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Effect of Thermal Spraying Method, Time and Temperature on the Thickness of Thermally Grown Oxide and Lifetime of Thermal Barrier Coatings

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Abstract

This paper investigates various parameters affecting the thickness of the thermally grown oxide (TGO) layer affecting the lifetime of conventional thermal barrier coatings (TBCs) with two new coatings. The thickness of the TGO layer directly influences the generation of interfacial stresses and delamination of the coating layers. This study examines the effects of the thermal spraying method, time, temperature, and the TC absence on the TGO thickness. In the first new coating, two bond coats are utilized, applied using the high-velocity oxygen fuel (HVOF) and air plasma spraying (APS) methods. The second new coating involves an aluminide diffusion coating applied between the bond coat and substrate. Scanning electron microscope (SEM) analysis of the test samples reveals that the HVOF-applied coating forms a TGO with lower thickness compared to the APS coating. The most extended lifetime of 336 h is achieved by the new coating with a two-layer bond coat, followed by the HVOF coating with 288 h, the diffusion coating with 238 h, and the APS coating with 192 h, respectively. Despite the lower TGO thickness in the HVOF coating compared to the two-layer bond coat, its lifetime is reduced due to severe spinel growth at the interface of TBCs with the HVOF bond coat caused by the faster depletion of aluminum (Al). The diffusion coating increases the concentration of Al in the upper part of the substrate, thereby reducing the depletion of Al from the bond coat through interdiffusion. By retaining the Al in the bond coat for a longer duration, the diffusion coating enhances the lifetime of TBCs.

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Notes

  1. In this article, the term APS-bond coat refers to the bond coat layer applied by the APS method, and the term HVOF-bond coat refers to the bond coat layer applied by the HVOF method.

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Authors and Affiliations

  1. Mechanical Engineering Department, Faculty of Engineering, University of Zanjan, Zanjan, Iran

    Javad Rahimi, Esmaeil Poursaeidi, Farzam Montakhabi, Mohammad Rasoul Javadi Sigaroodi & Yousef Yousefi Jamalabad

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  1. Javad Rahimi
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  2. Esmaeil Poursaeidi
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  3. Farzam Montakhabi
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Rahimi, J., Poursaeidi, E., Montakhabi, F. et al. Effect of Thermal Spraying Method, Time and Temperature on the Thickness of Thermally Grown Oxide and Lifetime of Thermal Barrier Coatings. J Therm Spray Tech 32, 2580–2602 (2023). https://doi.org/10.1007/s11666-023-01670-7

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