Characteristics and performance of suspension plasma sprayed thermal barrier coatings on additively manufactured superalloy substrates

CC BY 4.0
The complex-shaped hot-section parts of new-generation turbine engines demand unique design solutions. Additive Manufacturing (AM) is an emergent production method that can produce metallic parts with complex geometries and minimal material wastage. In this work, the characteristics and performance behavior of Thermal Barrier Coatings (TBCs) deposited on forged and AM-built HAYNES®282® superalloy substrates were studied and compared. The bond coats were produced by High-Velocity Air-Fuel (HVAF) spraying using NiCoCrAlY powder feedstock and TBC top-coats by Suspension Plasma Spraying (SPS) using water- and ethanol-based suspensions of Yttria-Stabilized Zirconia (YSZ). The microstructural features, adhesion, Thermal Cycling Fatigue (TCF) lifetime, and thermal shock lifetimes of the TBCs were comprehensively investigated. The results showed that the deposition of bond coats reduced the roughness and asperities of the AM-built substrates. Depending on the type of suspension used and the spray parameters employed, the TBCs exhibited vertically cracked and columnar microstructures. However, no significant differences in TCF and thermal shock lifetimes of TBCs on AM and forged substrates were observed. It is demonstrated that TBC systems can be produced on AM-built metallic substrates, and the resulting TBCs can have similar microstructures and properties as TBCs deposited on conventional substrates.

TEKNIK OCH TEKNOLOGIER Materialteknik Bearbetnings-, yt- och fogningsteknik hsv//swe
ENGINEERING AND TECHNOLOGY Materials Engineering Manufacturing, Surface and Joining Technology hsv//eng
Additive manufacturing
Thermal barrier coatings
Ni-based superalloys
Microstructural characterization
Thermal cycling
Thermal chock
Production Technology
Produktionsteknik

Florent, ManonHögskolan Väst,KAMPT (author)
Björklund, Stefan,1969-Högskolan Väst,Avdelningen för avverkande och additativa tillverkningsprocesser (AAT),KAMPT(Swepub:hv)tsb (author)
Li, Xin Haimens Energy AB, Finspang (SWE) (author)
Robert, FrykholmHoganas AB, Hoganas (SWE) (author)
Kjellman, BjörnGKN Aerospace AB, Trollhattan (SWE) (author)
Joshi, Shrikant V.,1960-Högskolan Väst,Avdelningen för avverkande och additativa tillverkningsprocesser (AAT),KAMPT(Swepub:hv)shrjos (author)
Markocsan, Nicolaie,1967-Högskolan Väst,Avdelningen för avverkande och additativa tillverkningsprocesser (AAT),KAMPT(Swepub:hv)tnm (author)
Högskolan VästKAMPT (creator_code:org_t)

By the author/editor: Bellippady, Madh ...; Florent, Manon; Björklund, Stefa ...; Li, Xin Hai; Robert, Frykholm; Kjellman, Björn; show more...; Joshi, Shrikant ...; Markocsan, Nicol ...; show less...

About the subject

ENGINEERING AND TECHNOLOGY: ENGINEERING AND ...; and Materials Engine ...; and Manufacturing Su ...

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