The objective of this study was to mimic the microstructure of MCrAlY coatings sprayed using HVOF (High Velocity Oxy-Fuel) processes by using an Air Plasma Spray (APS) process in order to improve oxidation and spallation life of MCrAlY APS coatings. Figure 1 shows the typical microstructures obtained when spraying bond coats using the (a) HVOF process, and (b) the APS process. The microstructur...

Ceramic Thermal Barrier Coatings (TBCs) on superalloy components are being used successfully in land-based gas turbine and aircraft engines. These coatings are generally made by either air plasma spraying (APS) or electron beam physical vapour deposition (EB-PVD). In general, EB-PVD TBCs have superior durability due to the columnar structure, but they are very expensive compared to APS TBCs. EB...

In the present research, the spherical FeCoCrNiMo0.2 high entropy alloy (HEA) powders with a single FCC solid solution structure were prepared by gas atomization. Subsequently, the FeCoCrNiMo0.2 coatings with a different content of oxide inclusions were prepared by air plasma spraying (APS) and high-velocity oxy-fuel spraying (HVOF), respectively. The microstructure, phase composition, mechanic...

Abstract This study investigates the optimal conditions to deposit a thermal barrier coating using micro- and nanopowders in air plasma spraying (APS) process. The influence of APS process parameters on thickness, porosity hardness yttria-stabilized zirconia (YSZ; ZrO 2 × 8Y O 3 ) coatings deposited with single-electrode gun was determined. temperature velocity melted particles were determined ...

In this study, small fraction of NiTi (5 wt%) was added to Yttria stabilized zirconia (YSZ) top coat to improve it sliding wear resistance. The measurement of width of wear tracks after wear tests under a 15 N load for 100 m sliding distances showed that the width of wear track in NiTi-YSZ coating is shorter than that in YSZ coating which depicts the higher wear resistance of NiTi-YSZ coa...

Suspension plasma spraying (SPS) has become an interesting method for the production of thermal barrier coatings for gas turbine components. The development of the SPS process has led to structures with segmented vertical cracks or column-like structures that can imitate strain-tolerant air plasma spraying (APS) or electron beam physical vapor deposition (EB-PVD) coatings. Additionally, SPS coa...

Yttria-stabilized zirconia (YSZ) has been used as a thermal/environmental barrier coating for gas turbine engine blades. Current methods of fabrication include air plasma spraying (APS) and electron-beam physical vapor deposition (EB-PVD). The APS technique results in a coating that loses effectiveness with thermal cycling. The EB-PVD technique deposits a columnar microstructure which accommoda...

Air plasma spray (APS) process is used to produce high density and flowability spherical powders. Phase transformation that occurred in this process isn’t well known. In this paper, the YSZ powders have been sprayed in water to investigate the morphology changes and phase transformations via air plasma spray (APS) method. Phase analysis of powders was examined by XRD and the crystallite size an...

In the combustion chambers of gas turbine engines, ZrO2-8wt.%Y2O3 (YSZ) TBCs are commonly applied by air plasma spray (APS) using Ar-/H2-based plasmas via legacy torches. Alternatively, N2/H2 could be used with potential increasing overall deposition efficiency (DE) and hence reduce consumption high-value feedstock powder. Also, DE, spraying time would reduced, thereby providing another contrib...