Investigation of microstructure and thermal properties of TBC-Polymer composite coatings

Global warming presents a significant challenge, prompting heavy-duty vehicle manufacturers to create energy-efficient, eco-friendly engines. To tackle this issue, it is essential to improve the efficiency of internal combustion engines. Innovative techniques, such as thermal barrier coatings (TBCs) applied to engine components, can enhance engine power and efficiency while reducing harmful emissions. TBCs use ceramic materials that insulate and retain heat, enabling higher operating temperatures and more effective fuel combustion. This leads to decreased pollution and improved engine performance. This study aims to improve engine efficiency and support the use of alternative fuels by designing thermal spray coatings with optimized morphology, microstructure, thickness, and material composition. Specifically, the research investigates the effect of polymeric pore formers on the microstructural and thermal properties of YSZ (yttria- stabilized zirconia) coatings. Coatings were sprayed with varying amounts of pore formers added to the YSZ powder. The resulting coatings were thoroughly characterized for their microstructure, porosity, topography, and thermal conductivity.
Keywords: TBC, Pore former, Polyester, Microstructure, Thermal conductivity