Abstract
Development of new surface technologies is important for successful and efficient exploitation of materials in advanced engineering systems, in particular energy conversion systems. Gas turbine engine efficiency can be improved by adopting advanced thermal barrier coatings. While existing traditional coating technologies were developed for specific requirements, new surface coating processes are actively being developed to meet the material and property challenges related to broader objectives, viz. improved performance at higher temperatures with longer design lives. A novel plasma spray process, so-called solution precursor plasma spray (SPPS), has been developed and used for the formation of various films and coatings from liquid precursor feedstock instead of solid feedstock used in conventional plasma spray. The outstanding features of SPPS-formed films and coatings include: formation of a variety of material coatings; generation of both thin films and thick coatings; tailored microstructures; good crystallinity, and nanostructured characteristics. With the SPPS process, nanostructured ceramic and ceramic-ceramic composite films and coatings, and metal-ceramic composites and coatings are being developed for various applications in gas turbine engines and solid oxide fuel cells.
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