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Epitaxial growth and cracking of highly tough 7YSZ splats by thermal spray technology
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Influence of Direct Splat-Affecting Parameters on the Splat-Type Distribution, Porosity, and Density of Segmentation Cracks in Plasma-Sprayed YSZ Coatings

18 March 2021

W. Tillmann, O. Khalil & I. Baumann

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  • Research Article
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  • Published: 28 December 2017

Epitaxial growth and cracking of highly tough 7YSZ splats by thermal spray technology

  • Lin Chen1 &
  • Guan-Jun Yang1 

Journal of Advanced Ceramics volume 7, pages 17–29 (2018)Cite this article

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Abstract

Thermally sprayed coatings are essentially layered materials and contain large numbers of lamellar pores. It is thus quite necessary to clarify the formation mechanism of lamellar pores which significantly influence coating performances. In the present study, to elaborate the formation mechanism of lamellar pores, the yttria-stabilized zirconia (ZrO2–7 wt% Y2O3, 7YSZ) splats, which have high fracture toughness and tetragonal phase stability, were employed. Interestingly, anomalous epitaxial growth occurred for all deposition temperatures in spite of the extremely high cooling rate, which clearly indicated chemical bonding and complete contact at splat/substrate interface before splat cooling. However, transverse spallation substantially occurred for all deposition temperatures in spite of the high fracture toughness of 7YSZ, which revealed that the lamellar pores were from transverse cracking/spallation due to the large stress during splat cooling. Additionally, fracture mechanics analysis was carried out, and it was found that the stress arose from the constraint effect of the shrinkage of the splat by locally heated substrate with the value about 1.97 GPa. This clearly demonstrated that the stress was indeed large enough to drive transverse cracking/spallation forming lamellar pores during splat cooling. All of these contribute to understanding the essential features of lamellar bonding and further tailoring the coating structures and performance.

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Acknowledgements

The present project is supported by National Basic Research Program of China (No. 2013CB035701), the Fundamental Research Funds for the Central Universities, and the National Program for Support of Top-notch Young Professionals.

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Authors and Affiliations

  1. State Key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, Xi’an Jiaotong University, Xi’an, Shaanxi, 710049, China

    Lin Chen & Guan-Jun Yang

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  1. Lin Chen
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Correspondence to Guan-Jun Yang.

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Chen, L., Yang, GJ. Epitaxial growth and cracking of highly tough 7YSZ splats by thermal spray technology. J Adv Ceram 7, 17–29 (2018). https://doi.org/10.1007/s40145-017-0252-2

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  • Received: 16 June 2017

  • Revised: 22 August 2017

  • Accepted: 27 October 2017

  • Published: 28 December 2017

  • Issue Date: March 2018

  • DOI: https://doi.org/10.1007/s40145-017-0252-2

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Keywords

  • epitaxial growth
  • crack patterns
  • transverse cracking/spallation
  • stress
  • locally heated substrate
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