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Manufacturing of Composite Coatings by Atmospheric Plasma Spraying Using Different Feed-Stock Materials as YSZ and MoSi2

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Abstract

Yttria-stabilized zirconia (YSZ) is the state-of-the-art material for the top coat of thermal barrier coatings. To increase the efficiency and lifetime of gas turbines, the integration of MoSi2 as a healing material was proposed. A new method of manufacture was explored in order to enable the spraying of a homogeneous mixed layer of YSZ and MoSi2. As the chemical and physical properties of these powders are very different, they require contrasting process conditions. Due to the evaporation of Si from MoSi2 at spraying conditions suitable for YSZ, more moderate conditions and a shorter time of flight are required for depositing MoSi2. At the same time, the spraying conditions still need to be sufficient for melting the YSZ particles in order to produce a coating. To obtain a homogeneous mixture, both conditions can be matched using an injection system that allows powder injection at two different locations of the plasma jet. Two-color pyrometry during flight (DPV-2000, Tecnar) was used to monitor the actual particle temperature. By optimizing the injection point for the MoSi2, a mixed coating was obtained without decomposition of the MoSi2, which has been analyzed by means of XRD and SEM.

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Acknowledgments

The authors would like to thank Karl-Heinz Rauwald and Frank Vondahlen for their support during the manufacture of the thermally sprayed samples, Dr. Doris Sebold for the SEM analysis of the coatings prepared with mixed powders, and Dr. Yoo Jung Sohn for the quantitative analysis of the XRD data (all Institute of Energy and Climate Research—Materials Synthesis and Processing (IEK-1), Forschungszentrum Jülich GmbH). The authors would also like to thank Dr. Egbert Wessel (Institute of Energy and Climate Research—Microstructure and Properties of Materials (IEK-2), Forschungszentrum Jülich GmbH) for the SEM analysis of the coating deposited when injecting YSZ and MoSi2 at different locations of the plasma jet. The research leading to these results has received funding from the European Union Seventh Framework Programme FP7 (2007–2013) under Grant Agreement No. 309849.

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

    D. Koch, G. Mauer & R. Vaßen

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  1. D. Koch
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  2. G. Mauer
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  3. R. Vaßen
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Correspondence to D. Koch.

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Koch, D., Mauer, G. & Vaßen, R. Manufacturing of Composite Coatings by Atmospheric Plasma Spraying Using Different Feed-Stock Materials as YSZ and MoSi2 . J Therm Spray Tech 26, 708–716 (2017). https://doi.org/10.1007/s11666-017-0537-6

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  • DOI: https://doi.org/10.1007/s11666-017-0537-6

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