Abstract
Ceramic topcoats of thermal barrier coatings (TBCs) make it possible to increase the working temperature of the hot sections of jet engines. Yttria-stabilized zirconia oxide (YSZ) is usually used to protect the turbine blades and vanes against high temperature and oxidation. It is necessary to develop new materials which can operate at higher temperatures in a highly oxidizing gas atmosphere. Re2Zr2O7-type pyrochlores are promising YSZ replacements. Usually, they are produced by mixing pure oxides in the calcination process at higher temperatures. In a recent article, the new concept of pyrochlore synthesis during the deposition process was presented. The new technology, called reactive plasma spray physical vapor deposition (reactive PS-PVD), was developed and a Gd2Zr2O7 (GZO) coating was achieved. The reactive PS-PVD process allowed for the use of a mixture of untreated ZrO2 and Gd2O3 powders as reactants, instead of the commercially available gadolinium zirconate powders used in other types of processes. The results of microstructure observations revealed a columnar microstructure in the produced ceramic layer. The phase composition indicated the presence of gadolinium zirconate. Thermal analysis showed a decrease in the thermal conductivity in the range of 700 to 1200 °C of the produced layers, as compared to the layer made of the currently used conventional YSZ.
Highlights
Aluminide coatings and thermal barrier coatings (TBCs) are used widely to protect the hot sections of jet engines and gas turbines against high temperature and oxidation [1,2,3,4].They permit the operating temperatures of the equipment elements to be increased by 80 to 150 ◦ C in comparison to the maximum temperature of these elements without such coatings [1]
We investigated the process parameters on the structures of Yttria-stabilized zirconia oxide (YSZ) coatings in the PS-PVD process [30]
We present our new concept of reactive PS-PVD technology with the synthesis of materials from base oxides during the deposition process
Summary
Aluminide coatings and thermal barrier coatings (TBCs) are used widely to protect the hot sections of jet engines and gas turbines against high temperature and oxidation [1,2,3,4].They permit the operating temperatures of the equipment elements to be increased by 80 to 150 ◦ C in comparison to the maximum temperature of these elements without such coatings [1]. Aluminide coatings and thermal barrier coatings (TBCs) are used widely to protect the hot sections of jet engines and gas turbines against high temperature and oxidation [1,2,3,4]. The ceramic topcoat of thermal barrier coatings is produced mainly by atmospheric plasma spraying (APS) or Electron Beam Physical Vapour Deposition (EB-PVD) processes. One of the methods considered as an alternative to electron beam physical vapor deposition (EB-PVD) is plasma spray physical vapor deposition (PS-PVD). This process enables the formation of columnar structures, which is one of its main advantages [15,16]. It is possible to control the formation process by changing the parameters, and as a result, 4.0/)
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