Column formation in suspension plasma-sprayed coatings and resultant thermal properties

Kent Vanevery; Matthew J.M. Krane; Rodney W. Trice; Hsin Wang; Wallace Porter; Matthew Besser; Daniel Sordelet; Jan Ilavsky; Jonathan Almer

doi:10.1007/s11666-011-9632-2

Column formation in suspension plasma-sprayed coatings and resultant thermal properties

Kent Vanevery, Matthew J.M. Krane, Rodney W. Trice, Hsin Wang, Wallace Porter, Matthew Besser, Daniel Sordelet, Jan Ilavsky, Jonathan Almer

Nuclear Energy Materials Microanalysis

Research output: Contribution to journal › Review article › peer-review

229 Scopus citations

Abstract

The suspension plasma spray (SPS) process was used to produce coatings from yttria-stabilized zirconia (YSZ) powders with median diameters of 15 μm and 80 nm. The powder-ethanol suspensions made with 15-μm diameter YSZ particles formed coatings with microstructures typical of the air plasma spray (APS) process, while suspensions made with 80-nm diameter YSZ powder yielded a coarse columnar microstructure not observed in APS coatings. To explain the formation mechanisms of these different microstructures, a hypothesis is presented which relates the dependence of YSZ droplet flight paths on droplet diameter to variations in deposition behavior. The thermal conductivity (k _th) of columnar SPS coatings was measured as a function of temperature in the as-sprayed condition and after a 50 h, 1200 °C heat treatment. Coatings produced from suspensions containing 80 nm YSZ particles at powder concentrations of 2, 8, and 11 wt.% exhibited significantly different k _th values. These differences are connected to microstructural variations between the SPS coatings produced by the three suspension formulations. Heat treatment increased the k _th of the coatings generated from suspensions containing 2 and 11 wt.% of 80 nm YSZ powder, but this k _th increase was less than has been observed in APS coatings.

Original language	English
Pages (from-to)	817-828
Number of pages	12
Journal	Journal of Thermal Spray Technology
Volume	20
Issue number	4
DOIs	https://doi.org/10.1007/s11666-011-9632-2
State	Published - Jun 2011

Funding

Major portions of this research were funded by the National Science Foundation via grant CMMI-0456534. Ames Laboratory is operated for the U.S. Department of Energy by Iowa State University under Contract No. DE-AC02-07CH11358. Use of the Advanced Photon Source at Argonne National Laboratory was supported by the U.S. Department of Energy, Office of Science, Office of Basic Energy Sciences, under Contract No. DE-AC02-06CH11357. This project involved research sponsored by the Assistant Secretary for Energy Efficiency and Renewable Energy, Office of FreedomCAR and Vehicle Technologies, as part of the High Temperature Materials Laboratory User Program, Oak Ridge National Laboratory, managed by UT-Battelle, LLC, for the U.S. Department of Energy under contract number DE-AC05-00OR22725.

Funders	Funder number
Office of Basic Energy Sciences
Office of FreedomCar
National Science Foundation	0822838, CMMI-0456534
U.S. Department of Energy
Office of Science
Office of Energy Efficiency and Renewable Energy
Oak Ridge National Laboratory	DE-AC05-00OR22725
Iowa State University

Keywords

APS coatings
PS microstructures
suspension plasma spray
thermal properties

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10.1007/s11666-011-9632-2

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title = "Column formation in suspension plasma-sprayed coatings and resultant thermal properties",

abstract = "The suspension plasma spray (SPS) process was used to produce coatings from yttria-stabilized zirconia (YSZ) powders with median diameters of 15 μm and 80 nm. The powder-ethanol suspensions made with 15-μm diameter YSZ particles formed coatings with microstructures typical of the air plasma spray (APS) process, while suspensions made with 80-nm diameter YSZ powder yielded a coarse columnar microstructure not observed in APS coatings. To explain the formation mechanisms of these different microstructures, a hypothesis is presented which relates the dependence of YSZ droplet flight paths on droplet diameter to variations in deposition behavior. The thermal conductivity (k th) of columnar SPS coatings was measured as a function of temperature in the as-sprayed condition and after a 50 h, 1200 °C heat treatment. Coatings produced from suspensions containing 80 nm YSZ particles at powder concentrations of 2, 8, and 11 wt.% exhibited significantly different k th values. These differences are connected to microstructural variations between the SPS coatings produced by the three suspension formulations. Heat treatment increased the k th of the coatings generated from suspensions containing 2 and 11 wt.% of 80 nm YSZ powder, but this k th increase was less than has been observed in APS coatings.",

keywords = "APS coatings, PS microstructures, suspension plasma spray, thermal properties",

author = "Kent Vanevery and Krane, {Matthew J.M.} and Trice, {Rodney W.} and Hsin Wang and Wallace Porter and Matthew Besser and Daniel Sordelet and Jan Ilavsky and Jonathan Almer",

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AU - Vanevery, Kent

AU - Krane, Matthew J.M.

AU - Trice, Rodney W.

AU - Wang, Hsin

AU - Porter, Wallace

AU - Besser, Matthew

AU - Sordelet, Daniel

AU - Ilavsky, Jan

AU - Almer, Jonathan

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N2 - The suspension plasma spray (SPS) process was used to produce coatings from yttria-stabilized zirconia (YSZ) powders with median diameters of 15 μm and 80 nm. The powder-ethanol suspensions made with 15-μm diameter YSZ particles formed coatings with microstructures typical of the air plasma spray (APS) process, while suspensions made with 80-nm diameter YSZ powder yielded a coarse columnar microstructure not observed in APS coatings. To explain the formation mechanisms of these different microstructures, a hypothesis is presented which relates the dependence of YSZ droplet flight paths on droplet diameter to variations in deposition behavior. The thermal conductivity (k th) of columnar SPS coatings was measured as a function of temperature in the as-sprayed condition and after a 50 h, 1200 °C heat treatment. Coatings produced from suspensions containing 80 nm YSZ particles at powder concentrations of 2, 8, and 11 wt.% exhibited significantly different k th values. These differences are connected to microstructural variations between the SPS coatings produced by the three suspension formulations. Heat treatment increased the k th of the coatings generated from suspensions containing 2 and 11 wt.% of 80 nm YSZ powder, but this k th increase was less than has been observed in APS coatings.

AB - The suspension plasma spray (SPS) process was used to produce coatings from yttria-stabilized zirconia (YSZ) powders with median diameters of 15 μm and 80 nm. The powder-ethanol suspensions made with 15-μm diameter YSZ particles formed coatings with microstructures typical of the air plasma spray (APS) process, while suspensions made with 80-nm diameter YSZ powder yielded a coarse columnar microstructure not observed in APS coatings. To explain the formation mechanisms of these different microstructures, a hypothesis is presented which relates the dependence of YSZ droplet flight paths on droplet diameter to variations in deposition behavior. The thermal conductivity (k th) of columnar SPS coatings was measured as a function of temperature in the as-sprayed condition and after a 50 h, 1200 °C heat treatment. Coatings produced from suspensions containing 80 nm YSZ particles at powder concentrations of 2, 8, and 11 wt.% exhibited significantly different k th values. These differences are connected to microstructural variations between the SPS coatings produced by the three suspension formulations. Heat treatment increased the k th of the coatings generated from suspensions containing 2 and 11 wt.% of 80 nm YSZ powder, but this k th increase was less than has been observed in APS coatings.

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Column formation in suspension plasma-sprayed coatings and resultant thermal properties

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