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Investigations on the Initial Stress Evolution During Atmospheric Plasma Spraying of YSZ by In Situ Curvature Measurement

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Abstract

The residual stresses within plasma-sprayed coatings are an important factor that can influence the lifetime as well as the performance in operation. The investigation of stresses evolving during deposition and post-deposition cooling for atmospheric plasma spraying of yttria-stabilized zirconia coatings using in situ measurement of the samples curvature is a powerful tool for identifying the factors that contribute to stress generation. Under various spray conditions, the first deposition pass leads to a significantly larger increase in samples curvature than the subsequent passes. It is shown in this work that the amount of curvature change at the onset of spraying is significantly influenced by the spray conditions, as well as by the substrate material. More information on the origin of this steep curvature increase at the onset of spraying was obtained by single splat experiments, which yielded information on the splat bonding behavior under various conditions. A comparison of the compressive yield strength for different substrate materials indicated the influence of substrate residual stress relaxation. Residual stress measurements using the incremental hole-drilling method and x-ray diffraction confirmed that the coating deposition affects the substrate residual stress level. The yield strength data were combined with the substrate near-surface temperature during deposition, obtained by finite element simulations, and with the measured residual stress-profile. This revealed that residual stress relaxation is the key factor for the initial curvature increase.

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Acknowledgments

The authors gratefully acknowledge the German Research Foundation (DGF) for funding this Project (VA163/6-1 and GI376/6-1). Furthermore, they gratefully acknowledge the assistance of Karl-Heinz Rauwald for the experimental support, Dr. Doris Sebold for the SEM image, and Mark Kappertz for his help with sample preparations.

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Authors and Affiliations

  1. Materials Synthesis and Processing (IEK-1), Institute of Energy and Climate Research, Forschungszentrum Jülich GmbH, 52425, Jülich, Germany

    Markus Mutter, Georg Mauer, Robert Mücke & Robert Vaßen

  2. Karlsruher Institut für Technologie (KIT), Institut für Angewandte Materialien – Werkstoffkunde (IAM-WK), 76131, Karlsruhe, Germany

    Hyoung Chul Back & Jens Gibmeier

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  1. Markus Mutter
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  2. Georg Mauer
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Correspondence to Markus Mutter.

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Mutter, M., Mauer, G., Mücke, R. et al. Investigations on the Initial Stress Evolution During Atmospheric Plasma Spraying of YSZ by In Situ Curvature Measurement. J Therm Spray Tech 25, 672–683 (2016). https://doi.org/10.1007/s11666-016-0398-4

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