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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.


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

Show Author's information Yan-Hong LuLu HuangMei-Jun LiuGuan-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:

transient temperature, in-situ deposit surface, heterogeneous layered structure, fracture mechanism, plasma spray-physical vapor deposition (PS-PVD)
Received: 28 August 2022 Revised: 01 November 2022 Accepted: 04 November 2022 Published: 17 January 2023 Issue date: February 2023
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Publication history
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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.

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