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Plasma-Sprayed Thermal Barrier Coatings: New Materials, Processing Issues, and Solutions

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Abstract

Growing demands on thermal barrier coatings (TBCs) for gas turbines regarding their temperature and cyclic capabilities, corrosion resistance, and erosion performance have instigated the development of new materials and coating systems. Different pyrochlores, perovskites, doped yttria-stabilized zirconia, and hexaaluminates have been identified as promising candidates. However, processing these novel TBC materials by plasma spraying is often challenging. During the deposition process, stoichiometric changes, formation of undesired secondary phases or non-optimum amorphous contents, as well as detrimental microstructural effects can occur in particular. This article describes these difficulties and the development of process-related solutions by employing diagnostic tools.

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Acknowledgments

The authors are grateful to Dr. Jürgen Malzbender (IEK-2), Mr. Mirko Ziegner (IEK-2), Mrs. Hannelore Lippert (ZCH), and the colleagues of IEK-1 in Forschungszentrum Jülich GmbH for their help in carrying out the experiments which results are reported in this article.

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  1. Institut für Energie- und Klimaforschung (IEK-1), Forschungszentrum Jülich GmbH, Jülich, Germany

    Georg Mauer, Maria Ophelia Jarligo, Daniel Emil Mack & Robert Vaßen

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  1. Georg Mauer
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  2. Maria Ophelia Jarligo
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  3. Daniel Emil Mack
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  4. Robert Vaßen
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Correspondence to Georg Mauer.

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Mauer, G., Jarligo, M.O., Mack, D.E. et al. Plasma-Sprayed Thermal Barrier Coatings: New Materials, Processing Issues, and Solutions. J Therm Spray Tech 22, 646–658 (2013). https://doi.org/10.1007/s11666-013-9889-8

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  • DOI: https://doi.org/10.1007/s11666-013-9889-8

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