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Research Article | Open Access

Heterogeneous layered structure in thermal barrier coatings by plasma spray-physical vapor deposition

Yan-Hong Lu†, Lu Huang†, Mei-Jun Liu, Guan-Jun Yang( ), Chang-Jiu Li
State Key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, Xi’an Jiaotong University, Xi’an 710049, China

† Yan-Hong Lu and Lu Huang contributed equally to this work.

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Graphical Abstract

Abstract

The unique columnar structure endows thermal barrier coatings (TBCs) prepared by plasma spray-physical vapor deposition (PS-PVD) with high thermal insulation and long lifetime. However, the coating delamination failure resulting from an intra-column fracture (within a column rather than between columns) is a bottleneck in the solid dust particle impact environment for aero-engine. To clarify the intra-column fracture mechanism, a basic layer deposition model is developed to explore a heterogeneous weak-to-strong layered structure formed by a local transient in-situ deposit temperature. During the PS-PVD, an in-situ deposit surface is continuously updated due to constantly being covered by vapor condensation, showing a transient temperature, which means that the in-situ deposit surface temperature rises sharply in short period of 0.2 s of depositing a thin layer during a single pass. Meanwhile, the increasing temperature of the in-situ deposit surface results in an experimentally observed heterogeneous weak-to-strong structure, showing a continuous transition from a porous weak structure at the bottom region to a dense strong structure at the top region. This structure easily makes the intra-column fracture at the porous weak region. The results shed light on improving TBC lifetime by restraining the intra-column fracture.

Keywords

transient temperaturein-situ deposit surfaceheterogeneous layered structurefracture mechanismplasma spray-physical vapor deposition (PS-PVD)

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Journal of Advanced Ceramics
Volume 12 Issue 2,
February 2023
Pages 386-398
DOI: 10.26599/JAC.2023.9220692
Cite this article:
Lu Y-H, Huang L, Liu M-J, et al. Heterogeneous layered structure in thermal barrier coatings by plasma spray-physical vapor deposition. Journal of Advanced Ceramics, 2023, 12(2): 386-398. https://doi.org/10.26599/JAC.2023.9220692

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Received: 28 August 2022
Revised: 01 November 2022
Accepted: 04 November 2022
Published: 17 January 2023
© The Author(s) 2022.

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