Columnar Thermal Barrier Coatings Produced by Different Thermal Spray Processes

Abstract Suspension plasma spraying (SPS) and spray-physical vapor deposition (PS-PVD) are the only thermal spray technologies shown to be capable of producing TBCs with columnar microstructures similar electron beam-physical (EB-PVD) process but at higher rates relatively lower costs. The objective this study was achieve fundamental understanding effect different produced by these two processes on their insulation lifetime performance propose an optimized microstructure. Characterization in terms microstructure, conductivity, cyclic fatigue burner rig performed. results were compared standard technique, atmospheric (APS). Bondcoats deposited emerging high-velocity air fuel (HVAF) vacuum plasma-sprayed (VPS) bondcoats investigate influence bondcoat as well topcoat–bondcoat interface topography. showed that dense PS-PVD-processed TBC had highest lifetime, although expense conductivity. reason for behavior attributed intracolumnar structure, wide intercolumnar gaps high column density, thus improving strain tolerance fracture toughness.