconia (YSZ)