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Phase Formation and Transformation in Alumina/YSZ Nanocomposite Coating Deposited by Suspension Plasma Spray Process

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Abstract

Suspension Plasma Spray process was used for deposition of pseudo-eutectic composition of alumina-yttria-stabilized zirconia as a potential thermal barrier coating using Mettech axial III torch. Process variables including feed and plasma parameters were altered to find their effects on the formation of phases in the composite coating. The in-flight particle velocity was found to be the crucial parameter on phase formation in the resulting coatings. Low particle velocities below 650 m/s result in the formation of stable phases i.e., α-alumina and tetragonal zirconia. In contrast, high particle velocities more than 750 m/s favor the metastable γ-alumina and cubic zirconia phases as dominant structures in as-deposited coatings. Accordingly, the plasma auxiliary gas and plasma power as influential parameters on the particle velocity were found to be reliable tools in controlling the resulting coating structure thus, the consequent properties. The noncrystalline portion of the coatings was also studied. It was revealed that upon heating, the amorphous phase prefers to crystallize into pre-existing crystalline phases in the as-deposited coating. Thus, the ultimate crystalline structure can be designed using the parameters that control the particle velocity during plasma spray coating.

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Acknowledgment

Financial support from the Natural Sciences and Engineering Research Council of Canada (NSERC) is gratefully acknowledged.

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Authors and Affiliations

  1. Department of Mechanical and Industrial Engineering, S-EV 4411, Concordia University, Sir George Williams Campus, 1515 St. Catherine W., Montreal, QC, H3G 2W1, Canada

    F. Tarasi, M. Medraj & A. Dolatabadi

  2. NRC-IMI, Boucherville, QC, Canada

    J. Oberste-Berghaus & C. Moreau

Authors
  1. F. Tarasi
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  2. M. Medraj
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  3. A. Dolatabadi
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  4. J. Oberste-Berghaus
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  5. C. Moreau
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Correspondence to M. Medraj.

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Tarasi, F., Medraj, M., Dolatabadi, A. et al. Phase Formation and Transformation in Alumina/YSZ Nanocomposite Coating Deposited by Suspension Plasma Spray Process. J Therm Spray Tech 19, 787–795 (2010). https://doi.org/10.1007/s11666-009-9461-8

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  • DOI: https://doi.org/10.1007/s11666-009-9461-8

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