Low-Pressure Plasma-Induced Physical Vapor Deposition of Advanced Thermal Barrier Coatings: Microstructures, Modelling and Mechanisms

2021 ◽  
pp. 100481
Author(s):  
Sen-Hui Liu ◽  
Juan P. Trelles ◽  
Anthony B. Murphy ◽  
Wen-Ting He ◽  
Jia Shi ◽  
...  
Keyword(s):  
Thermal Barrier Coatings ◽  
Vapor Deposition ◽  
Physical Vapor Deposition ◽  
Low Pressure ◽  
Thermal Barrier ◽  
Barrier Coatings ◽  
Pressure Plasma ◽  
Low Pressure Plasma

Equipment for Low Pressure Plasma Spraying Processes – A Review

2015 ◽  
Vol 227 ◽  
pp. 561-564
Author(s):  
Marek Góral ◽  
Tadeusz Kubaszek
Keyword(s):  
Plasma Spraying ◽  
Thermal Barrier Coatings ◽  
Low Pressure ◽  
Thermal Barrier ◽  
Barrier Coatings ◽  
Pressure Plasma ◽  
The World ◽  
Low Pressure Plasma ◽  
Low Pressure Plasma Spraying

The paper presents basic methods of plasma spraying at very low pressure (<2 mbar). Described in the text are conditions which influence microstructure of Thermal Barrier Coatings obtained by these methods. A review and characteristics of the LPPS-TF system applied around the world has been provided.

Influence of Low Pressure Plasma Spraying Parameters on MCrAlY Bond Coat and its Microstructure

2013 ◽  
Vol 592-593 ◽  
pp. 421-424 ◽  
Author(s):  
Marek Góral ◽  
Slawomir Kotowski ◽  
Kamil Dychtoń ◽  
Marcin Drajewicz ◽  
Tadeusz Kubaszek
Keyword(s):  
Plasma Spraying ◽  
Thermal Barrier Coatings ◽  
Bond Coat ◽  
Low Pressure ◽  
Thermal Barrier ◽  
Barrier Coatings ◽  
Pressure Plasma ◽  
Low Pressure Plasma ◽  
Inconel 617 ◽  
Low Pressure Plasma Spraying

Low pressure plasma spraying (LPPS) is one of the most advanced processes of an MCrAlY bond coat formation. It ensures the forming of metallic coatings free of oxides which can act as an bond coat for thermal barrier coatings used, among others, for protection of turbine blade surface. The paper presents results of tests into microstructure of coatings made from AMDRY 997 powder on the base of type Inconel 617 heat-resistant nickel alloy. The tests were carried out using light and scanning electron microscopy. Evaluated was the influence of spraying conditions on microstructure, porosity and thickness of the obtained coating. Test results show that the LPPS method allows to form coatings of low porosity and free of oxides which can be used as an bond coat in thermal barrier coatings.

Strain Tolerance and Microstructure of Thermal Barrier Coatings Produced by Electron Beam Physical Vapor Deposition Process

2006 ◽  
Vol 522-523 ◽  
pp. 267-276 ◽  
Author(s):  
Kunihiko Wada ◽  
Yutaka Ishiwata ◽  
Norio Yamaguchi ◽  
Hideaki Matsubara
Keyword(s):  
Electron Beam ◽  
High Temperature ◽  
Thermal Barrier Coatings ◽  
Vapor Deposition ◽  
Physical Vapor Deposition ◽  
Aging Treatment ◽  
Nanoindentation Test ◽  
Thermal Barrier ◽  
Barrier Coatings ◽  
Strain Tolerance

Several kinds of thermal barrier coatings (TBCs) deposited by electron beam physical vapor deposition (EB-PVD) were produced as a function of electron beam power in order to evaluate their strain tolerance. The deposition temperatures were changed from 1210 K to 1303 K depending on EB power. In order to evaluate strain tolerances of the EB-PVD/TBCs, a uniaxial compressive spallation test was newly proposed in this study. In addition, the microstructures of the layers were observed with SEM and Young’s moduli were measured by a nanoindentation test. The strain tolerance in as-deposited samples decreased with an increase in deposition temperature. In the sample deposited at 1210 and 1268 K, high-temperature aging treatment at 1273 K for 10 h remarkably promoted the reduction of the strain tolerance. The growth of thermally grown oxide (TGO) layer generated at the interface between topcoat and bondcoat layers was the principal reason for this strain tolerance reduction. We observed TGO-layer growth even in the as-deposited sample. Although the thickness of the initial TGO layer in the sample deposited at high temperature was thicker, the growth rate during aging treatment was smaller than those of the other specimens. This result suggests that we can improve the oxidation resistance of TBC systems by controlling the processing parameters in the EB-PVD process.

Vapor Phase Deposition Using a Plasma Spray Process

2010 ◽  
Author(s):  
Konstantin von Niessen ◽  
Malko Gindrat
Keyword(s):  
Plasma Spraying ◽  
Thermal Spray ◽  
Vapor Phase ◽  
Plasma Spray ◽  
Vapor Deposition ◽  
Physical Vapor Deposition ◽  
Low Pressure ◽  
Spray Process ◽  
Pressure Plasma ◽  
Low Pressure Plasma

Plasma spray - physical vapor deposition (PS-PVD) is a low pressure plasma spray technology recently developed by Sulzer Metco AG (Switzerland) to deposit coatings out of the vapor phase. PS-PVD is developed on the basis of the well established low pressure plasma spraying (LPPS) technology. In comparison to conventional vacuum plasma spraying (VPS) and low pressure plasma spraying (LPPS), these new process use a high energy plasma gun operated at a work pressure below 2 mbar. This leads to unconventional plasma jet characteristics which can be used to obtain specific and unique coatings. An important new feature of PS-PVD is the possibility to deposit a coating not only by melting the feed stock material which builds up a layer from liquid splats but also by vaporizing the injected material. Therefore, the PS-PVD process fills the gap between the conventional physical vapor deposition (PVD) technologies and standard thermal spray processes. The possibility to vaporize feedstock material and to produce layers out of the vapor phase results in new and unique coating microstructures. The properties of such coatings are superior to those of thermal spray and electron beam - physical vapor deposition (EB-PVD) coatings. In contrast to EB-PVD, PS-PVD incorporates the vaporized coating material into a supersonic plasma plume. Due to the forced gas stream of the plasma jet, complex shaped parts like multi-airfoil turbine vanes can be coated with columnar thermal barrier coatings using PS-PVD. Even shadowed areas and areas which are not in the line of sight to the coating source can be coated homogeneously. This paper reports on the progress made by Sulzer Metco to develop a thermal spray process to produce coatings out of the vapor phase. Columnar thermal barrier coatings made of Yttria stabilized Zircona (YSZ) are optimized to serve in a turbine engine. This includes coating properties like strain tolerance and erosion resistance but also the coverage of multiple air foils.

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