Skip to main content
SpringerLink
Log in

Relationship Between the Microstructure and Thermal Conductivity of Plasma-Sprayed ZrO2 Coatings

  • Peer Reviewed
  • Published:
Journal of Thermal Spray Technology Aims and scope Submit manuscript

Abstract

Plasma-sprayed yttria-stabilized zirconia coatings have a complex microstructure consisting of a variety of pores and cracks. These microstructure features which are determined by the spray process are known to influence the thermal conductivity of coatings. In this article, the microstructure features such as total porosity, large pores, and small pores were quantified by means of scanning electron microscopy (SEM) and image analysis, and for each spray process, the particle velocity and particle temperature were measured prior to impact onto the substrate using the online monitoring system (Spray Watch 2i). Multiple linear regression was used to find the relationship between the particle state and the spray gun parameters. The linear regression models were also investigated between the particle state and the microstructure features, in addition, between the microstructure features and the thermal conductivity. The comprehensive correlation of spray process-microstructure-thermal conductivity was established for plasma-sprayed ZrO2 coatings.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5

Similar content being viewed by others

References

  1. N.P. Padture, M. Gell, and E.H. Jordan, Materials Science—Thermal Barrier Coatings for Gas-Turbine Engine Applications, Science, 2002, 296(5566), p 280-284

    Article  CAS  Google Scholar 

  2. P. Fauchais et al., Knowledge Concerning Splat Formation: An Invited Review, J. Therm. Spray Technol., 2004, 13(3), p 337-360

    Article  CAS  Google Scholar 

  3. J.F. Li et al., Optimizing the Plasma Spray Process Parameters of Yttria Stabilized Zirconia Coatings Using a Uniform Design of Experiments, J. Mater. Process. Technol., 2005, 160(1), p 34-42

    Article  CAS  Google Scholar 

  4. H. Zhang et al., Melting Behavior of In-flight Particles and its Effects on Splat Morphology in Plasma Spraying, 2002 ASME International Mechanical Engineering Congress and Exposition, November 17, 2002-November 22, 2002, American Society of Mechanical Engineers, New Orleans, LA, 2002

  5. H. Liu et al., Experiments and Modeling of Rapid Solidification of Plasma-Sprayed Yttria-Stabilized Zirconia, Acta Mater., 2009, 57(20), p 6013-6021

    Article  CAS  Google Scholar 

  6. G. Mauer, R. Vassen, and D. Stover, Atmospheric Plasma Spraying of Yttria-Stabilized Zirconia Coatings with Specific Porosity, Surf. Coat. Technol., 2009, 204(1-2), p 172-179

    Article  CAS  Google Scholar 

  7. S. Paul, Assessing Coating Reliability Through Pore Architecture Evaluation, J. Therm. Spray Technol., 2010, 19(4), p 779-786

    Article  CAS  Google Scholar 

  8. M. Prystay, P. Gougeon, and C. Moreau, Structure of Plasma-Sprayed Zirconia Coatings Tailored by Controlling the Temperature and Velocity of the Sprayed Particles, J. Therm. Spray Technol., 2001, 10(1), p 67-75

    Article  CAS  Google Scholar 

  9. X.Q. Cao, R. Vassen, and D. Stoever, Ceramic Materials for Thermal Barrier Coatings, J. Eur. Ceram. Soc., 2004, 24(1), p 1-10

    Article  CAS  Google Scholar 

  10. H. Wang, R.B. Dinwiddie, and W.D. Porter, Development of a Thermal Transport Database for Air Plasma Sprayed ZrO2-Y2O3 Thermal Barrier Coatings, J. Therm. Spray Technol., 2010, 19(5), p 879-883

    Article  CAS  Google Scholar 

  11. J.R. Fincke, D.C. Haggard, and W.D. Swank, Particle Temperature Measurement in the Thermal Spray Process, J. Therm. Spray Technol., 2001, 10(2), p 255-266

    Article  Google Scholar 

  12. J.R. Fincke et al., Diagnostics and Control in the Thermal Spray Process, Surf. Coat. Technol., 2001, 146, p 537-543

    Article  Google Scholar 

  13. J. Vattulainen et al., Novel Method for In-Flight Particle Temperature and Velocity Measurements in Plasma Spraying Using a Single CCD Camera, J. Therm. Spray Technol., 2001, 10(1), p 94-104

    Article  CAS  Google Scholar 

  14. Z.J. Yin et al., Particle In-Flight Behavior and Its Influence on the Microstructure and Mechanical Properties of Plasma-Sprayed Al2O3 Coatings, J. Eur. Ceram. Soc., 2008, 28(6), p 1143-1148

    Article  CAS  Google Scholar 

  15. A. Vaidya et al., Process Maps for Plasma Spraying of Yttria-Stabilized Zirconia: An Integrated Approach to Design, Optimization and Reliability, Mater. Sci. Eng. A Struct. Mater. Prop. Microstruct. Process., 2008, 497(1-2), p 239-253

    Google Scholar 

  16. S. Sampath et al., Sensing, Control, In Situ Measurement of Coating Properties: An Integrated Approach Toward Establishing Process-Property Correlations, J. Therm. Spray Technol., 2009, 18(2), p 243-255

    Article  CAS  Google Scholar 

  17. W. Zhang and S. Sampath, A Universal Method for Representation of In-Flight Particle Characteristics in Thermal Spray Processes, J. Therm. Spray Technol., 2009, 18(1), p 23-34

    Article  Google Scholar 

  18. G. Dwivedi et al., Assessing Process and Coating Reliability Through Monitoring of Process and Design Relevant Coating Properties, J. Therm. Spray Technol., 2010, 19(4), p 695-712

    Article  CAS  Google Scholar 

  19. C. Zhang et al., Effect of in-Flight Particle Velocity on the Performance of Plasma-Sprayed YSZ Electrolyte Coating for Solid Oxide Fuel Cells, Surf. Coat. Technol., 2008, 202(12), p 2654-2660

    Article  CAS  Google Scholar 

  20. A. Kulkarni et al., Comprehensive Microstructural Characterization and Predictive Property Modeling of Plasma-Sprayed Zirconia Coatings, Acta Mater., 2003, 51(9), p 2457-2475

    Article  CAS  Google Scholar 

  21. W. Chi, S. Sampath, and W. Hsin, Microstructure-Thermal Conductivity Relationships for Plasma-Sprayed Yttria-Stabilized Zirconia Coatings, J. Am. Ceram. Soc., 2008, 91, p 2636-2645

    Article  CAS  Google Scholar 

  22. Z. Wang et al., Effects of Pores and Interfaces on Effective Properties of Plasma Sprayed Zirconia Coatings, Acta Mater., 2003, 51(Compendex), p 5319-5334

    Article  CAS  Google Scholar 

  23. G. Bertrand et al., Low Conductivity Plasma Sprayed Thermal Barrier Coating Using Hollow PSZ Spheres: Correlation Between Thermophysical Properties and Microstructure, Surf. Coat. Technol., 2008, 202(10), p 1994-2001

    Article  CAS  Google Scholar 

  24. C.J. Li and A. Ohmori, Relationships Between the Microstructure and Properties of Thermally Sprayed Deposits, J. Therm. Spray Technol., 2002, 11(3), p 365-374

    Article  CAS  Google Scholar 

  25. C.J. Li and W.Z. Wang, Quantitative Characterization of Lamellar Microstructure of Plasma-Sprayed Ceramic Coatings Through Visualization of Void Distribution, Mater. Sci. Eng. A Struct. Mater. Prop. Microstruct. Process., 2004, 386(1-2), p 10-19

    Google Scholar 

  26. Y. Li et al., Relation Between Microstructure and Thermal Conductivity oF Plasma-Sprayed 8YSZ Coating, Int. J. Mod. Phys. B, 2010, 24(15-16), p 3017-3022

    Article  CAS  Google Scholar 

  27. Y.S. Touloukian and E.H. Buyco, Thermophysical Properties of Matter, Vol. 5, Specific Heat, IFI/Plenum Press, New York, 1970

    Google Scholar 

  28. M. Friis, C. Persson, and J. Wigren, Influence of Particle In-Flight Characteristics on the Microstructure of Atmospheric Plasma Sprayed Yttria Stabilized ZrO2, Surf. Coat. Technol., 2001, 141(2-3), p 115-127

    Article  CAS  Google Scholar 

  29. P.G. Klemens and M. Gell, Thermal Conductivity of Thermal Barrier Coatings, Mater. Sci. Eng. A Struct. Mater. Prop. Microstruct. Process., 1998, 245(2), p 143-149

    Google Scholar 

  30. F. Cernuschi et al., Modelling of Thermal Conductivity of Porous Materials: Application to Thick Thermal Barrier Coatings, J. Eur. Ceram. Soc., 2004, 24(9), p 2657-2667

    Article  CAS  Google Scholar 

  31. S. Ahmaniemi et al., Modified Thick Thermal Barrier Coatings: Thermophysical Characterization, J. Eur. Ceram. Soc., 2004, 24(9), p 2669-2679

    Article  CAS  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. The State Key Lab of High Performance Ceramics and Superfine Microstructure Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai, 200050, China

    Yongzhe Wang, Wei Wu & Yi Zeng

  2. Key Laboratory of Inorganic Coating Materials, Chinese Academy of Sciences, Shanghai, 200050, China

    Xuebin Zheng

  3. State Key Laboratory Breeding Base of Crime Scene Evidence, Shanghai, 200083, China

    Minju Ding & Chenggong Zhang

Authors
  1. Yongzhe Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Wei Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Xuebin Zheng
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yi Zeng
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Minju Ding
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Chenggong Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yi Zeng.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Wang, Y., Wu, W., Zheng, X. et al. Relationship Between the Microstructure and Thermal Conductivity of Plasma-Sprayed ZrO2 Coatings. J Therm Spray Tech 20, 1177–1182 (2011). https://doi.org/10.1007/s11666-011-9660-y

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11666-011-9660-y

Keywords

Search

Navigation