Abstract
Plasma spray-physical vapor deposition (PS-PVD) is a unique processing method that bridges the gap between conventional thermal spray and vapor phase methods, and enables highly tailorable coatings composed of a variety of materials in thin, dense layers or columnar microstructures with modification of the processing conditions. The strengths of this processing technique are material and microstructural flexibility, deposition speed, and potential for non-line-of-sight (NLOS) capability by vaporization of the feedstock material. The NLOS capability of PS-PVD is investigated here using yttria-stabilized zirconia and gadolinium zirconate, which are materials of interest for turbine engine applications. PS-PVD coatings were applied to static cylindrical substrates approximately 6-19 mm in diameter to study the coating morphology as a function of angle. In addition, coatings were deposited on flat substrates under various impingement configurations. Impingement angle had significant effects on the deposition mode, and microscopy of coatings indicated that there was a shift in the deposition mode at approximately 90° from incidence on the cylindrical samples, which may indicate the onset of more turbulent flow and PVD-like growth. Coatings deposited at non-perpendicular angles exhibited a higher density and nearly a 2× improvement in erosion performance when compared to coatings deposited with the torch normal to the surface.
Similar content being viewed by others
References
K. Von Niessen, M. Gindrat, and A. Refke, Vapor Phase Deposition Using Plasma Spray-PVD, J. Therm. Spray Technol., 2010, 19(1-2), p 502-509
A. Refke, M. Gindrat, K. Von Niessen, R. Damani, LPPS Thin Film: A Hybrid Coating Technology Between Thermal Spray and PVD for Functional Thin Coatings and Large Area Applications. Proc. Int. Therm. Spray Conf., p 705-710 (2007)
K. Von Niessen and M. Gindrat, Plasma Spray-PVD: A New Thermal Spray Process to Deposit out of the Vapor Phase, J. Therm. Spray Technol., 2011, 20(4), p 736-743
K. von Niessen and M. Gindrat, Vapor Phase Deposition Using a Plasma Spray Process, J. Eng. Gas Turbines Power, 2011, 133(6), p 61301. doi:10.1115/1.4002469
G. Mauer, A. Hospach, N. Zotov, and R. Vaßen, Process Conditions and Microstructures of Ceramic Coatings by Gas Phase Deposition Based on Plasma Spraying, J. Therm. Spray Technol., 2013, 22(2-3), p 83-89
N. Spinhirne, A. Hall, J. Mccloskey, The Development and Characterization of Novel Yttria-Stabilized Zirconia Coatings Deposited by Very Low Pressure Plasma Spray. Proc. Int. Therm. Spray Conf., p 750-755 (2009)
A. Hospach, G. Mauer, R. Vaßen, and D. Stöver, Columnar-Structured Thermal Barrier Coatings (TBCs) by Thin Film Low-Pressure Plasma Spraying (LPPS-TF), J. Therm. Spray Technol., 2011, 20, p 116-120
B.J. Harder and D. Zhu, Plasma Spray-Physical Vapor Deposition (PS-PVD) of Ceramics for Protective Coatings, Adv. Ceram. Coat. Mater. Extreme Environ., 2011, doi:10.1002/9781118095232.ch7
M. Goral, S. Kotowski, A. Nowotnik, M. Pytel, M. Drajewicz, and J. Sieniawski, PS-PVD Deposition of Thermal Barrier Coatings, Surf. Coat. Technol., 2013, 237, p 51-55. doi:10.1016/j.surfcoat.2013.09.028
K. Szymański, M. Góral, T. Kubaszek, and P.C. Monteiro, Microstructure of TBC Coatings Deposited by HVAF and PS-PVD Methods, Solid State Phenom., 2015, 227, p 373-376. doi:10.4028/www.scientific.net/SSP.227.373
L. Gao, H. Guo, L. Wei, C. Li, S. Gong, and H. Xu, Microstructure and Mechanical Properties of Yttria Stabilized Zirconia Coatings Prepared by Plasma Spray Physical Vapor Deposition, Ceram. Int., 2015, 41(7), p 8305-8311. doi:10.1016/j.ceramint.2015.02.141
M.P. Schmitt, B.J. Harder, and D.E. Wolfe, Process–Structure–Property Relations for the Erosion Durability of Plasma Spray-Physical Vapor Deposition (PS-PVD) Thermal Barrier Coatings, Surf. Coat. Technol., 2016, 297, p 11-18. doi:10.1016/j.surfcoat.2016.04.029
D.D. Hass, Y. Marciano, and H.N.G. Wadley, Physical Vapor Deposition on Cylindrical Substrates, Surf. Coat. Technol., 2004, 185(2-3), p 283-291
K.D. Harris, D. Vick, E.J. Gonzalez, T. Smy, K. Robbie, and M.J. Brett, Porous Thin Films for Thermal Barrier Coatings, Surf. Coat. Technol., 2001, 138(2-3), p 185-191
X.F. Zhang, K.S. Zhou, C.M. Deng, M. Liu, Z.Q. Deng, C.G. Deng, and J.B. Song, Gas-Deposition Mechanisms of 7YSZ Coating Based on Plasma Spray-Physical Vapor Deposition, J. Eur. Ceram. Soc., 2016, 36(3), p 697-703
P. Han and T. Yoshida, Modeling of Clusters Deposition Under the Effect of Thermophoresis During Thermal Plasma Flash Evaporation Process, Sci. Technol. Adv. Mater., 2001, 2(2), p 367-374
P. Han and T. Yoshida, Growth and Transport of Clusters in Thermal Plasma Vapor Deposition of Silicon, J. Appl. Phys., 2002, 92(8), p 4772. doi:10.1063/1.1506396
M.P. Schmitt, Advanced Thermal Barrier Coating Materials and Design Architectures for Improved Durability (Doctoral Dissertation, The Pennsylvania State University, 2016)
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Harder, B.J., Zhu, D., Schmitt, M.P. et al. Microstructural Effects and Properties of Non-line-of-Sight Coating Processing via Plasma Spray-Physical Vapor Deposition. J Therm Spray Tech 26, 1052–1061 (2017). https://doi.org/10.1007/s11666-017-0570-5
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11666-017-0570-5