Bimodal TBCs with low thermal conductivity deposited by a powder-suspension co-spray process

doi:10.1016/j.jmst.2017.11.052

Abstract

Abstract:

Advanced thermal barrier coatings (TBCs) with better thermal barrier performance are required by both advanced gas turbine and air engine. In this work, novel bimodal TBCs with low thermal conductivity were deposited and characterized by a novel co-spray approach with both solid powder and suspension. Experimental and finite element analyses were used to optimize the process parameters to prepare the specific morphology nanostructure features. With a comprehensive understanding on the influence of spraying parameters on the morphology of nano-particles, homogeneous nano-particle heaps with a large aspect ratio were introduced to conventional layered coatings by plasma co-spraying with suspension and solid powder. Co-sprayed bimodal microstructure composite coatings resulted from both wet suspension droplets and molten particle droplets exhibited low thermal conductivity. The thermal conductivity of the composite coating was 1/5 lower than that of the counterpart coatings by conventional plasma spraying with solid powder. This study sheds light to the structural tailoring towards the advanced TBCs with low thermal conductivity.

Key words: Thermal barrier coatings, Aspect ratio, Bimodal microstructure, Thermal conductivity, Co-spray process

Wei-Wei Zhang, Guang-Rong Li, Qiang Zhang, Guan-Jun Yang, Guo-Wang Zhang, Hong-Min Mu. Bimodal TBCs with low thermal conductivity deposited by a powder-suspension co-spray process[J]. J. Mater. Sci. Technol., 2018, 34(8): 1293-1304.

Figures/Tables 17

Fig. 1. Developed model used in finite element simulation.

Table 1 Parameters of the developed model with nano-particle heaps used in simulation.

Parameters	Value
Model height (h), μm	30
Model width (w), μm	120
Nano-particle heaps porosity, %	1
Nano-particle heaps thickness (d_v), μm	0.3-6
Nano-particle heaps diameter (d), μm	6-120
Nano-particle heaps aspect ratio (d/d_v)	1-400
Thermal conductivity of the matrix (in-depth), W m^-1 K^-1	1.0
Thermal conductivity of the matrix (in-plane), W m^-1 K^-1	1.5
Thermal conductivity of the nano-particle heaps, W m^-1 K^-1	0.04

Fig. 2. Temperature (a, b), heat flux distribution (c, d) and the corresponding heat flux vector (e, f) under different aspect ratios of the inserted nano-particle heaps: (a, c, e) 30; (b, d, f) 300. The volumetric ratio of the nano-particle heaps is fixed to be 1%.

Fig. 3. Evolution of the normalized effective area and thermal conductivity as a function of aspect ratio.

Fig. 4. Schematics of low thermal conductivity structure with the inserted nano-particle heaps.

Fig. 5. Schematics of the plasma co-spraying with suspension and solid powder.

Fig. 6. Schematic of suspension-plasma interaction and possible associated changes.

Table 2 Specification of suspension liquid used in spraying.

ZrO	Y₂O₃	Solvent	Solid volume
UG-R10C	Y₂O₃	Absolute ethanol	3%
UG-R10W	Yttrium(III) nitrate hexahydrate	Deionized water	3%

Fig. 7. Schematic diagram of the liquid feedstock plasma-spray process.

Table 3 Plasma spray parameters for individual nano-particle heaps.

Parameters	Parameter 1	Parameter 2
Plasma arc voltage, kW	39	39
Flow rate of primary gas (Ar), L min^-1	60	60
Flow rate of secondary gas (H₂), L min^-1	4	4
Distance between Torch and substrate, mm	80	-
Distance between Torch and liquid nozzle, mm	-	20
Distance between liquid nozzle and substrate(SD), mm	40, 50, 60	200, 250, 300
Liquid flow rate, ml min^-1	48	20
Torch traverse speed, mm s^-1	2000	2000

Fig. 8. Deposits collected form ethanol-based suspensions with different spray distance: (a, d) 60 mm, (b, e) 50 mm, (c, f) 40 mm.

Fig. 9. Deposits collected from water-based suspensions with different spray distance: (a, d) 40 mm, (b, e) 50 mm, (c, f) 60 mm. (a, b, c) deposits band center; (d, e, f) deposits band edge.

Fig. 10. Deposits collected from water-based suspensions with different spray distance: (a, d) 200 mm, (b, e) 250 mm and (c, f) 300 mm.

Fig. 11. (a) coverage rate, flattening ratio, (b) thickness and diameter of disk shaped nano-particle heap obtained form water-based suspensions as a function of spray distance, (c) aspect ratio distribution of the introduced disk shaped nano-particle heaps.

Fig. 12. Evolution of normalized effective area as Ln-C.

Fig. 13. As-sprayed cross section of (a, b) lamellar and (c, d) composite coatings.

Fig. 14. (a) Thermal diffusivity results of the as-sprayed coating compared with the references data. (b) Thermal conductivity as a function of temperature for lamellar and composite coatings.

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