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Columnar-Structured Thermal Barrier Coatings (TBCs) by Thin Film Low-Pressure Plasma Spraying (LPPS-TF)

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Abstract

The very low-pressure plasma Spray (VLPPS) process has been developed with the aim of depositing uniform and thin coatings with coverage of a large area by plasma spraying. At typical pressures of 100-200 Pa, the characteristics of the plasma jet change compared to conventional low-pressure plasma-spraying processes (LPPS) operating at 5-20 kPa. The combination of plasma spraying at low pressures with enhanced electrical input power has led to the development of the LPPS-TF process (TF = thin film). At appropriate parameters, it is possible to evaporate the powder feedstock material providing advanced microstructures of the deposits. This technique offers new possibilities for the manufacturing of thermal barrier coatings (TBCs). Besides the material composition, the microstructure is an important key to reduce thermal conductivity and to increase strain tolerance. In this regard, columnar microstructures deposited from the vapor phase show considerable advantages. Therefore, physical vapor deposition by electron beam evaporation (EB-PVD) is applied to achieve such columnar-structured TBCs. However, the deposition rate is low, and the line-of-sight nature of the process involves specific restrictions. In this article, the deposition of TBCs by the LPPS-TF process is shown. How the evaporation of the feedstock powder could be improved and to what extent the deposition rates could be increased were investigated.

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Authors and Affiliations

  1. Institute of Energy Research (IEF-1), Forschungszentrum Jülich GmbH, Jülich, Germany

    Andreas Hospach, Georg Mauer, Robert Vaßen & Detlev Stöver

Authors
  1. Andreas Hospach
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  2. Georg Mauer
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  3. Robert Vaßen
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  4. Detlev Stöver
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Corresponding author

Correspondence to Andreas Hospach.

Additional information

This article is an invited paper selected from presentations at the 2010 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Thermal Spray: Global Solutions for Future Applications, Proceedings of the 2010 International Thermal Spray Conference, Singapore, May 3-5, 2010, Basil R. Marple, Arvind Agarwal, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Ghislain Montavon, Ed., ASM International, Materials Park, OH, 2011.

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Hospach, A., Mauer, G., Vaßen, R. et al. Columnar-Structured Thermal Barrier Coatings (TBCs) by Thin Film Low-Pressure Plasma Spraying (LPPS-TF). J Therm Spray Tech 20, 116–120 (2011). https://doi.org/10.1007/s11666-010-9549-1

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  • DOI: https://doi.org/10.1007/s11666-010-9549-1

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