In this study, thermal barrier coatings with different porosities were prepared using 8 wt-% yttria-stabilized zirconia by atmospheric plasma spray on a superalloy substrate. The porosity of the ceramic coating was increased by modulating the primary gas flow rate and the secondary gas flow rate. The elastic modulus and fracture toughness of the coatings were measured by the indentation method, and the thermal shock resistance was evaluated by quenching the samples from 1050°C to room temperature. The Vickers hardness and elastic modulus of the coating were decreased by increasing the volume of the pores, and the fracture toughness was enhanced. It was found that the thermal shock resistance was improved owing to the stress release due to the pores.
MeierSM, GuptaDK, ShefflerKD.Ceramic thermal barrier coatings for commercial gas turbine engines. JOM. 1991;43(3):50–53.
2.
HouR, WenF, TangX, Improvement of film cooling performance by trenched holes on turbine leading-edge models. Numer Heat Transfer A: Appl. 2019;76(3):160–177.
3.
TangWS, XiaoJF, NanQ, Study of microstructure degradation and rejuvenation evolution for F-class gas turbine blade. Mater Sci Technol. 2019;35(10):1275–1282.
4.
ChellaganeshD, KhanMA, JappesJTW.Hot corrosion behaviour of nickel–iron-based superalloy in gas turbine application. Int J Ambient Energy. 2018:1–5.
5.
WangL, DiY, WangH, Effect of lanthanum zirconate on high temperature resistance of thermal barrier coatings. Trans Indian Ceram Soc. 2019;78(4):212–218.
6.
SenguptaP, BhattacharjeeA, MaitiHS.Zirconia: a unique multifunctional ceramic material. Trans Indian I Metals. 2019;72(8):1981–1998.
7.
ChevalierJ, GremillardL, VirkarAV, The tetragonal-monoclinic transformation in zirconia: lessons learned and future trends. J Am Ceram Soc. 2009;92(9):1901–1920.
8.
ZhuX, HuangY, ZhengW, Crystallinity, stresses, and cracks of YSZ coatings characterized by SEM–EBSD–Raman spectroscopy. J Therm Spray Technol. 2020;29(5):995–1001.
LiM, HuW, SunX, Study on elastic modulus and fracture toughness of an EB-PVD thermal barrier coatings. Rare Metal Mater Eng. 2006;35(4):577–580.
11.
LiC, JacquesSDM, ChenY, A synchrotron X-ray diffraction deconvolution method for the measurement of residual stress in thermal barrier coatings as a function of depth. J Appl Crystallogr. 2016;49(6):1904–1911.
WangT, FanX, SunY, The stresses and cracks in thermal barrier coating system: a review. Chin J Solid Mech. 2016;37(6):477–517.
14.
Di GirolamoG, AlfanoM, PagnottaL, On the early stage isothermal oxidation of APS CoNiCrAlY coatings. J Mater Eng Perform. 2012;21(9):1989–1997.
15.
LipkinDM, KrogstadJA, GaoY, Phase evolution upon aging of air-plasma sprayed t′-Zirconia coatings: I—synchrotron x-ray diffraction. J Am Ceram Soc. 2013;96(1):290–298.
16.
WangY, ZhangL, WuW, Enhancement of thermal properties of ytterbium-cerium oxide by zirconium doping for thermal barrier coatings. Phil Mag Lett. 2019;99(9):309–316.
17.
SinghJ, ThakurL, AngraS.A study of tribological behaviour and optimization of WC-10Co-4Cr Cladding. Surf Eng. 2020:1–10.
18.
KeyvaniA, BahamirianM.Hot corrosion and mechanical properties of nanostructured Al2O3/CSZ composite TBCs. Surf Eng. 2017;33(6):433–443.
WangYM, WengWX, ChiMH, Investigation into the evolution of interface fracture toughness of thermal barrier coatings with thermal exposure treatment by wedge indentation. J Mater Res. 2020;35(13):1715–1725.
21.
Ravi ShankarA, Kamachi MudaliU.Preparation of the plasma-sprayed graded thermal barrier coating by co-injection of premixed powders through a single plasma torch. Surf Eng. 2018;34(10):728–736.
22.
DuG, LiZ, TanZ, Damping performance of YSZ coating prepared by different EB-PVD parameters. Surf Eng. 2019;35(1):22–28.
23.
HuiY, ChenT, ZhaoS, Evolution of phase composition and fluorescence properties in zirconia degraded under hydrothermal conditions. J Alloy Compd. 2015;626:1–8.
24.
PourbafraniM, RazaviRS, BakhshiSR, Effect of microstructure and phase of nanostructured YSZ thermal barrier coatings on its thermal shock behaviour. Surf Eng. 2015;31(1):64–73.
25.
LimaRS, MarpleBR.Toward highly sintering-resistant nanostructured ZrO2-7wt.%Y2O3 coatings for TBC applications by employing differential sintering. J Therm Spray Technol. 2008;17(5):846–852.
26.
GaoP-H, YangG-J, CaoS-T, Heredity and variation of hollow structure from powders to coatings through atmospheric plasma spraying. Surf Coat Technol. 2016;305:76–82.
27.
ToscanoJ, GilA, HüttelT, Temperature dependence of phase relationships in different types of MCrAlY-coatings. Surf Coat Technol. 2007;202(4-7):603–607.
28.
LuGX, HaoLJ, ChengZX, Enhancement on thermal shock resistance of TBCs with EP interlayer. Surf Eng. 2014;30(8):579–588.
29.
WangY, LiMX, SuoHL.Mechanical properties of YSZ thermal barrier coatings with segmented structure. Surf Eng. 2012;28(5):329–332.
30.
OliverWC, PharrGM.Measurement of hardness and elastic modulus by instrumented indentation: advances in understanding and refinements to methodology. J Mater Sci. 2004;19(1):3–20.
KaraoglanliAC, TurkA, OzdemirI.Effect of sintering on mechanical properties of cold sprayed thermal barrier coatings. Surf Eng. 2016;32(9):686–690.
33.
ShangFL, ZhangX, GuoXC, Determination of high temperature mechanical properties of thermal barrier coatings by nanoindentation. Surf Eng. 2014;30(4):283–289.
34.
ZhangX, WangY-w, SunW-w, Microstructure and properties of Al2O3–ZrO2–Y2O3 composite coatings prepared by plasma spraying. J Therm Spray Technol. 2020;29(5):967–978.
35.
PontonCB, RawlingsRD.Vickers indentation fracture toughness test part 1 review of literature and formulation of standardised indentation toughness equations. Mater Sci Technol. 1989;5(9):865–872.
36.
ChoiSR, ZhuD, MillerRA.Mechanical properties/database of plasma-sprayed ZrO2-8 wt% Y2O3 thermal barrier coatings. Int J Appl Ceram Technol. 2004;1(4):330–342.
37.
RabieiA, EvansAG.Failure mechanisms associated with the thermally grown oxide in plasma-sprayed thermal barrier coatings. Acta Mater. 2000;48(15):3963–3976.
38.
JamaliH, MozafariniaR, Shoja RazaviR, Comparison of thermal shock resistances of plasma-sprayed nanostructured and conventional yttria stabilized zirconia thermal barrier coatings. Ceram Int. 2012;38(8):6705–6712.
39.
ZhouD, MackDE, BakanE, Thermal cycling performances of multilayered yttria-stabilized zirconia/gadolinium zirconate thermal barrier coatings. J Am Ceram Soc. 2020;103(3):2048–2061.
40.
ChenWR.Degradation of a TBC with HVOF-CoNiCrAlY bond coat. J Therm Spray Technol. 2014;23(5):876–884.
41.
NaumenkoD, ShemetV, SingheiserL, Failure mechanisms of thermal barrier coatings on MCrAlY-type bondcoats associated with the formation of the thermally grown oxide. J Mater Sci. 2009;44(7):1687–1703.
42.
ChoiSR, ZhuD, MillerRA.Effect of sintering on mechanical properties of plasma-sprayed zirconia-based thermal barrier coatings. J Am Ceram Soc. 2005;88(10):2859–2867.
43.
SteinbrechRW.Thermomechanical behavior of plasma sprayed thermal barrier coatings; Cocoa Beach, Florida): 26th annual Conference on Composites, Advanced Ceramics, Materials, And Structures: B: Ceramic Engineering and science proceedings; 2002. p. 397–408.
44.
TriceRW, PrineDW, FaberKT.Deformation mechanisms in compression-loaded, stand-alone plasma-sprayed alumina coatings. J Am Ceram Soc. 2000;83(12):3057–3064.
45.
ZhuD, MillerRA.Thermal conductivity and elastic modulus evolution of thermal barrier coatings under high heat flux conditions. J Therm Spray Technol. 2000;9(2):175–180.
46.
LiCL, WangW, TanSL, Bond strength and oxidation resistance of YSZ/(Ni, Al) composite coatings. Surf Eng. 2014;30(9):619–623.
