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Environmental barrier coatings
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Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 15-22, May 5–8, 2025,
Abstract
View Papertitled, Effects of Various Air Plasma Spraying Processes on the Spraying Power and Bond Strength of Yb 2 Si 2 O 7 /Si-HfO 2 Environmental Barrier Coatings
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for content titled, Effects of Various Air Plasma Spraying Processes on the Spraying Power and Bond Strength of Yb 2 Si 2 O 7 /Si-HfO 2 Environmental Barrier Coatings
In this study, nine coating systems of Yb 2 Si 2 O 7 /Si-HfO 2 EBCs with varying spraying process parameters were deposited on silicon carbide (SiC) substrates using the air plasma spraying (APS) process and an orthogonal experimental method. The effects of variations in spraying distance, current, and hydrogen flow rate on spraying power and coating bond strength were investigated.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 52-59, May 5–8, 2025,
Abstract
View Papertitled, Performance Comparison of Atmospheric Plasma Spraying and Plasma Spraying Physical Vapor Deposition for Environmental Barrier Coatings
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for content titled, Performance Comparison of Atmospheric Plasma Spraying and Plasma Spraying Physical Vapor Deposition for Environmental Barrier Coatings
The commonly used method for preparing EBCs is atmospheric plasma spraying (APS), but it has problems such as easy oxidation of the coating, low spraying power, and low substrate temperature, resulting in the coating having multiple pores, cracks, and insufficient density. The new plasma spraying physical vapor deposition (PS-PVD) technology can solve these problems. This article compares the microstructure, mechanical properties, and phase composition of EBCs prepared using APS and PS-PVD processes.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 457-464, May 5–8, 2025,
Abstract
View Papertitled, The Influence of Particle Size Distribution for Homogeneity of Ytterbium Silicate Coating Prepared by Atmospheric Plasma Spraying
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for content titled, The Influence of Particle Size Distribution for Homogeneity of Ytterbium Silicate Coating Prepared by Atmospheric Plasma Spraying
This study investigates the effects of varying particle size and particle size distribution of stoichiometric Yb 2 Si 2 O 7 feedstock powder on SiO volatilization, Yb 2 SiO 5 secondary phase formation, and crack behavior in Yb 2 Si 2 O 7 EBCs.
Proceedings Papers
ITSC 2022, Thermal Spray 2022: Proceedings from the International Thermal Spray Conference, 1-13, May 4–6, 2022,
Abstract
View Papertitled, Atmospheric Plasma Spraying of Environmental Barrier Coatings – A Parametric Study
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for content titled, Atmospheric Plasma Spraying of Environmental Barrier Coatings – A Parametric Study
Environmental barrier coatings (EBCs) are required to protect SiC based composites in high temperature, steam containing combustion environments found in the latest generation of high efficiency gas turbine aeroengines. Ytterbium disilicate has shown promise as an environmental barrier coating, showing excellent phase stability at high temperature and a coefficient of thermal expansion close to that of SiC; however, its performance is dependent on the conditions under which the coating was deposited. In this work, a parametric study was undertaken to demonstrate how processing parameters using a widely used Praxair SG-100 atmospheric plasma spraying torch affect the phase composition, microstructure and mechanical properties of ytterbium disilicate environmental barrier coatings. Ytterbium disilicate coatings were deposited using 5 sets of spray parameters, varying arc current and secondary gas flow. The phases present in these coatings were quantified using X-ray diffraction with Rietveld refinement, and the level of porosity was measured. Using this data, the relationship between processing parameters and phase composition and microstructure was examined. Abradable coatings are used throughout gas turbine engines to increase efficiency in the compression and combustion phases of the turbine. Abradable coatings are soft enough to be worn away by turbine blade tips (without damaging the tip itself), allowing for tighter clearances to be used, limiting leakages and increasing efficiency. Using the optimum process parameter window determined in this work, a low density abradable Yb 2 Si 2 O 7 layer will be deposited in future research.
Proceedings Papers
ITSC 2022, Thermal Spray 2022: Proceedings from the International Thermal Spray Conference, 422-431, May 4–6, 2022,
Abstract
View Papertitled, As-Sprayed Highly Crystalline Yb 2 Si 2 O 7 Environmental Barrier Coatings (EBCs) by Atmospheric Plasma Spray (APS)
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for content titled, As-Sprayed Highly Crystalline Yb 2 Si 2 O 7 Environmental Barrier Coatings (EBCs) by Atmospheric Plasma Spray (APS)
High amorphous phase formation tendency, a desirable microstructure and phase composition and silicon evaporation are the challenges of spraying Yb 2 Si 2 O 7 environmental barrier coatings (EBCs). This research addresses these issues by depositing as-sprayed high crystalline Yb 2 Si 2 O 7 using atmospheric plasma spray (APS) without any auxiliary heat-treating during spraying, vacuum chamber, or subsequent furnace heat treatment, leading to considerable cost, time, and energy savings. Yb 2 Si 2 O 7 powder was sprayed on SiC substrates with three different plasma powers of (90, 72 and 53 kW) and exceptional high crystallinity levels of up to ~91% and deposition efficiency of up to 85% were achieved. The silicon mass evaporation during spraying was controlled with a short stand-ff distance of 50 mm, and an optimum fraction of Yb 2 SiO 5 secondary phases (<20 wt.%) was evenly distributed in the final deposits. The desirable microstructure, including a dense structure with uniform distribution of small porosities, was observed. The undesirable vertical crack formation and any interconnected discontinuities were prevented. Reducing the plasma power from 90 kW to 53 kW, while conducive for mitigating the silicon mass loss, was detrimental for microstructure by increasing the fraction of porosities and partially melted or unmelted fragments. The gradual decrease of the coating temperature after deposition alleviated microcracking but has an insignificant effect on the crystallinity level. Coatings annealed close to their operating temperature at 1300 °C for 24 hours demonstrated sintering and a crack healing effect, closing the tiny microcracks through the thickness. An improved coating composition was detected after annealing by the transformation of Yb 2 SiO 5 to Yb 2 Si 2 O 7 (up to ~10 wt.%).
Proceedings Papers
ITSC 2021, Thermal Spray 2021: Proceedings from the International Thermal Spray Conference, 23-30, May 24–28, 2021,
Abstract
View Papertitled, Oxygen Permeability and Its Role in Governing Life of YbDS Environmental Barrier Coatings
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for content titled, Oxygen Permeability and Its Role in Governing Life of YbDS Environmental Barrier Coatings
The growth kinetics of thermally grown oxide (TGO) silica in Yb-disilicate (YbDS) environmental barrier coatings (EBCs) significantly affects the durability of EBCs. The oxygen permeability can control the TGO growth kinetics and thus could play an essential role in determining EBCs life. Therefore, the oxygen permeability constant of YbDS and TGO is systematically evaluated and quantified in terms of thermodynamics using defect reactions and the parabolic rate constant (kp), respectively. Dry oxygen and wet oxygen conditions as well as different temperatures, partial pressures and top coat modifiers are investigated. The results offer evidence that the oxygen permeability constant for the YbDS top coat is an order of magnitude higher than for the TGO. As such, the TGO hinders the oxidant diffusion stronger, proving to be the diffusion rate controlling layer. Moreover, water vapor strongly increases the oxygen permeability with defect reactions playing a key role. It is suggested that the mass transfer through the top coat is primarily by outward ytterbium ion diffusion and inward oxygen ion movement, with the latter being dominant, particularly in wet environments. The effect of top coat modifiers on oxidant permeation is composition sensitive and seems to be related to their interaction with oxygen ions and their mobility.
Proceedings Papers
ITSC 2021, Thermal Spray 2021: Proceedings from the International Thermal Spray Conference, 700-707, May 24–28, 2021,
Abstract
View Papertitled, Ni-5wt% Al Coatings Deposited by Twin Wire Arc Spraying for Molten Aluminum Attack Protection
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for content titled, Ni-5wt% Al Coatings Deposited by Twin Wire Arc Spraying for Molten Aluminum Attack Protection
Nickel-aluminum alloys are widely used in harsh environments due to their corrosion resistance, high melting temperature, and thermal conductivity. In this work, Ni-5wt%Al coatings were deposited by twin-wire arc spraying (TWAS) on tool steel using a design of experiments approach to study the effect of process parameters on coating microstructure and performance. Test results presented in the form of process maps show how N2 pressure, stand-off distance, and current affect in-flight particle velocity and temperature as well as coating thickness and oxide content. Using this information, optimized coatings were then deposited on test substrates and subjected, along with uncoated tool steel, to several hours of molten aluminum attack. The coated samples showed no signs of physical or chemical damage, whereas the uncoated substrates experienced oxidation, aluminum infiltration, and formation of Fe-Al intermetallics.
Proceedings Papers
Anderson Gerlado Marenda Pukasiewicz, Gustavo Bavaresco Sucharski, Irene Bida de Araújo Fernandes Siqueira, Juliano de Andrade, Rodolpho Fernando Váz ...
ITSC 2019, Thermal Spray 2019: Proceedings from the International Thermal Spray Conference, 359-368, May 26–29, 2019,
Abstract
View Papertitled, Corrosion Resistance of Iron-Based Alloy Coatings Deposited by HVOF Process
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for content titled, Corrosion Resistance of Iron-Based Alloy Coatings Deposited by HVOF Process
Hydraulic turbines, valves, and pumps operate in environments where they are exposed to cavitation phenomena and corrosion, which can result in mass loss, leading to reduced performance and failure. HVOF spraying has been used to repair eroded surfaces on such components and new alloys are being developed to reduce repair costs. This investigation assesses the cavitation resistance of FeMnCrSiNiB alloy coatings deposited by HVOF spraying. Corrosion rates and oxidation potentials are measured under different conditions and compared to stainless steel coatings normally used on water turbine runners.
Proceedings Papers
ITSC 2019, Thermal Spray 2019: Proceedings from the International Thermal Spray Conference, 400-405, May 26–29, 2019,
Abstract
View Papertitled, Etch Behavior of Yttrium-Based Plasma Resistant Coating Prepared by Vacuum Kinetic Spray
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for content titled, Etch Behavior of Yttrium-Based Plasma Resistant Coating Prepared by Vacuum Kinetic Spray
This study assesses the plasma erosion resistance of Y 2 O 3 and YF 3 films deposited on aluminum 6061 substrates by vacuum kinetic spraying, a low-temperature deposition process. Y 2 O 3 and YF 3 powders with different particle sizes were selected as feedstock materials and characterized in their as-delivered and heat-treated states. Dense films several micrometers in thickness were sprayed using helium as the process gas and surface component analysis confirmed the successful formation of the yttrium-based layers. Plasma etch rates were measured in nanometers per minute and the results show that there is no significant difference between the two films.
Proceedings Papers
ITSC 2019, Thermal Spray 2019: Proceedings from the International Thermal Spray Conference, 406-412, May 26–29, 2019,
Abstract
View Papertitled, Field Application of Cold Spray for Repairs in the Navy and Industry
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for content titled, Field Application of Cold Spray for Repairs in the Navy and Industry
This paper provides an update on the state of cold spray corrosion mitigation and repair as it applies to equipment operated by the U.S. Navy. It also presents several application scenarios in which cold-sprayed Al 6061 and NiCr-CrC can improve preventative maintenance and dimensional restoration procedures currently used on A36 steel and CuNi structures.
Proceedings Papers
ITSC 2019, Thermal Spray 2019: Proceedings from the International Thermal Spray Conference, 109-114, May 26–29, 2019,
Abstract
View Papertitled, Evaluation of Advanced Weld Overlay, Thermal Spray, and Laser Clad Coatings in an Operating Waste-Wood Fired Biomass Boiler
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for content titled, Evaluation of Advanced Weld Overlay, Thermal Spray, and Laser Clad Coatings in an Operating Waste-Wood Fired Biomass Boiler
Different surface protection technologies were investigated in a waste-wood fired fluidized bed boiler. This biomass fuel environment is more aggressive than those firing virgin wood due to the elevated presence of sodium, potassium, lead, and zinc, leading to the deposit of alkali metal chlorides in conjunction with ash on boiler tube surfaces. As laboratory tests are seldom representative of the complex firing, chemistry, temperature, and local heat flux encountered in actual operating conditions, five different commercial, near commercial, and development coatings were applied to a 1 m length of plain carbon steel tubing used in the furnace walls. The coatings were fully characterized and measured prior to installation and after exposure. Iron and nickel-based weld overlays, two high velocity thermal spray coatings, and a laser-clad nanosteel coating were tested. After exposure, the tube was extracted from the boiler and corrosion scales and material losses were evaluated in comparison to unprotected tube material.
Proceedings Papers
ITSC 2017, Thermal Spray 2017: Proceedings from the International Thermal Spray Conference, 380-381, June 7–9, 2017,
Abstract
View Papertitled, An Assessment of Thermal Spray Technologies for Deposition of Environmental Barrier Coatings (EBC)
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for content titled, An Assessment of Thermal Spray Technologies for Deposition of Environmental Barrier Coatings (EBC)
Environmental barrier coatings (EBC) are currently being investigated to protect ceramic matrix composite (CMC) turbine engine components in water-vapor rich combustion environments. Dense, crack-free, uniform and well-adhered coatings are demanded for this purpose. This paper represents an assessment of different thermal spray techniques for deposition of Yb 2 Si 2 O 7 and silicon (Si) EBC layers. Plasma spraying of refractory silicates is known to be complicated by undesired glass transition due to rapid solidification as well as evaporation of Si-bearing species during spraying. Plasma spraying of low-density Si also requires careful optimizations as it tends to oxidize during spraying, particularly at atmospheric conditions. Bearing these problems in mind, the Yb 2 Si 2 O 7 coatings were deposited by atmospheric plasma spraying (APS), high-velocity oxygen-fuel spraying (HVOF), and plasma-spray physical vapor deposition (PS-PVD) techniques. As-sprayed microstructure, amorphous content and phase composition of the coatings were analyzed. Based on the findings, the advantages and disadvantages of each method over other techniques are discussed with respect to process parameters and material properties.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 312-317, May 21–23, 2014,
Abstract
View Papertitled, Thermal Spray Coatings for High Temperature Corrosion Protection in Biomass Co-Fired Boilers
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for content titled, Thermal Spray Coatings for High Temperature Corrosion Protection in Biomass Co-Fired Boilers
In this study, several thermal spray coatings and reference materials were evaluated for potential use in biomass co-fired boilers. The coatings were applied to T92, A263, and X10Cr13 substrates by HVOF and wire-arc spraying using powder (IN625, FeCr, NiCr) and wire (NiCrTi) feedstocks. Coating samples were examined then tested for 5900 h in the superheater area of a fluidized bed boiler burning a mixture of wood, peat, and coal. The corrosion behavior of the coating and reference materials is reported in the paper and the underlying corrosion mechanisms are discussed.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 340-344, May 21–23, 2014,
Abstract
View Papertitled, A 25 Year Exposure Test of Thermal Sprayed Zn, Al, and Zn-Al Coatings in Marine Environments
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for content titled, A 25 Year Exposure Test of Thermal Sprayed Zn, Al, and Zn-Al Coatings in Marine Environments
This paper presents key findings from an ongoing study on the marine corrosion behavior of thermally sprayed zinc and aluminum coatings. Zn, Al, and Zn-Al layers of varied thickness were applied to twelve steel pipes by arc and flame spraying and subjected to different post-spray treatments such as sealing and painting. The pipes are mounted vertically on a test rig in the Pacific Ocean and have been inspected annually to record the appearance and thickness of the coatings. After 7 years, the Zn coatings began to show signs of degradation in the immersed portion of the pipe, although no such changes occurred with Al and Zn-Al coatings. After 18 years, heavily damaged sections of three pipes were removed and new pipe was welded in place. The repaired regions were coated with Al-5%Mg, which has performed well so far.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 345-348, May 21–23, 2014,
Abstract
View Papertitled, Improved Efficiency in Paper Making by Thermal Spray Coatings
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for content titled, Improved Efficiency in Paper Making by Thermal Spray Coatings
This paper discusses the different types of rolls used in paper machines, the functions and performance required of them, and recent improvements achieved with the aid of thermal spray coatings. It presents examples showing how metal and ceramic coatings applied by HVOF and plasma spraying have reduced operating expenses and extended roll life by stabilizing and improving various surface properties.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 353-358, May 21–23, 2014,
Abstract
View Papertitled, Effect of Al Enrichment by Pack Cementation of FeCr Coatings Deposited by HVOF
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for content titled, Effect of Al Enrichment by Pack Cementation of FeCr Coatings Deposited by HVOF
In this study, FeCr coatings with different percentages of chromium were deposited on Grade 91 steel substrates by HVOF spraying, followed by aluminum enrichment via pack cementation. Overaluminizing parameters were optimized to prevent changes in the substrate microstructure, making it possible to determine the role of Cr and the effect of Al enrichment on anticorrosion behavior. The combination of HVOF spraying and pack cementation are shown to be adequate techniques for depositing intermediate and top layers in protective coating systems.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 491-496, May 21–23, 2014,
Abstract
View Papertitled, Corrosion Protection for Wind Power Plants – The Influence of the Application Conditions by Thermally Spraying on the Corrosion Behaviour of ZnAl Coatings
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for content titled, Corrosion Protection for Wind Power Plants – The Influence of the Application Conditions by Thermally Spraying on the Corrosion Behaviour of ZnAl Coatings
The aim of this study is to compare the quality of corrosion-resistant thermal spray coatings depending on where and how they are applied. ZnAl 15 coatings were applied to S235 steel substrates by wire arc spraying in keeping with standard (EN ISO 2063) practice. The coatings were sprayed under factory conditions and in a simulated onsite environment using manual and automated methods. As-sprayed and sprayed-and-sealed coating samples were subjected to climate-cycle and corrosion testing. Coatings applied onsite varied in quality to a much greater extent than those sprayed under workshop conditions. Poor quality, and implicitly a lower corrosion resistance, was widely detected in coatings where ZnAl was manually sprayed under simulated onsite conditions. The implications of the study are particularly relevant to the sustainability of coastal and offshore wind power generators due to maintenance challenges.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 546-550, May 21–23, 2014,
Abstract
View Papertitled, Enhancing High Temperature Erosion-Corrosion Resistance of SA213-T91 Steel by HVOF Sprayed Nano-Structured Ni-20Cr Coating
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for content titled, Enhancing High Temperature Erosion-Corrosion Resistance of SA213-T91 Steel by HVOF Sprayed Nano-Structured Ni-20Cr Coating
This study assesses the fireside erosion-corrosion behavior of nanostructured NiCr coatings in a power plant boiler operating at 750 °C. In the experiments, Ni-20Cr nanocrystalline powder was synthesized by ball milling and deposited on T91 boiler steel substrates by HVOF spraying. Coated and uncoated steel specimens were thermally cycled in the superheater zone of a coal fired boiler. After 15 heating and cooling cycles, the specimens were examined and erosion-corrosion kinetics were established via weight-change and thickness-loss measurements. The results show that the nanostructured coatings reduced the erosion-corrosion rate of T91 steel by 85%.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 551-555, May 21–23, 2014,
Abstract
View Papertitled, Performance of D-Gun Sprayed Coatings in Na 2 SO 4 -60%V 2 O 5 Environment at 900 °C
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for content titled, Performance of D-Gun Sprayed Coatings in Na 2 SO 4 -60%V 2 O 5 Environment at 900 °C
In this study, detonation spraying was used to deposit commercially available Ni-20Cr and WC-Co powders on SA213-T22 boiler steel. Coated and uncoated specimens were subjected to 50 thermal cycles in a molten salt boiler environment 900 °C in order to evaluate their hot corrosion behavior. Mass change measurements were made at the end of each cycle to assess corrosion kinetics and XRD and SEM/EDS were used to characterize corrosion products. An analysis of the reaction kinetics and the formation of oxide scales is provided in the paper.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 556-561, May 21–23, 2014,
Abstract
View Papertitled, Preparation and Characterization of WC/Co-W-C Cermet Coatings with Molten Zinc Corrosion Resistance by HVOF Spraying of Bimodal-Structured WC/Co Powder
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for content titled, Preparation and Characterization of WC/Co-W-C Cermet Coatings with Molten Zinc Corrosion Resistance by HVOF Spraying of Bimodal-Structured WC/Co Powder
In this study, WC-CoWC coatings were produced by HVOF spraying using bimodal-structured WC-Co powder with both micro- and nano-sized WC particles. Due to the melting characteristics of the powder during spraying, the microsized particles are retained in the deposit, but the nanosized particles dissolve into the Co matrix, forming a Co-W-C ternary phase. Compared to coatings sprayed from conventional WC-CoWC powder, the bimodal coatings are more resistant to corrosion and wear and are comparable in microhardness.
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