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Deposition Behavior of PS-PVD Yttria Partially Stabilized Zirconia Coatings

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Abstract

As a novel processing technology, plasma spray-physical vapor deposition (PS-PVD) enables coatings to be deposited mainly from vapor phase. To explore the potential advantages of such a plasma spray-based processes, the deposition mechanisms and their dependency on process conditions should be better investigated. In this work, yttria partially stabilized zirconia thermal barrier coatings with quasi-columnar structure were fabricated by PS-PVD. The morphologies of the coatings for each set of deposition durations (from 30 ms to 100 s) and spray distances range from 800 to 1000 mm were studied. Besides, a design-of-experiment was used to investigate the non-line-of-sight capability of PS-PVD coatings, which were deposited on flat superalloy substrates that mounted on a static cylindrical graphite holder approximately 40 mm in diameter at various deposition angle (from 0° to 270°). Moreover, the residual stresses in the topcoat and thermally grown oxide scale were measured non-destructively using Raman spectroscopy and photoluminescence piezospectroscopy, respectively. The stage growth process of PS-PVD coatings was obtained by electron backscattered diffraction characterization of the crystal orientations and distributions of crystal size. The various microstructures of the coatings help to improve the understanding of the deposition mechanisms of PS-PVD coatings.

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Acknowledgments

This work was jointly supported by the National Science and Technology Major Project (2017-VI-0010-0082), Science and Technology Innovation of Shanghai (No. 18511108702) and National Natural Science Foundation of China (NSFC) (No. 51701235).

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Authors and Affiliations

  1. The Key Laboratory of Inorganic Coating Materials CAS, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai, 201899, People’s Republic of China

    Jiasheng Yang, Zefei Cheng, Xinghua Zhong, Fang Shao, Huayu Zhao, Yin Zhuang, Jing Sheng, Jinxing Ni & Shunyan Tao

  2. Center of Materials Science and Optoelectronics Engineering, University of Chinese Academy of Sciences, Beijing, 100049, People’s Republic of China

    Zefei Cheng

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  1. Jiasheng Yang
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Correspondence to Shunyan Tao.

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Yang, J., Cheng, Z., Zhong, X. et al. Deposition Behavior of PS-PVD Yttria Partially Stabilized Zirconia Coatings. J Therm Spray Tech 30, 1136–1147 (2021). https://doi.org/10.1007/s11666-021-01196-w

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  • DOI: https://doi.org/10.1007/s11666-021-01196-w

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