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Suspension sprayed YSZ thermal barrier coatings: Road to industrial application

: Barbosa, Maria Manuel; Toma, Filofteia-Laura; Beitelschmidt, Denise; Ligabue, Omar; Bursich, Simone; Tagliaferri, Luca

Azarmi, F. ; The Thermal Spray Society -TSS-; ASM International; International Institute of Welding -IIW-:
International Thermal Spray Conference, ITSC 2018 : Orlando, Florida, USA, 7-10 May 2018
Red Hook/NY: Curran Associates, 2019
ISBN: 978-1-5108-8040-5
International Thermal Spray Conference (ITSC) <2018, Orlando/Fla.>
Conference Paper
Fraunhofer IWS ()

Thermal barrier coatings (TBCs) are one of the most promising applications for suspension thermal spraying. By using a liquid feedstock, coating morphologies close to the columnar-like structure of electron-beam physical vapor deposition (EB-PVD) are possible. Additionally, vertically cracked TBC coatings (VC-TBC) have shown a great potential for industrial applications. In this work, we will analyze the process window for TBCs produced by using suspension spraying. Commercially available alcohol-and water-based YSZ suspensions have been processed using suspension atmospheric plasma spraying (S-APS) and suspension high-velocity oxy-fuel (S-HVOF) to achieve both columnar-like and VC morphologies. The coatings have been analyzed and compared in terms of microstructure, phase composition, bond strength and thermal cycling performance. Additionally, the suitability of S-APS and S-HVOF TBCs for industrial applications will be discussed, as well as which actions are needed to increase its competitiveness.