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Thermal Shock Resistance and Bonding Strength of Novel-Structured Thermal Barrier Coatings with Different Microstructure

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Abstract

Structural tailoring is an effective method for improving the performance of thermal barrier coatings. In this study, embedded micro-agglomerated particle (EMAP) coatings were fabricated using a non-conventional air plasma spray method. The effects of microstructure of EMAP coating on the bond strength and thermal shock lifetime were investigated in detail. A finite element model was also proposed to evaluate the stress distribution of the EMAP coatings. Results show that the EMAP coatings exhibited composite structure, in which micro-agglomerated particles are embedded in the coating matrix. Both the total porosity and thermal shock lifetime of the coatings decreased with the decrease in plasma gun speed from 500 to 150 mm/s. Meanwhile, with the increase in feed rate of ‘Powder 2,’ the embedded particles in the coating become noticeable. The thermal shock lifetime and bond strength of the coating deposited by highest ‘Powder 2’ feed rate were approximately 124 cycles and 21.5 MPa. A finite element model implies the thermal stress concentration of the coatings gradually decreased with an increase in the embedded particle area, and the propagation of cracks consumed more energy. Using this novel coating deposition method, the microstructure in EMAP coatings can be conveniently adjusted to obtain the designed coating performance.

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Acknowledgment

This research is sponsored by the National Natural Science Foundation of China (Grant No. 51775189), Shanghai Aerospace Science and Technology Innovation Fund (SAST2019056) and Shanghai Commercial Aero Engine Joint Innovation Program.

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Authors and Affiliations

  1. Key Laboratory of Pressure System and Safety, Ministry of Education, East China University of Science and Technology, Shanghai, 200237, China

    Ting Yang, Weize Wang, Zining Yang, Huangjie Fang & Dongdong Ye

  2. National Engineering Laboratory for Modern Materials Surface Engineering Technology, Institute of New Materials, Guangdong Academy of Sciences, Guangzhou, 510650, China

    Jibo Huang

  3. Ningbo Huaxiang Automotive Technology Co., Ltd, Ningbo, 315033, Zhejiang, China

    Lubin Wang

  4. School of Mechanical Engineering, Anhui Polytechnic University, Wuhu, 241000, China

    Dongdong Ye

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  1. Ting Yang
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  2. Weize Wang
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Correspondence to Weize Wang.

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Yang, T., Wang, W., Huang, J. et al. Thermal Shock Resistance and Bonding Strength of Novel-Structured Thermal Barrier Coatings with Different Microstructure. J Therm Spray Tech 31, 1540–1555 (2022). https://doi.org/10.1007/s11666-022-01353-9

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  • DOI: https://doi.org/10.1007/s11666-022-01353-9

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