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Experiments, Statistical Analysis, and Modeling to Evaluate the Porosity Influence in SPS Coatings

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Abstract

Suspension plasma spray (SPS) is far more complicated than conventional plasma spray and requires a deep knowledge about the influence of process parameters and their correlations. In this study, YSZ coatings were manufactured by SPS with six different process parameters such as plasma power, suspension mass load, original powder size, substrate surface topology, spray distance, and spray step. Afterward, the porosity of as-prepared coatings was investigated by image method and x-ray transmission technique. A multivariate analysis on the collected experimental data was carried out by employing mathematical statistics methods. The results showed that: (1) coating porosity has a negative correlation with plasma power and suspension mass load and a positive correlation with the original powder size, spray distance, spray step, and substrate roughness; (2) spraying distance is the main factor affecting to coating porosity, followed by suspension mass load and substrate surface roughness, respectively. A linear model for porosity prediction was developed and was verified by experiments. The mechanism by which process parameters influence coating porosity is also discussed.

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Acknowledgments

This research used resources of the Advanced Photon Source, a US Department of Energy (DOE) Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory under Contract No. DE-AC02-06CH11357.

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Authors and Affiliations

  1. ICB, UMR 6303, CNRS, Université de Bourgogne Franche-Comté, UTBM, 90010, Belfort, France

    Yongli Zhao, François Peyraut, Marie-Pierre Planche, Hanlin Liao & Ghislain Montavon

  2. Advanced Photon Source, Argonne National Laboratory, 9700 S. Cass Avenue, Argonne, IL, 60439, USA

    Jan Ilavsky

  3. Saint-Gobain CREE, 84300, Cavaillon, France

    Audrey Lasalle & Alain Allimant

Authors
  1. Yongli Zhao
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  2. François Peyraut
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  3. Marie-Pierre Planche
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  4. Jan Ilavsky
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  5. Hanlin Liao
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  6. Audrey Lasalle
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  7. Alain Allimant
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  8. Ghislain Montavon
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Corresponding author

Correspondence to Yongli Zhao.

Additional information

This article is an invited paper selected from presentations at the 2018 International Thermal Spray Conference, held May 7-10, 2018, in Orlando, Florida, USA, and has been expanded from the original presentation.

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Zhao, Y., Peyraut, F., Planche, MP. et al. Experiments, Statistical Analysis, and Modeling to Evaluate the Porosity Influence in SPS Coatings. J Therm Spray Tech 28, 76–86 (2019). https://doi.org/10.1007/s11666-018-0749-4

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  • DOI: https://doi.org/10.1007/s11666-018-0749-4

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