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

[1] Dimiduk DM, Perepezko JH. Mo-Si-B alloys: developing a revolutionary turbine-engine material. MRS Bull. 2003;28(9):639–45. https://doi.org/10.1557/mrs2003.191 DimidukDM PerepezkoJH Mo-Si-B alloys: developing a revolutionary turbine-engine material MRS Bull 2003 28 9 639 45 https://doi.org/10.1557/mrs2003.191 10.1557/mrs2003.191 Search in Google Scholar

[2] Perepezko JH. The hotter the engine, the better. Science. 2009;326(5956):1068–9. https://doi.org/10.1126/science.1179327 PerepezkoJH The hotter the engine, the better Science 2009 326 5956 1068 9 https://doi.org/10.1126/science.1179327 10.1126/science.117932719965415 Search in Google Scholar

[3] Darolia R. Thermal barrier coatings technology: critical review, progress update, remaining challenges and prospects. Int Mater Rev. 2013;58(6):315–48. https://doi.org/10.1179/1743280413Y.0000000019 DaroliaR Thermal barrier coatings technology: critical review, progress update, remaining challenges and prospects Int Mater Rev 2013 58 6 315 48 https://doi.org/10.1179/1743280413Y.0000000019 10.1179/1743280413Y.0000000019 Search in Google Scholar

[4] Moskal G, Swadźba L, Mendala B, Góral M, Hetmańczyk M. Degradation of the TBC system during the static oxidation test. J Microsc. 2010;237(3):450–5. https://doi.org/10.1111/j.1365-2818.2009.03290.x MoskalG SwadźbaL MendalaB GóralM HetmańczykM Degradation of the TBC system during the static oxidation test J Microsc 2010 237 3 450 5 https://doi.org/10.1111/j.1365-2818.2009.03290.x 10.1111/j.1365-2818.2009.03290.x20500416 Search in Google Scholar

[5] Feuerstein A, Knapp J, Taylor T, Ashary A, Bolcavage A, Hitchman N. Technical and economical aspects of current thermal barrier coating systems for gas turbine engines by thermal spray and EBPVD: A review. J Therm Spray Technol. 2008;17(2):199–213. https://doi.org/10.1007/s11666-007-9148-y FeuersteinA KnappJ TaylorT AsharyA BolcavageA HitchmanN Technical and economical aspects of current thermal barrier coating systems for gas turbine engines by thermal spray and EBPVD: A review J Therm Spray Technol 2008 17 2 199 213 https://doi.org/10.1007/s11666-007-9148-y 10.1007/s11666-007-9148-y Search in Google Scholar

[6] Rezanka S, Mack DE, Mauer G, Sebold D, Guillon O, Vaßen R. Investigation of the resistance of open-column-structured PS-PVD TBCs to erosive and high-temperature corrosive attack. Surf Coat Technol. 2017;324:222–35. https://doi.org/10.1016/J.SURFCOAT.2017.05.003 RezankaS MackDE MauerG SeboldD GuillonO VaßenR Investigation of the resistance of open-column-structured PS-PVD TBCs to erosive and high-temperature corrosive attack Surf Coat Technol 2017 324 222 35 https://doi.org/10.1016/J.SURFCOAT.2017.05.003 10.1016/j.surfcoat.2017.05.003 Search in Google Scholar

[7] Rakhadilov BK, Kenesbekov AB, Kowalevski P, Ocheredko IA, Sagdoldina ZB. Development of air-plasma technology for hardening cutting tools by applying wear-resistant coatings. News Natl Acad Sci Repub Kazakhstan, Ser Geol Tech Sci. 2020;3(441):54–62. https://doi.org/10.32014/2020.2518-170X.54 RakhadilovBK KenesbekovAB KowalevskiP OcheredkoIA SagdoldinaZB Development of air-plasma technology for hardening cutting tools by applying wear-resistant coatings News Natl Acad Sci Repub Kazakhstan, Ser Geol Tech Sci 2020 3 441 54 62 https://doi.org/10.32014/2020.2518-170X.54 10.32014/2020.2518-170X.54 Search in Google Scholar

[8] Bernard B, Quet A, Bianchi L, Joulia A, Malié A, Schick V, et al. Thermal insulation properties of YSZ coatings: Suspension Plasma Spraying (SPS) versus Electron Beam Physical Vapor Deposition (EB-PVD) and Atmospheric Plasma Spraying (APS). Surf Coat Technol. 2017;318:122–8. https://doi.org/10.1016/j.surfcoat.2016.06.010 BernardB QuetA BianchiL JouliaA MaliéA SchickV Thermal insulation properties of YSZ coatings: Suspension Plasma Spraying (SPS) versus Electron Beam Physical Vapor Deposition (EB-PVD) and Atmospheric Plasma Spraying (APS) Surf Coat Technol 2017 318 122 8 https://doi.org/10.1016/j.surfcoat.2016.06.010 10.1016/j.surfcoat.2016.06.010 Search in Google Scholar

[9] Goral M, Kotowski S, Sieniawski J. The technology of plasma spray physical vapour deposition. High Temp Mater Process. 2013;32(1):33–9. https://doi.org/10.1515/htmp-2012-0051 GoralM KotowskiS SieniawskiJ The technology of plasma spray physical vapour deposition High Temp Mater Process 2013 32 1 33 9 https://doi.org/10.1515/htmp-2012-0051 10.1515/htmp-2012-0051 Search in Google Scholar

[10] Zhou D, Guillon O, Vaßen R. Development of YSZ thermal barrier coatings using axial suspension plasma spraying. Coatings. 2017;7(8):120–37. https://doi.org/10.3390/coatings7080120 ZhouD GuillonO VaßenR Development of YSZ thermal barrier coatings using axial suspension plasma spraying Coatings 2017 7 8 120 37 https://doi.org/10.3390/coatings7080120 10.3390/coatings7080120 Search in Google Scholar

[11] von Niessen K, Gindrat M. Plasma spray-PVD: a new thermal spray process to deposit out of the vapor phase. J Therm Spray Technol. 2011;20(4):736–43. https://doi.org/10.1007/s11666-011-9654-9 von NiessenK GindratM Plasma spray-PVD: a new thermal spray process to deposit out of the vapor phase J Therm Spray Technol 2011 20 4 736 43 https://doi.org/10.1007/s11666-011-9654-9 10.1007/s11666-011-9654-9 Search in Google Scholar

[12] Sokołowski P, Nylen P, Musalek R, Łatka L, Kozerski S, Dietrich D, et al. The microstructural studies of suspension plasma sprayed zirconia coatings with the use of high-energy plasma torches. Surf Coat Technol. 2017;318:250–61. https://doi.org/10.1016/j.surfcoat.2017.03.025 SokołowskiP NylenP MusalekR ŁatkaL KozerskiS DietrichD The microstructural studies of suspension plasma sprayed zirconia coatings with the use of high-energy plasma torches Surf Coat Technol 2017 318 250 61 https://doi.org/10.1016/j.surfcoat.2017.03.025 10.1016/j.surfcoat.2017.03.025 Search in Google Scholar

[13] Fauchais P, Vardelle M, Goutier S, Vardelle A. Key challenges and opportunities in suspension and solution plasma spraying. Plasma Chem Plasma Process. 2014;35(3):511–25. https://doi.org/10.1007/s11090-014-9594-5 FauchaisP VardelleM GoutierS VardelleA Key challenges and opportunities in suspension and solution plasma spraying Plasma Chem Plasma Process 2014 35 3 511 25 https://doi.org/10.1007/s11090-014-9594-5 10.1007/s11090-014-9594-5 Search in Google Scholar

[14] Góral M, Kubaszek T, Kotowski S, Sieniawski J, Dudek S. Influence of deposition parameters on structure of TBCS deposited by PS-PVD method. Solid State Phenom. 2015;227:369–72. https://doi.org/10.4028/www.scientific.net/SSP.227.369 GóralM KubaszekT KotowskiS SieniawskiJ DudekS Influence of deposition parameters on structure of TBCS deposited by PS-PVD method Solid State Phenom 2015 227 369 72 https://doi.org/10.4028/www.scientific.net/SSP.227.369 10.4028/www.scientific.net/SSP.227.369 Search in Google Scholar

[15] Góral M, Kubaszek T. The influence of process parameters on structure of ceramic coatings deposited by PS-PVD method. Solid State Phenom. 2017;267:243–7. https://doi.org/10.4028/www.scientific.net/SSP.267.243 GóralM KubaszekT The influence of process parameters on structure of ceramic coatings deposited by PS-PVD method Solid State Phenom 2017 267 243 7 https://doi.org/10.4028/www.scientific.net/SSP.267.243 10.4028/www.scientific.net/SSP.267.243 Search in Google Scholar

[16] Bacciochini A, Ben-Ettouil F, Brousse E, Ilavsky J, Montavon G, Denoirjean A, et al. Quantification of void networks of as-sprayed and annealed nanostructured yttria-stabilized zirconia (YSZ) deposits manufactured by suspension plasma spraying. Surf Coatings Technol. 2010;205(3):683–9. https://doi.org/10.1016/j.surfcoat.2010.06.013 BacciochiniA Ben-EttouilF BrousseE IlavskyJ MontavonG DenoirjeanA Quantification of void networks of as-sprayed and annealed nanostructured yttria-stabilized zirconia (YSZ) deposits manufactured by suspension plasma spraying Surf Coatings Technol 2010 205 3 683 9 https://doi.org/10.1016/j.surfcoat.2010.06.013 10.1016/j.surfcoat.2010.06.013 Search in Google Scholar

[17] Fauchais P, Etchart-Salas R, Rat V, Coudert JF, Caron N, Wittmann-Ténèze K. Parameters controlling liquid plasma spraying: solutions, sols, or suspensions. J Therm Spray Technol. 2008;17(1):31–59. https://doi.org/10.1007/s11666-007-9152-2 FauchaisP Etchart-SalasR RatV CoudertJF CaronN Wittmann-TénèzeK Parameters controlling liquid plasma spraying: solutions, sols, or suspensions J Therm Spray Technol 2008 17 1 31 59 https://doi.org/10.1007/s11666-007-9152-2 10.1007/s11666-007-9152-2 Search in Google Scholar

[18] Łatka L, Cattini A, Pawłowski L, Valette S, Pateyron B, Lecompte JP, et al. Thermal diffusivity and conductivity of yttria stabilized zirconia coatings obtained by suspension plasma spraying. Surf Coat Technol. 2012;208:87–91. https://doi.org/10.1016/j.surfcoat.2012.08.014 ŁatkaL CattiniA PawłowskiL ValetteS PateyronB LecompteJP Thermal diffusivity and conductivity of yttria stabilized zirconia coatings obtained by suspension plasma spraying Surf Coat Technol 2012 208 87 91 https://doi.org/10.1016/j.surfcoat.2012.08.014 10.1016/j.surfcoat.2012.08.014 Search in Google Scholar

[19] Bernard B, Schick V, Remy B, Quet A, Bianchi L. High temperature thermal properties of columnar yttria stabilized zirconia thermal barrier coating performed by suspension plasma spraying. J Phys Conf Ser. 2016;745:1–8. https://doi.org/10.1088/1742-6596/745/3/032012 BernardB SchickV RemyB QuetA BianchiL High temperature thermal properties of columnar yttria stabilized zirconia thermal barrier coating performed by suspension plasma spraying J Phys Conf Ser 2016 745 1 8 https://doi.org/10.1088/1742-6596/745/3/032012 10.1088/1742-6596/745/3/032012 Search in Google Scholar

[20] Algenaid W, Ganvir A, Calinas RF, Varghese J, Rajulapati KV, Joshi S. Influence of microstructure on the erosion behaviour of suspension plasma sprayed thermal barrier coatings. Surf Coat Technol. 2019;375:86–99. https://doi.org/10.1016/j.surfcoat.2019.06.075 AlgenaidW GanvirA CalinasRF VargheseJ RajulapatiKV JoshiS Influence of microstructure on the erosion behaviour of suspension plasma sprayed thermal barrier coatings Surf Coat Technol 2019 375 86 99 https://doi.org/10.1016/j.surfcoat.2019.06.075 10.1016/j.surfcoat.2019.06.075 Search in Google Scholar

[21] Hospach A, Mauer G, Vaen R, Stöver D. Columnar-structured thermal barrier coatings (TBCs) by thin film low-pressure plasma spraying (LPPS-TF). J Therm Spray Technol. 2011;20(1–2):116–20. https://doi.org/10.1007/s11666-010-9549-1 HospachA MauerG VaenR StöverD Columnar-structured thermal barrier coatings (TBCs) by thin film low-pressure plasma spraying (LPPS-TF) J Therm Spray Technol 2011 20 1–2 116 20 https://doi.org/10.1007/s11666-010-9549-1 10.1007/s11666-010-9549-1 Search in Google Scholar

[22] Dwivedi G, Viswanathan V, Sampath S, Shyam A, Lara-Curzio E. Fracture toughness of plasma-sprayed thermal barrier ceramics: influence of processing, microstructure, and thermal aging. J Am Ceram Soc. 2014;97(9):2736–44. https://doi.org/10.1111/jace.13021 DwivediG ViswanathanV SampathS ShyamA Lara-CurzioE Fracture toughness of plasma-sprayed thermal barrier ceramics: influence of processing, microstructure, and thermal aging J Am Ceram Soc 2014 97 9 2736 44 https://doi.org/10.1111/jace.13021 10.1111/jace.13021 Search in Google Scholar

[23] Huang J, Wang W, Lu X, Liu S, Li C. Influence of lamellar interface morphology on cracking resistance of plasma-sprayed YSZ coatings. Coatings. 2018;8(5):1–15. https://doi.org/10.3390/coatings8050187 HuangJ WangW LuX LiuS LiC Influence of lamellar interface morphology on cracking resistance of plasma-sprayed YSZ coatings Coatings 2018 8 5 1 15 https://doi.org/10.3390/coatings8050187 10.3390/coatings8050187 Search in Google Scholar

[24] Gao Y, Zhao Y, Yang D, Gao J. A novel plasma-sprayed nanostructured coating with agglomerated-unsintered feedstock. J Therm Spray Technol. 2016;25(1–2):291–300. https://doi.org/10.1007/s11666-015-0340-1 GaoY ZhaoY YangD GaoJ A novel plasma-sprayed nanostructured coating with agglomerated-unsintered feedstock J Therm Spray Technol 2016 25 1–2 291 300 https://doi.org/10.1007/s11666-015-0340-1 10.1007/s11666-015-0340-1 Search in Google Scholar

[25] Kubaszek T, Góral M. Influence of air plasma spraying process parameters on ceramic layer in thermal barrier coatings. Solid State Phenom. 2017;267:207–11. https://doi.org/10.4028/www.scientific.net/SSP.267.207 KubaszekT GóralM Influence of air plasma spraying process parameters on ceramic layer in thermal barrier coatings Solid State Phenom 2017 267 207 11 https://doi.org/10.4028/www.scientific.net/SSP.267.207 10.4028/www.scientific.net/SSP.267.207 Search in Google Scholar

[26] Chyrkin A, Gunduz KO, Fedorova I, Sattari M, Visibile A, Halvarsson M, et al. High-temperature oxidation behavior of additively manufactured IN625: Effect of microstructure and grain size. Corros Sci. 2022;205(December 2021):110382. https://doi.org/10.1016/j.corsci.2022.110382 ChyrkinA GunduzKO FedorovaI SattariM VisibileA HalvarssonM High-temperature oxidation behavior of additively manufactured IN625: Effect of microstructure and grain size Corros Sci 2022 205 December 2021 110382. https://doi.org/10.1016/j.corsci.2022.110382 10.1016/j.corsci.2022.110382 Search in Google Scholar

[27] Aranke O, Gupta M, Markocsan N. Microstructural evolution and sintering of suspension plasma-sprayed columnar thermal barrier coatings. J Therm Spray Tech. 2019;28(1–2):198–211. https://doi.org/10.1007/s11666-018-0778-z ArankeO GuptaM MarkocsanN Microstructural evolution and sintering of suspension plasma-sprayed columnar thermal barrier coatings J Therm Spray Tech 2019 28 1–2 198 211 https://doi.org/10.1007/s11666-018-0778-z 10.1007/s11666-018-0778-z Search in Google Scholar

[28] Oerlikon Metco. Metco 6609 – material product data sheet Internet.. cited 2022 Nov 14. https://www.oerlikon.com/ecoma/files/DSM-0406.2_ZrO2_8Y2O3_Suspensions.pdf (accessed 2022-11-14) Oerlikon Metco Metco 6609 – material product data sheet Internet cited 2022 Nov 14. https://www.oerlikon.com/ecoma/files/DSM-0406.2_ZrO2_8Y2O3_Suspensions.pdf (accessed 2022-11-14) Search in Google Scholar

[29] Mauer G, Vaßen R. Plasma Spray-PVD: plasma characteristics and impact on coating properties. J Phys Conf Ser. 2012;406(1):012005. https://doi.org/10.1088/1742-6596/406/1/012005 MauerG VaßenR Plasma Spray-PVD: plasma characteristics and impact on coating properties J Phys Conf Ser 2012 406 1 012005 https://doi.org/10.1088/1742-6596/406/1/012005 10.1088/1742-6596/406/1/012005 Search in Google Scholar

[30] Oerlikon Metco. Metco 204NS – material product data sheet Internet.. cited 2022 Nov 14. https://www.oerlikon.com/ecoma/files/DSM-0242.5_8YO_ZrO_HOSP.pdf (accessed 2022-11-14) Oerlikon Metco Metco 204NS – material product data sheet Internet cited 2022 Nov 14. https://www.oerlikon.com/ecoma/files/DSM-0242.5_8YO_ZrO_HOSP.pdf (accessed 2022-11-14) Search in Google Scholar

[31] Fauchais PL, Heberlein JVR, Boulos MI. Thermal spray fundamentals. Boston: Springer; 2014. https://doi.org/10.1007/978-0-387-68991-3_1 FauchaisPL HeberleinJVR BoulosMI Thermal spray fundamentals Boston Springer 2014 https://doi.org/10.1007/978-0-387-68991-3_1 10.1007/978-0-387-68991-3 Search in Google Scholar

[32] Nicoll AR, Gruner H, Prince R, Wuest G. Thermal spray coatings for high temperature protection. Surf Eng. 1985;1(1):59–71. https://doi.org/10.1179/sur.1985.1.1.59 NicollAR GrunerH PrinceR WuestG Thermal spray coatings for high temperature protection Surf Eng 1985 1 1 59 71 https://doi.org/10.1179/sur.1985.1.1.59 10.1179/sur.1985.1.1.59 Search in Google Scholar

[33] Liu SH, Trelles JP, Murphy AB, He WT, Shi J, Li S, et al. Low-pressure plasma-induced physical vapor deposition of advanced thermal barrier coatings: microstructures, modelling and mechanisms. Mater Today Phys. 2021;21:100481. https://doi.org/10.1016/j.mtphys.2021.100481 LiuSH TrellesJP MurphyAB HeWT ShiJ LiS Low-pressure plasma-induced physical vapor deposition of advanced thermal barrier coatings: microstructures, modelling and mechanisms Mater Today Phys 2021 21 100481. https://doi.org/10.1016/j.mtphys.2021.100481 10.1016/j.mtphys.2021.100481 Search in Google Scholar

[34] Zhang B, Wei L, Guo H, Xu H. Microstructures and deposition mechanisms of quasi-columnar structured yttria-stabilized zirconia coatings by plasma spray physical vapor deposition. Ceram Int. 2017;43(15):12920–9. https://doi.org/10.1016/j.ceramint.2017.06.190 ZhangB WeiL GuoH XuH Microstructures and deposition mechanisms of quasi-columnar structured yttria-stabilized zirconia coatings by plasma spray physical vapor deposition Ceram Int 2017 43 15 12920 9 https://doi.org/10.1016/j.ceramint.2017.06.190 10.1016/j.ceramint.2017.06.190 Search in Google Scholar

[35] Seshadri RC, Dwivedi G, Viswanathan V, Sampath S. Characterizing suspension plasma spray coating formation dynamics through curvature measurements. J Therm Spray Technol. 2016;25(8):1666–83. https://doi.org/10.1007/s11666-016-0460-2 SeshadriRC DwivediG ViswanathanV SampathS Characterizing suspension plasma spray coating formation dynamics through curvature measurements J Therm Spray Technol 2016 25 8 1666 83 https://doi.org/10.1007/s11666-016-0460-2 10.1007/s11666-016-0460-2 Search in Google Scholar