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Investigation of Vapor Phase Deposited Columnar Plasma Spray Coatings

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Published/Copyright: June 11, 2013
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Practical Metallography
From the journal Practical Metallography Volume 49 Issue 12

Abstract

The relatively new PS-PVD method (Plasma Spray – Physical Vapor Deposition) allows for an almost complete evaporation of the spray powder by means of a high energy input and a low ambient pressure. On the substrate to be coated, the spraying material condenses to columnar, feather-like structured layers as are known from the EB-PVD process (Electron Beam – Physical Vapor Deposition). These layer structures are of interest in applications in which high strain tolerances are required, such as for thermal barrier coatings in gas turbines where cyclic heating and cooling of the coatings takes place. Courtesy of the high growth rate, PS-PVD can represent a more cost-effective alternative to EB-PVD.

The main difference compared to EB-PVD coatings is the higher porosity of the PS-PVD coatings. However, this higher porosity leads to difficulties during the preparation when coatings are characterized.

This publication describes how YSZ-coatings (Yttrium-stabilized zirconia) produced by means of PS-PVD are characterized with regard to specific surface area, density, pore distribution, hardness, and sintering activity and compared with EB-PVD coatings.

Kurzfassung

Bei dem noch relativ neuen Verfahren PS-PVD (Plasma Spray – Physical Vapour Deposition) kann das Spritzpulver durch hohe Energiezufuhr und geringem Umgebungsdruck fast vollständig verdampft werden. Auf dem zu beschichtenden Substrat kondensiert das Spritzmaterial zu kolumnaren, federartig strukturierten Schichten wie man sie vom EB-PVD (Electron Beam – Physical Vapour Deposition) –Verfahren her kennt. Diese Schichtstrukturen sind für Anwendungen interessant bei denen hohe Dehnungstoleranzen gefordert sind, wie z.B. bei Wärmedämmschichten in Gasturbinen, wo es zu zyklischem Aufheizen und Abkühlen der Schichten kommt. Durch die hohe Schichtwachstumsrate kann PS-PVD eine kostengünstigere Alternative zu EB-PVD darstellen.

Der Hauptunterschied zu EB-PVD-Schichten besteht in der höheren Porosität der PS-PVD-Schichten. Diese höhere Porosität führt jedoch zu präparativen Schwierigkeiten bei der Charakterisierung der Schichten.

In dieser Veröffentlichung werden mittels PS-PVD hergestellte YSZ (Yttrium stabilisiertes Zirconiumdioxid) -Schichten hinsichtlich spezifischer Oberfläche, Dichte, Porenverteilung, Härte und Sinteraktivität charakterisiert und mit EB-PVD-Schichten verglichen.

Translation: E. Engert

Mark Kappertz Born in 1971, was trained as metallographer and since 1999 he is working as head of the metallographic laboratory at the Institute of Energy and Climate Research, Materials Synthesis and Processing (IEK-1), Forschungszentrum Jülich. The main research areas are currently solid oxide fuel cells (SOFCs), barrier coatings for power plant engineering and gas separation membranes.

Andreas Hospach Born in 1981, he studied mineralogy with specialization in materials science at the University of Tuebingen. His master's thesis in the field of micro analysis was made 2006 at the NMI in Reutlingen. Since 2007 he has worked at the Research Center Juelich (IEK-1) in the plasma spray group. Right now he is analyzing the PS-PVD process as a PhD student.

References / Literatur

[1] Flores Renteria, A.; Saruhan, B.; Schulz, U.; Raetzer-Scheibe, H.-J.; Haug, J.; Wiedenmann, A.: Effect of morphology on thermal conductivity of EB-PVD PYSZ TBCs. Surface and Coatings Technology, 2006.201 (6): p. 2611–2620.10.1016/j.surfcoat.2006.05.003Search in Google Scholar

[2] Chuang, T.H.; Yeh, M.S.; Chai, Y.H.: Brazing of Zirconia with AgCuTi and SnAgTi Active Filler Metals. Metallurgical and Materials Transactions A, 2000. 31(A): p. 1591–1597.10.1007/s11661-000-0169-0Search in Google Scholar

[3] Kelly, M.; Singh, J.; Todd, J.; Copley, S.; Wolfe, D.E.: Metallographic techniques for evaluation of thermal barrier coatings produced by electron beam physical vapor deposition, in Materials characterization. 2008. p. 863–70.10.1016/j.matchar.2007.07.010Search in Google Scholar

[4] Schulz, U.; Rätzer-ScheibeH.-J.; Saruhan, B.; Renteria, A.F.: Thermal conductivity issues of EB-PVD thermal barrier coatings. Materialwissenschaft und Werkstofftechnik, 2007. 38(9): p. 659–666.10.1002/mawe.200700189Search in Google Scholar

[5] Limarga, A.M.; Clarke, D.R.: Characterization of Electron Beam Physical Vapor-Deposited Thermal Barrier Coatings Using Diffuse Optical Reflectance. International Journal of Applied Ceramic Technology, 2009. 6 (3): p. 400–409.10.1111/j.1744-7402.2008.02349.xSearch in Google Scholar

[6] Rätzer-Scheibe, H.-J.; Schulz, U.: The effects of heat treatment and gas atmosphere on the thermal conductivity of APS and EB-PVD PYSZ thermal barrier coatings. Surface and Coatings Technology, 2007. 201 (18): p. 7880–7888.10.1016/j.surfcoat.2007.03.028Search in Google Scholar

Received: 2012-5-8
Accepted: 2012-9-10
Published Online: 2013-06-11
Published in Print: 2012-12-01

© 2012, Carl Hanser Verlag, München

Articles in the same Issue

  1. Contents/Inhalt
  2. Contents
  3. Editorial
  4. Editorial
  5. Technical Contributions/Fachbeiträge
  6. Examination of the Microstructure and Properties of Low-Frequency Electromagnetic Casting 6060 Aluminum Alloy Billets and Bars
  7. Investigation of Vapor Phase Deposited Columnar Plasma Spray Coatings
  8. Microstructural Characterization of Carbides in a Cast High-Speed Steel Using Different Metallographic Techniques
  9. Moving Blade Failure in the Low-Pressure Turbine of a Steam Turbo Set
  10. Meeting Diary/Veranstaltungskalender
  11. Meeting Diary
https://doi.org/10.3139/147.110197

Articles in the same Issue

  1. Contents/Inhalt
  2. Contents
  3. Editorial
  4. Editorial
  5. Technical Contributions/Fachbeiträge
  6. Examination of the Microstructure and Properties of Low-Frequency Electromagnetic Casting 6060 Aluminum Alloy Billets and Bars
  7. Investigation of Vapor Phase Deposited Columnar Plasma Spray Coatings
  8. Microstructural Characterization of Carbides in a Cast High-Speed Steel Using Different Metallographic Techniques
  9. Moving Blade Failure in the Low-Pressure Turbine of a Steam Turbo Set
  10. Meeting Diary/Veranstaltungskalender
  11. Meeting Diary
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