Performance of Atmospheric Plasma-Sprayed Thermal Barrier Coatings on Additively Manufactured Super Alloy Substrates

Author:

Bellippady Madhura1ORCID,Björklund Stefan1,Li Xin-Hai2,Frykholm Robert3,Kjellman Bjorn4,Joshi Shrikant1ORCID,Markocsan Nicolaie1ORCID

Affiliation:

1. Department of Engineering Science, University West, 461 32 Trollhattän, Sweden

2. Siemens Energy AB, 612 31 Finspang, Sweden

3. Hoganas AB, 263 39 Hoganas, Sweden

4. GKN Aerospace AB, 461 38 Trollhattän, Sweden

Abstract

This work represents a preliminary study of atmospheric plasma-sprayed (APS) Yttria-Stabilized Zirconia (YSZ)-based thermal barrier coatings (TBCs) deposited on forged and additive manufactured (AM) HAYNES®282® (H282) superalloy substrates. The effect of different feedstock morphologies and spray gun designs with radial and axial injection on APS-deposited YSZ layer characteristics such as microstructure, porosity content, roughness, etc., has been investigated. The performance of TBCs in terms of thermal cycling fatigue (TCF) lifetime and erosion behaviour were also comprehensively investigated. In view of the high surface roughness of as-built AM surfaces compared to forged substrates, two different types of NiCoCrAlY bond coats were examined: one involved high-velocity air fuel (HVAF) spraying of a finer powder, and the other involved APS deposition of a coarser feedstock. Despite the process and feedstock differences, the above two routes yielded comparable bond coat surface roughness on both types of substrates. Variation in porosity level in the APS topcoat was observed when deposited using different YSZ feedstock powders employing axial or radial injection. However, the resultant TBCs on AM-derived substrates were observed to possess similar microstructures and functional properties as TBCs deposited on reference (forged) substrates for any given YSZ deposition process and feedstock.

Funder

Knowledge Foundation, Sweden, for the project Engineered coatings for next generation gas turbine components

Publisher

MDPI AG

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