Process parameters for enhanced microstructure and composition of as-sprayed Yb2Si2O7 environmental barrier coatings via atmospheric plasma spray

Abstract

Achieving high crystallinity levels, dense, crack-free microstructures with near-stoichiometric phase composition and controlled secondary phase formation are crucial for enhancing the performance of environmental barrier coatings (EBCs). To investigate the impact of APS process parameters on the as-sprayed crystallinity, microstructure, and phase composition of Yb2Si2O7 EBCs, various spraying conditions were explored by adjusting torch power, nozzle size, powder feedrate, stand-off distance, and adding a shroud attachment to the torch. The velocity of particles controlled the density of the EBCs by an interplay between deposition efficiency and splat flattening ratios. Increasing nozzle size from 5/16″ to 1/2″ reduced particle velocity by up to 40 %, resulting in improved deposition efficiencies, porosity levels and coating thickness. However, larger nozzles led to higher silicon evaporation and up to 8 wt% more stable Yb2SiO5 (I2/a) secondary phase was formed. Increasing the stand-off distance from 50 mm had minimal effect on microstructure, but metastable Yb2SiO5 (P21/c) was detected (up to 9 wt%) at longer stand-off distances of 100 and 150 mm. Raising the powder feedrate from 15 gr/min to 60 gr/min improved deposition efficiency (up to 9 %) and density (up to 15 %) of EBCs, yet resulted in higher silicon-depleted phase formation (up to 12 wt%). Adding a shroud to the torch nozzle exit led to severe silicon evaporation and formation of up to 42 wt% and 6 wt% of Yb2SiO5 (I2/a) and Yb2O3, respectively. Moreover, due to the shroud's funnelling effect on smaller particles as well as particle overheating, porous microstructures with up to 28 % porosity levels were formed. High levels of crystallinity (∼75–91 %) were achieved in the as-sprayed condition for all the coatings, indicating real-time crystallization during spraying in all the spraying conditions.