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Overview on Recent Developments of Bondcoats for Plasma-Sprayed Thermal Barrier Coatings

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Abstract

The performance of MCrAlY (M = Ni, Co) bondcoats for atmospheric plasma-sprayed thermal barrier coatings (APS-TBCs) is substantially affected by the contents of Co, Ni, Cr, and Al as well as minor additions of Y, Hf, Zr, etc., but also by manufacturing-related properties such as coating thickness, porosity, surface roughness, and oxygen content. The latter properties depend in turn on the exact technology and set of parameters used for bondcoat deposition. The well-established LPPS process competes nowadays with alternative technologies such as HVOF and APS. In addition, new technologies have been developed for bondcoats manufacturing such as high-velocity APS or a combination of HVOF and APS for application of a flashcoat. Future developments of the bondcoat systems will likely include optimization of thermal spraying methods for obtaining complex bondcoat roughness profiles required for extended APS-TBC lifetimes. Introduction of the newest generation single-crystal superalloys possessing low Cr and high Al and refractory metals (Re, Ru) contents will require definition of new bondcoat compositions and/or multilayered bondcoats to minimize interdiffusion issues. The developments of new bondcoat compositions may be substantially facilitated using thermodynamic–kinetic modeling, the vast potential of which has been demonstrated in recent years.

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Acknowledgments

The authors are grateful to the following colleagues in the Institute for Energy and Climate Research of the Forschungszentrum Jülich for assistance in the coatings procurement, experimental and analytical work, and fruitful discussions: H. Cosler, A. Kick, E. Wessel, D. Grüner, V. Gutzeit, M. Subanovic, J. Toscano, I. Keller, P. Song, W. Nowak, T. Huang, E. Hejrani, A. Jalowicka, R. Vassen, D. Mack, G. Mauer, D. Sebold, J. Bergholz. The authors acknowledge partial funding of this work by the German Research Foundation (DFG) under the Grant No. NA-615-2 and the European Union (R&D Project H2-IGCC).

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  1. Forschungszentrum Jülich GmbH, Institute for Energy and Climate Research (IEK): Microstructure and Properties of Materials (IEK-2), 52425, Jülich, Germany

    D. Naumenko, R. Pillai, A. Chyrkin & W. J. Quadakkers

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  1. D. Naumenko
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Naumenko, D., Pillai, R., Chyrkin, A. et al. Overview on Recent Developments of Bondcoats for Plasma-Sprayed Thermal Barrier Coatings. J Therm Spray Tech 26, 1743–1757 (2017). https://doi.org/10.1007/s11666-017-0649-z

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