Advanced Coating Processes for the Manufacture of Thermal Barrier Coatings

Advanced Coating Processes for the Manufacture of Thermal Barrier Coatings

Robert Vaßen, Georg Mauer, Stefan Rezanka

IEK-1, Forschungszentrum Jülich GmbH, Jülich, Germany

ABSTRACT

Recently suspension plasma spraying (SPS) and plasma spray- physical vapor deposition (PS-PVD) of yttria stabilized zirconia (YSZ) have attracted a lot of interest as they are able to produced columnar structures similar to those made by electron beam – physical vapor deposition (EB-PVD). The paper will outline the influence of the processing conditions and of the substrate morphology on the resulting microstructures for SPS and PS-PVD coatings. While smooth bond coats are needed for the PS-PVD coatings, certain roughness peaks seem to be needed to generate columnar structures in the SPS process. Furthermore the performance of these coatings during furnace tests and in thermal cycling rigs will be shown and compared to the one of conventional micro-cracked TBCs.