Journal Home > Volume 12 , Issue 2
Journal of Advanced Ceramics 2023, 12(2): 386-398 https://doi.org/10.26599/JAC.2023.9220692
Research Article | Open Access | Issue | Published: 17 January 2023

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

Show Author's Information 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.

Keywords:
fracture mechanism, plasma spray-physical vapor deposition (PS-PVD), transient temperature, in-situ deposit surface, heterogeneous layered structure
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
Download citation
EndNote(RIS)
BibTeX

894

Views

177

Downloads

Citations

0

Crossref

0

WoS

0

Scopus

0

CSCD

Abstract Full text About this article

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.


menu
Abstract
Full text
Outline
About this article

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

Show Author's information 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.

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: fracture mechanism, plasma spray-physical vapor deposition (PS-PVD), transient temperature, in-situ deposit surface, heterogeneous layered structure

References(39)

[1]
Wei ZY, Meng GH, Chen L, et al. Progress in ceramic materials and structure design toward advanced thermal barrier coatings. J Adv Ceram 2022, 11: 985–1068.
DOI Google Scholar
[2]
Yang JS, Cheng ZF, Zhong XH, et al. Deposition behavior of PS-PVD yttria partially stabilized zirconia coatings. J Therm Spray Techn 2021, 30: 1136–1147.
DOI Google Scholar
[3]
Shen ZY, He LM, Xu ZH, et al. Rare earth oxides stabilized La2Zr2O7 TBCs: EB-PVD, thermal conductivity and thermal cycling life. Surf Coat Tech 2019, 357: 427–432.
DOI Google Scholar
[4]
Zhang XF, Deng ZQ, Li H, et al. Al2O3-modified PS-PVD 7YSZ thermal barrier coatings for advanced gas-turbine engines. npj Mat Degrad 2020, 4: 31.
DOI Google Scholar
[5]
Zhang XF, Liu M, Li H, et al. Structural evolution of Al-modified PS-PVD 7YSZ TBCs in thermal cycling. Ceram Int 2019, 45: 7560–7567.
DOI Google Scholar
[6]
Dai MQ, Song XM, Lin CC, et al. Investigation of microstructure changes in Al2O3−YSZ coatings and YSZ coatings and their effect on thermal cycle life. J Adv Ceram 2022, 11: 345–353.
DOI Google Scholar
[7]
Zhang XF, Li M, Zhang A, et al. Al-modification for PS-PVD 7YSZ TBCs to improve particle erosion and thermal cycle performances. J Adv Ceram 2022, 11: 1093–1103.
DOI Google Scholar
[8]
Zhang XF, Zhou KS, Liu M, et al. Mechanisms governing the thermal shock and tensile fracture of PS-PVD 7YSZ TBC. Ceram Int 2018, 44: 3973–3980.
DOI Google Scholar
[9]
Anwaar A, Wei LL, Guo HB, et al. Plasma–powder feedstock interaction during plasma spray–physical vapor deposition. J Therm Spray Techn 2017, 26: 292–301.
DOI Google Scholar
[10]
Yin JN, Zhang X, Feng JL, et al. Effect of powder composition upon plasma spray-physical vapor deposition of 8YSZ columnar coating. Ceram Int 2020, 46: 15867–15875.
DOI Google Scholar
[11]
Góral M, Swadźba R, Kubaszek T. TEM investigations of TGO formation during cyclic oxidation in two- and three-layered Thermal Barrier Coatings produced using LPPS, CVD and PS-PVD methods. Surf Coat Tech 2020, 394: 125875.
DOI Google Scholar
[12]
Zhao C, He WT, Wei LL, et al. Microstructures of La2Ce2O7 coatings produced by plasma spray-physical vapor deposition. J Eur Ceram Soc 2020, 40: 1462–1470.
DOI Google Scholar
[13]
Mauer G, Vaßen R. Conditions for nucleation and growth in the substrate boundary layer at plasma spray-physical vapor deposition (PS-PVD). Surf Coat Tech 2019, 371: 417–427.
DOI Google Scholar
[14]
Seynstahl A, Krauß S, Bitzek E, et al. Microstructure, mechanical properties and tribological behavior of magnetron-sputtered MoS2 solid lubricant coatings deposited under industrial conditions. Coatings 2021, 11: 455.
DOI Google Scholar
[15]
Liu MJ, Yang GJ. Condensation behavior of gaseous phase during transported in the near-substrate boundary layer of plasma spray-physical vapor deposition. J Mater Sci Technol 2021, 67: 127–134.
DOI Google Scholar
[16]
Liu MJ, Zhang M, Zhang XF, et al. Transport and deposition behaviors of vapor coating materials in plasma spray-physical vapor deposition. Appl Surf Sci 2019, 486: 80–92.
DOI Google Scholar
[17]
Burov A, Fedorova E. Modeling of interface failure in a thermal barrier coating system on Ni-based superalloys. Eng Fail Anal 2021, 123: 105320.
DOI Google Scholar
[18]
Yuan B, Harvey CM, Thomson RC, et al. A new spallation mechanism of thermal barrier coatings and a generalized mechanical model. Compos Struct 2019, 227: 111314.
DOI Google Scholar
[19]
Liu DB, Shi BL, Geng LY, et al. High-entropy rare-earth zirconate ceramics with low thermal conductivity for advanced thermal-barrier coatings. J Adv Ceram 2022, 11: 961–973.
DOI Google Scholar
[20]
Guo L, Li G, Gan ZL. Effects of surface roughness on CMAS corrosion behavior for thermal barrier coating applications. J Adv Ceram 2021, 10: 472–481.
DOI Google Scholar
[21]
Mohammadi M, Poursaeidi E, Torkashvand K. Finite element analysis of the effect of thermal cycles and ageing on the interface delamination of plasma sprayed thermal barrier coatings. Surf Coat Tech 2019, 375: 243–255.
DOI Google Scholar
[22]
Zhou QQ, Yang L, Luo C, et al. Thermal barrier coatings failure mechanism during the interfacial oxidation process under the interaction between interface by cohesive zone model and brittle fracture by phase-field. Int J Solids Struct 2021, 214–215: 18–34.
DOI Google Scholar
[23]
Liu MJ, Zhang M, Zhang Q, et al. Evaporation of droplets in plasma spray–physical vapor deposition based on energy compensation between self-cooling and plasma heat transfer. J Therm Spray Techn 2017, 26: 1641–1650.
DOI Google Scholar
[24]
Cheng XD, Min J, Zhu ZQ, et al. Preparation of high emissivity NiCr2O4 powders with a spinel structure by spray drying. Int J Min Met Mater 2012, 19: 173–178.
DOI Google Scholar
[25]
Deng ZQ, Liu M, Mao J, et al. Stage growth of columnar 7YSZ coating prepared by plasma spray-physical vapor deposition. Vacuum 2017, 145: 39–46.
DOI Google Scholar
[26]
Li DX, Jiang P, Gao RH, et al. Experimental and numerical investigation on the thermal and mechanical behaviours of thermal barrier coatings exposed to CMAS corrosion. J Adv Ceram 2021, 10: 551–564.
DOI Google Scholar
[27]
Butterfield DJ, Iverson BD, Maynes D, et al. Transient heat transfer of impinging jets on superheated wetting and non-wetting surfaces. Int J Heat Mass Tran 2021, 175: 121056.
DOI Google Scholar
[28]
Hao L, Lawrence J. Numerical modelling of the laser surface processing of magnesia partially stabilized zirconia by the means of three-dimensional transient finite element analysis. P Roy Soc A-Math Phy 2006, 462: 43–57.
DOI Google Scholar
[29]
Ma W. Thermal analysis of microstructural evolution of Al2O3 surface modified layers. Surf Coat Tech 2010, 204: 1689–1696.
DOI Google Scholar
[30]
Anwaar A, Wei LL, Zhang BP, et al. Plasma flow optimization for 7YSZ quasi-columnar coating by plasma spray-physical vapor deposition. In: Proceedings of the 2018 15th International Bhurban Conference on Applied Sciences and Technology, Islamabad, Pakistan, 2018: 5–11.
DOI
[31]
Long Y, Chen XH, Wang YZ, et al. Conjugate flow and heat transfer analysis between segmented thermal barrier coatings and cooling film. Int J Therm Sci 2021, 167: 107003.
DOI Google Scholar
[32]
Elhoriny M, Wenzelburger M, Killinger A, et al. Finite element simulation of residual stress development in thermally sprayed coatings. J Therm Spray Techn 2017, 26: 735–744.
DOI Google Scholar
[33]
Kazemi Z, Soleimani M, Rokhgireh H, et al. Melting pool simulation of 316L samples manufactured by Selective Laser Melting method, comparison with experimental results. Int J Therm Sci 2022, 176: 107538.
DOI Google Scholar
[34]
Zhao C, He WT, Shi J, et al. Deposition mechanisms of columnar structured La2Ce2O7 coatings via plasma spray-PVD. Ceram Int 2020, 46: 13424–13432.
DOI Google Scholar
[35]
Zhou FF, Wang Y, Wang YM, et al. A promising non-transformable tetragonal YSZ nanostructured feedstocks for plasma spraying-physical vapor deposition. Ceram Int 2018, 44: 1201–1204.
DOI Google Scholar
[36]
Li B, Fan XL, Okada H, et al. Mechanisms governing the failure modes of dense vertically cracked thermal barrier coatings. Eng Fract Mech 2018, 189: 451–480.
DOI Google Scholar
[37]
Zhou FF, Wang Y, Wang L, et al. High temperature oxidation and insulation behavior of plasma-sprayed nanostructured thermal barrier coatings. J Alloys Compd 2017, 704: 614–623.
DOI Google Scholar
[38]
Zhou FF, Wang Y, Liu M, et al. Thermo-physical and thermal insulation properties of multi-scale nanostructured thermal barrier coatings using as-prepared tʹ-8YSZ feedstocks. Ceram Int 2019, 45: 24096–24103.
DOI Google Scholar
[39]
Wu X, Fan JF, Chen XY, et al. Microstructure evolution of Al-modified 7YSZ PS-PVD TBCs in thermal cycle. Ceram Int 2021, 47: 12170–12180.
DOI Google Scholar
Publication history
Copyright
Acknowledgements
Rights and permissions

Publication history

Received: 28 August 2022
Revised: 01 November 2022
Accepted: 04 November 2022
Published: 17 January 2023
Issue date: February 2023

Copyright

© The Author(s) 2022.

Acknowledgements

This project was supported by the National Natural Science Foundation of China (No. 51901175), the China Postdoctoral Science Foundation Funded Project (No. 2020T130499), and the National Program for Support of Top-notch Young Professionals.

Rights and permissions

Open Access This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made.

The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder.

To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/.

Return