Abstract
Plasma spray-physical vapor deposition (PS-PVD), called the third-generation method for thermal barrier coatings (TBCs) fabrication, has great potential for their using in gas-turbine engines. Compared to atmospheric plasma spray (APS), called the first-generation TBCs, and electron beam-PVD (EB-PVD), called the second generation, PS-PVD has many interesting features, including non-line sight deposition, high deposition rate, and microstructural flexibility, among others. Such advantages make them a promising approach to prepare thermal barrier coatings for advanced gas-turbine engines. Using PS-PVD, feather-like columnar TBCs with good strain tolerance and low thermal conductivity can be fabricated. However, prior to their application in gas-turbine engines, some disadvantages, such as CMAS (CaO–MgO–Al2O3–SiO2, etc.) corrosion and oxidation resistance, need to be addressed. In this work, a method to develop Al2O3-modified PS-PVD 7YSZ TBCs was proposed. The experimental results demonstrate that the Al2O3-modification process is an effective approach to address the aforementioned weaknesses of traditional PS-PVD 7YSZ TBCs.
Highlights
The development of aero-engine has benefited from the progress of thermal barrier coatings (TBCs)[1,2,3,4]
plasma spray-physical vapor deposition (PS-PVD) was presented in the 2000s as a novel approach to achieve such goal[21,22], by developing feather-like columnar-structured TBCs (Fig. 2c), resulting from multiphase deposition
Feather-like TBCs prepared by PS-PVD have attracted much attention worldwide (USA, Germany, Poland, China, etc.) due to its higher thermal cycle performance and lower thermal conductivity[26,27]
Summary
The development of aero-engine has benefited from the progress of thermal barrier coatings (TBCs)[1,2,3,4]. The TBCs with different materials and various structure designs have been widely used for turbine blades protection in gas-turbine engines. In the 1980s, the APS TBCs were unable to meet the necessary service conditions of moving turbine blades in some advanced gas-turbine engines due to high rotation velocities (>20,000 r/min) and frequent takeoffs and landings[14,15]. PS-PVD was presented in the 2000s as a novel approach to achieve such goal[21,22], by developing feather-like columnar-structured TBCs (Fig. 2c), resulting from multiphase deposition (mainly vapor, some liquid and solid).
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