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Influence of air plasma spraying process parameters on the thermal barrier coating deposited with micro- and nanopowders

Tadeusz Kubaszek
Tadeusz Kubaszek
, 
Marek Góral
Marek Góral
 and 
Paweł Pędrak
Paweł Pędrak
   | Dec 31, 2022
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Published Online: Dec 31, 2022
Page range: 80 - 92
Received: Oct 03, 2022
Accepted: Dec 13, 2022
DOI: https://doi.org/10.2478/msp-2022-0034
Keywords
© 2022 Tadeusz Kubaszek et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Fig. 1

Microstructure of the TBC YSZ layer: (A) initial image; (B) after binarization; and (C) image after binarization combined with the initial image.TBC, thermal barrier coating; YSZ, yttria-stabilized zirconia
Microstructure of the TBC YSZ layer: (A) initial image; (B) after binarization; and (C) image after binarization combined with the initial image.TBC, thermal barrier coating; YSZ, yttria-stabilized zirconia

Fig. 2

Dependence of temperature (A) and velocity (B) of Metco-204NS powder particles in the plasma stream on the H2 flow rate and the current. NLPM, normal liter per minute
Dependence of temperature (A) and velocity (B) of Metco-204NS powder particles in the plasma stream on the H2 flow rate and the current. NLPM, normal liter per minute

Fig. 3

Dependence of temperature (A) and velocity (B) of Metco-6700 powder particles in the plasma stream on the H2 flow rate and the current
Dependence of temperature (A) and velocity (B) of Metco-6700 powder particles in the plasma stream on the H2 flow rate and the current

Fig. 4

Contour plot of temperature and velocity of standard Metco-204NS particle (A, B) and Metco-6700 micropowder (C, D) with APS process parameters: current 800 A; H2 flow rate 18 NLPM (A, B) and 6 NLPM (C, D)
Contour plot of temperature and velocity of standard Metco-204NS particle (A, B) and Metco-6700 micropowder (C, D) with APS process parameters: current 800 A; H2 flow rate 18 NLPM (A, B) and 6 NLPM (C, D)

Fig. 5

Dependence of thickness (A), porosity (B), and hardness (C) of the TBC ceramic layer on the current and H2 flow rate, with the use of Metco-204NS ceramic powder.NLPM, normal liter per minute; TBC, thermal barrier coating
Dependence of thickness (A), porosity (B), and hardness (C) of the TBC ceramic layer on the current and H2 flow rate, with the use of Metco-204NS ceramic powder.NLPM, normal liter per minute; TBC, thermal barrier coating

Fig. 6

Microstructure (A, B) and surface morphology (C) of the TBC ceramic layer deposited from Metco-204NS powder using 800 A current and 12 NLPM flow rate of H2. 1: YSZ ceramic layer; 2: NiCoCrAlY metallic bond coat; and 3: Inconel 625 substrate material.NLPM, normal liter per minute; TBC, thermal barrier coating; YSZ, yttria-stabilized zirconia
Microstructure (A, B) and surface morphology (C) of the TBC ceramic layer deposited from Metco-204NS powder using 800 A current and 12 NLPM flow rate of H2. 1: YSZ ceramic layer; 2: NiCoCrAlY metallic bond coat; and 3: Inconel 625 substrate material.NLPM, normal liter per minute; TBC, thermal barrier coating; YSZ, yttria-stabilized zirconia

Fig. 7

Dependence of thickness (A), porosity (B), and hardness (C) of the TBC ceramic layer on the current and H2 flow rate, with use of Metco-6700 ceramic powder.NLPM, normal liter per minute; TBC, thermal barrier coating
Dependence of thickness (A), porosity (B), and hardness (C) of the TBC ceramic layer on the current and H2 flow rate, with use of Metco-6700 ceramic powder.NLPM, normal liter per minute; TBC, thermal barrier coating

Fig. 8

Microstructure (A, B) and surface morphology (C) of the TBC ceramic layer deposited from Metco-6700 powder using 800 A current and 6 NLPM flow rate of H2. 1 – YSZ ceramic layer; 2 – NiCoCrAlY metallic bond coat; 3: Inconel 625 substrate material.NLPM, normal liter per minute; TBC, thermal barrier coating; YSZ, yttria-stabilized zirconia
Microstructure (A, B) and surface morphology (C) of the TBC ceramic layer deposited from Metco-6700 powder using 800 A current and 6 NLPM flow rate of H2. 1 – YSZ ceramic layer; 2 – NiCoCrAlY metallic bond coat; 3: Inconel 625 substrate material.NLPM, normal liter per minute; TBC, thermal barrier coating; YSZ, yttria-stabilized zirconia

Fig. 9

Dependence of thickness (A), porosity (B), and hardness (C) of the TBC ceramic layer on the current and H2 flow rate, with use of Metco-6609 ceramic powder.NLPM, normal liter per minute; TBC, thermal barrier coating
Dependence of thickness (A), porosity (B), and hardness (C) of the TBC ceramic layer on the current and H2 flow rate, with use of Metco-6609 ceramic powder.NLPM, normal liter per minute; TBC, thermal barrier coating

Fig. 10

Microstructure (A, B) and surface morphology (C) of the TBC ceramic layer deposited from Metco-6609 powder using 600 A current and 12 NLPM flow rate of H2. 1 – YSZ ceramic layer; 2 – NiCoCrAlY metallic bond coat; 3 – Inconel 625 substrate material.NLPM, normal liter per minute; TBC, thermal barrier coating; ; YSZ, yttria-stabilized zirconia
Microstructure (A, B) and surface morphology (C) of the TBC ceramic layer deposited from Metco-6609 powder using 600 A current and 12 NLPM flow rate of H2. 1 – YSZ ceramic layer; 2 – NiCoCrAlY metallic bond coat; 3 – Inconel 625 substrate material.NLPM, normal liter per minute; TBC, thermal barrier coating; ; YSZ, yttria-stabilized zirconia

APS process parameters for deposition of YSZ ceramic outer layer of TBC

Process parameters Value
Plasma torch A60
Plasma gases Ar/H2 [NLPM] 54/6; 48/12; 42/18
Current [A] 600; 700; 800
Substrate radial velocity [rev/min] 150
Plasma torch feed rate [mm/s] 3
Time of spraying [s] 1,110
Spray distance [mm] 100
Spray angle [°] 90
Carrier gas [NLPM] 6
Powder feed rate [g/min] 10
Angle of powder injection to plasma plume [°] 90
eISSN:
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Journal Subjects:
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