Condensation behavior of gaseous phase during transported in the near-substrate boundary layer of plasma spray-physical vapor deposition

doi:10.1016/j.jmst.2020.07.005

Abstract

Abstract:

Plasma spray-physical vapor deposition (PS-PVD) has exhibited the potential ability to prepare columnar structures for advanced thermal barrier coatings (TBCs). The coating structure is nominally affected by operating parameters, but it is controlled by the type of deposition unit actually and essentially. In order to realize the columnar structure deposited by gaseous phase units, the transition behavior of gaseous phase units to clusters must be fundamentally understood. This work investigated the transport process of gaseous phase units in the PS-PVD near-substrate boundary layer along with the condensation behavior. The Monte Carlo method was used to examine the transport process and condensation behavior of gaseous phase units under different scale boundary layers. Simulation results show that it is easier to form more numerous larger clusters at the edge of the plasma jet than at the center. Based on the understanding of the changes in deposition unit caused by the condensation of gaseous phase in the near-substrate boundary layer of PS-PVD, an outlook towards TBCs with different structures is presented. And it is in good agreement with the experimental data.

Key words: Condensation behavior, Transport process, Cluster, Boundary layer, PS-PVD

Mei-Jun Liu, Guan-Jun Yang. Condensation behavior of gaseous phase during transported in the near-substrate boundary layer of plasma spray-physical vapor deposition[J]. J. Mater. Sci. Technol., 2021, 67: 127-134.

Figures/Tables 14

Fig. 1. The computational domain of the PS-PVD flow field for numerical simulation. The “SD” is the spray distance.

Table 1 Simulation parameters.

Parameters	Value
Ar / slpm	35
He / slpm	60
Net power / kW	60
Operating pressure / Pa	200
Spray distance / mm	1000

Fig. 2. Collision model of the gaseous phase particle during transported in the boundary layer. Random particle could be Ar, He and gaseous phase.

Fig. 3. Simulation results of PS-PVD flow field with substrate. (a), (b) and (c) is the simulation result of the pressure, temperature and velocity, respectively, where the plasma gases are Ar and He, and the operating pressure is 200 Pa; (d), (e) and (f) is the simulation result of the pressure, temperature and velocity, respectively, where the plasma gases are Ar and H2, and the operating pressure is 100 Pa [33].

Fig. 4. The data of temperature and pressure extract from the Fig. 3. (a) is the temperature distribution near the substrate from Fig. 3(a), (b) is the pressure distribution near the substrate from Fig. 3(b).

Fig. 5. Dissociation behaviors of ZrO2 and ZrO at the pressure of 200 Pa.

Fig. 6. Partial pressure distributions of gaseous phase at the powder feed rate of 20 g·min-1.

Fig. 7. Vapor pressure distributions of gaseous phase in the near-substrate area.

Fig. 8. Supersaturation distribution in the near-substrate. (a), (b) and (c) is are the supersaturated boundary layers when the powder feed rate is 20 g·min-1, 10 g·min-1 and 2 g·min-1, respectively.

Fig. 9. Collision frequency of the gaseous phase during transported in the boundary layer.

Fig. 10. Transport behavior of gaseous phase near the substrate. (a) - (d) is the transport trajectories of gaseous phase with different collision times in the boundary layer.

Fig. 11. Condensation behavior of gaseous phase during transported in the center of boundary layer. (a) Quantity distribution of cluster, (b) diameter of cluster.

Fig. 12. Condensation behavior of gaseous phase when the thickness twice that of the center of boundary layer. (a) Quantity distribution of cluster, (b) diameter of cluster.

Fig. 13. Effect of condensation behavior on the coating structure. The SEM images of TBCs are from reference [23].

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