Hostname: page-component-586b7cd67f-l7hp2 Total loading time: 0 Render date: 2024-11-20T09:35:27.657Z Has data issue: false hasContentIssue false
  • English
  • Français

Mechanisms of ceramic coating deposition in solution-precursor plasma spray

Published online by Cambridge University Press:  31 January 2011

Tania Bhatia ,
Alper Ozturk ,
Liangde Xie ,
Eric H. Jordan ,
Baki M. Cetegen ,
Maurice Gell ,
Xinqin Ma  and
Nitin P. Padture
Tania Bhatia
Affiliation:
Department of Metallurgy and Materials Engineering, Institute of Materials Science, University of Connecticut, Storrs, Connecticut 06269-3136
Alper Ozturk
Affiliation:
Department of Mechanical Engineering, Institute of Materials Science, University of Connecticut, Storrs, Connecticut 06269-3136
Liangde Xie
Affiliation:
Department of Metallurgy and Materials Engineering, Institute of Materials Science, University of Connecticut, Storrs, Connecticut 06269-3136
Eric H. Jordan
Affiliation:
Department of Mechanical Engineering, Institute of Materials Science, University of Connecticut, Storrs, Connecticut 06269-3136
Baki M. Cetegen
Affiliation:
Department of Mechanical Engineering, Institute of Materials Science, University of Connecticut, Storrs, Connecticut 06269-3136
Maurice Gell
Affiliation:
Department of Metallurgy and Materials Engineering, Institute of Materials Science, University of Connecticut, Storrs, Connecticut 06269-3136
Xinqin Ma
Affiliation:
Inframat Corporation, Farmington, Connecticut 06032
Nitin P. Padture
Affiliation:
Department of Metallurgy and Materials Engineering, Institute of Materials Science, University of Connecticut, Storrs, Connecticut 06269-3136
Get access

Abstract

The solution-precursor plasma spray (SPPS) method is a new process for depositing thick ceramic coatings, where solution feedstock (liquid) is injected into a plasma. This versatile method has several advantages over the conventional plasma spray method, and it can be used to deposit nanostructured, porous coatings of a wide variety of oxide and non-oxide ceramics for a myriad of possible applications. In an effort to understand the SPPS deposition process, key diagnostic and characterization experiments were performed on SPPS coatings in the Y2O3-stabilized ZrO2 (YSZ) system. The results from these experiments show that there are multiple pathways to SPPS coating formation. The atomized precursor droplets undergo rapid evaporation and breakup in the plasma. This is followed by precipitation, gelation, pyrolysis, and sintering. The different types of particles reach the substrate and are bonded to the substrate or the coating by sintering in the heat of the plasma. The precursor also reaches the substrate or the coating. This precursor pyrolyzes in situ on the substrate, either after it reaches a “cold” substrate or upon contact on a “hot” substrate and helps bond the particles. The coating microstructure evolves during SPPS deposition as the coating temperature reaches approximately 770 °C.

Type
Articles
Information
Journal of Materials Research , Volume 17 , Issue 9 , September 2002 , pp. 2363 - 2372
Copyright
Copyright © Materials Research Society 2002

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

REFERENCES

1.Powlowski, L., The Science and Engineering of Thermal Spray Coatings (Wiley, New York, 1995).Google Scholar
2.Herman, H., Sampath, S., and McCune, R., MRS Bull. 25, 17 (2000).CrossRefGoogle Scholar
3.Boulos, M. and Pfender, E., MRS Bull. 21, 65 (1996).CrossRefGoogle Scholar
4.Fang, X., Heberlein, J., Pfender, E. and Gerberich, W., in Proceedings of the 8th National Thermal Spray Conference, edited by Berndt, C.C. and Bernecki, T.F. (ASM International, Materials Park, OH, 1995), p. 31.Google Scholar
5.Choy, K.L., Mater. Sci. Forum 343–346, 461 (2000).CrossRefGoogle Scholar
6.Karthikeyan, J., Berndt, C.C., Reddy, S., Wang, J-Y., King, A.H., and Herman, H., J. Am. Ceram. Soc. 81, 121 (1998).CrossRefGoogle Scholar
7.Strutt, P.R., Kear, B.H., and Boland, R., U.S. Patent No. 6 025 034 (2000).Google Scholar
8.Padture, N.P., Schlichting, K.W., Bhatia, T., Ozturk, A., Cetegen, B., Jordan, E.H., Gell, M., Jiang, S., Xiao, T.D., Strutt, P.R., Garcia, E., Miranzo, P., and Osendi, M.I., Acta Mater. 49, 2251 (2001).CrossRefGoogle Scholar
9.Parukuttyamma, S.D., Margolis, J., Liu, H., Grey, C.P., Sampath, S., Herman, H., and Parise, J.B., J. Am. Ceram. Soc. 84, 1906 (2001).CrossRefGoogle Scholar
10.Bouyer, E., Schiller, G., Mueller, M., and Henne, R.H., Appl. Organomet. Chem. 15, 833 (2001).CrossRefGoogle Scholar
11.Monaster, A. and Golightly, D.W., Inductively Coupled Plasmas in Analytical Atomic Spectrometry, 2nd ed. (VCH Publishers, New York, 1992).Google Scholar
12.Padture, N.P., Gell, M., and Jordan, E.H., Science 296, 280 (2002).CrossRefGoogle Scholar
13.Dobbins, R.A. and Megaridis, C.M., Langmuir 3, 254 (1987).CrossRefGoogle Scholar
14.Klug, H.P. and Alexander, L.E., X-Ray Procedures for Polycrystalline and Amorphous Materials (John Wiley and Sons, New York, 1974).Google Scholar
15.Liebert, C.H., Thin Solid Films 53, 235 (1978).CrossRefGoogle Scholar
16.Jayaram, V., deGraef, M., and Levi, C.G., Acta Mater. 42, 1829 (1994).CrossRefGoogle Scholar
17.Bhatia, T., Aindow, M., and Padture, N.P., Philos. Mag. Lett. (2002, submitted for publication).Google Scholar
18.Yashima, M., Kato, T.A., Kakihana, M., Gülgün, M.A., Matsuo, Y., and Yoshimura, M., J. Mater. Res. 12, 2575 (1997).CrossRefGoogle Scholar
19.Ponchert, C.J., The Aldrich Library of Infrared Spectra (Aldrich Chemical Company, Milwaukee, WI, 2000).Google Scholar
20.Messing, G.L., Zhang, S-C., and Jayanthi, G.V., J. Am. Ceram. Soc. 76, 2707 (1993).CrossRefGoogle Scholar
21.Semenov, S. and Cetegen, B., J. Therm. Spray Technol. 10, 326 (2001).CrossRefGoogle Scholar
22.Chan, C.K., Flagan, R.C., and Seinfeld, J.H., J. Am. Ceram. Soc. 81, 646 (1998).CrossRefGoogle Scholar