The need for sustainable use of resources requires continuous improvement in the energy efficiency and development of new approaches to the design and processing of suitable materials. The concept of high entropy alloys (HEAs) has recently been extended to more general compositional complex alloys (CCAs) and multi-principal element alloys (MPEAs). One of the major challenges on the way to application of these alloys is the extensive design and selection efforts due to the great variety of possible compositions and its consequences for workability and resulting material properties. The favorable high-temperature strength of Ni-based and Co-based superalloys is ascribed to a defined γ/γ’ structure consisting of a disordered FCC A1 matrix and ordered L 12 γ’ precipitates. In the current work we extended this design concept to CCAs, allowing disordered BCC A2 and ordered B2 phases in additions or in substitution of the original γ/γ’ structure. We used a high-throughput screening approach combining CALPHAD-based computational tools with in situ alloying by means of laser cladding. Wall-type specimens with gradient composition in the system Al-Co-Cr-Fe-Ni-Ti with varying Al, Ti and Cr content were analyzed. The combined modelling and experimental screening approach was demonstrated to be a powerful tool for designing new high performance AM-ready feedstock.

Systematic variation of the induction plasma spray (IPS) conditions, i.e. (i) plasma power, (ii) carrier gas flow rate, and (iii) powder feed rate was performed to deposit TiO 2 coatings using statistical design of experiments (SDE) methodology. The microstructure, surface morphology, and anatase-rutile ratio of the coatings were studied by grazing-incidence X-ray diffraction (GIXD) and surface mapping with micro-probe Raman spectroscopy to determine the spatial phase distribution of anatase and rutile. The photocatalytic activity of the TiO 2 coatings was tested by decomposition of 4-chlorophenol in aqueous solution in the dark and under UV irradiation. The rates of pH changes measured were compared with those of standard Degussa P-25 coatings. The photocatalytic activity of the samples shows a reasonable correlation with the phase content and the plasma processing conditions prevailing during coating deposition.

This paper presents selected research results of the DFG founded project group, consisting of four institutes focusing on diagnostic methods in thermal coating processes. The aim of this group is to characterize the Atmospheric Plasma Spraying (APS) process by means of diagnostic methods so that – based on the requirement profile of the coating – appropriate adjusting of the process parameters can be realized. For this purpose, different diagnostic tools like Particle Shape Imaging, Laser Doppler Anemometry, Schlieren Technique, Particle Image Velocimetry, Enthalpy Probe, DPV 2000 and Thermography were qualified and adjusted to each other. Most of the results presented in this article are limited to the area close to the substrate which is difficult to handle with diagnostic methods. Additionally, new achievements concerning nozzle design and system enhancements are introduced.

This paper investigates the potential of radio frequency thermal plasma chemical vapor deposition for producing Sr-doped La-Mn-perovskite and yttria-doped zirconia layers for solid-oxide fuel cells. Aqueous solutions were used as starting materials and were injected into the hot plasma core by means of an air-assist atomizer. Test results show how the microstructure, dopant distribution, and phase purity of the resulting layers depends both on process conditions and the material system. Paper includes a German-language abstract.

In this paper a process based on both Thermal Plasma Chemical Vapor Deposition (TPCVD) and Suspension Plasma Spraying (SPS) is applied on r.f. induction thermal plasma for α/β-SiC ceramic synthesis and deposition. The starting materials are low-cost liquid disilanes. The resulting coatings are investigated by means of SEM and XRD. Results on the influence of the processing parameters (i.e. pressure, spray distance, substrate temperature, plasma gas nature and composition, precursor composition, atomization parameters) on the coating phase and microstructure are shown. Control of the microstructure (or nanostructure) as well as of the phase content, namely the ratio α/β can be achieved. A processing route presenting the elementary steps of SiC TPCVD is also proposed.

DC plasma spraying with its products has gained a high technical importance. With the availability of technically reliable high-frequency plasma torches whose basic development can be traced back to about 40 years ago, some of the disadvantages of the DC spray method are no longer existing or can be avoided to a great extent. This paper describes the principle, construction, and function of high-frequency plasma torches in which the plasma is generated by induction and metallic electrodes are not required (as is the case with conventional DC plasma torches). Typical examples of HF plasma spray application are discussed. Paper includes a German-language abstract.

This paper compares the features of direct current and radio frequency (RF) plasma spraying, but also the properties of aluminum coatings that are reinforced with short carbon fibers and manufactured using these two methods. It shows that the embedding of the fibres during the RF plasma spray process is very poor due to the low velocity of the plasma jet. Paper includes a German-language abstract.

This paper reports on the synthesis of SiC material through the decomposition of silanes in a thermal high frequency (HF) plasma. The process is based on thermal plasma technology for chemical deposition from the gas phase and on suspension plasma spray technology, in which a liquid or suspension is injected axially and atomized in the plasma flame. The liquid silane then decomposes, and forms SiC with some gaseous by-products such as HCl. Various plasma parameters were varied, for example the plasma power level, the plasma gas composition, the chamber pressure, and the silane composition. The paper also presents first investigations into the elementary and phase composition as well as the morphology of the powders and coatings. Paper includes a German-language abstract.

Perovskite-type LaMnO 3 powders and coatings have been prepared by a novel technique, the reactive suspension plasma spraying (SPS) using an inductively coupled plasma of about 40 kW plate power and an oxygen plasma sheath gas. Suitable precursor mixtures were found on the basis of solid state reactions, solubility and the phases obtained during the spray process. Best results were achieved by spraying a suspension of fine MnO 2 powder in a saturated ethanol solution of LaCl 3 with a 1:1 molar ratio of La and Mn. Low reactor pressure was helpful in order to diminish the amount of corrosive chlorine compounds in the reactor. As-sprayed coatings and collected powders showed perovskite contents of 70-90%. After a post-treatment with an 80% oxygen plasma an almost pure LaMnO 3 deposit was achieved in the center of the incident plasma jet.

Dc plasma torches typically use a mixture of inert and molecular gases when spraying high melting powders. The addition of molecular gases increases the enthalpy of plasma jets, but it also produces arc root fluctuations that can cause variations in injected powders. This paper describes an innovative plasma torch system characterized by a long nozzle and three parallel cathodes. The nozzle consists of several electrically insulated rings and a ring-shaped anode. By adding more rings, the arc gap and voltage can be increased along with the enthalpy of the plasma jet. The results of various tests, comparing the spray rates and deposition efficiencies of new and conventional torches, are presented in the paper.

The central components for solid oxide fuel cells (SOFC) are the electrodes-electrolyte multilayer arrangement (PEN) and the separating bipolar plates. The PEN (Positive electrode- Electrolyte-Negative electrode) assembly consists of a dense gastight yttria-stabilized zirconia (YSZ) electrolyte and porous electrodes for which usually Ni-YSZ cermet anode and Sr-doped LaMnO 3 cathode layers are used. The various PEN units are connected in a cell stack by bipolar plates which are either metallic or ceramic ones. Furthermore, a protective layer on the metallic bipolar plates consisting of a chromium alloy is required to prevent chromium evaporation leading to a rapid and strong degradation of the SOFC performance. At the DLR Stuttgart both the DC and the RF vacuum plasma spraying technique have been further developed and adapted to meet the requirements for the manufacture of the different SOFC components. The DCVPS process using specially developed Laval-like nozzles is especially appropriate to the production of thin and dense coatings as required for the electrolyte and the protective layers. However, applying special spray parameters and nozzles it is also possible to deposit porous electrode layers. The production of the entire PEN arrangement in one consecutive DC-VPS process is the objective of the actual development. On the other hand, the RF plasma spray technique is suitable for the near net-shape production of bulk components such as the metallic bipolar plate. The development of the deposition processes for the production of SOFC components using DC and RF plasma spray methods and the results obtained concerning PEN fabrication, deposition of protective layers and the near net-shape production of metallic bipolar plates are presented in the paper.

Fine (median size 6 μm and 0.3 μm) cobalt spinel (Co 3 O 4 ) powders were processed suspended in a suitable liquid phase. Suspensions exceeding 50 wt.% solid phase content were successfully injected into an inductively coupled plasma. Spheroidized powders with large particle size (up to 80 μm) were prepared, and cobalt oxide coatings were produced by this novel RF-SPS method. The microstructural features of the coatings can be controlled by parameter optimization similarly to plasma spraying of dry powders. Numerous variations of the physical and chemical conditions of the process were performed in an attempt to overcome the main disadvantage of the process, i.e. the decomposition of the spinel phase to CoO. So far, the spinel phase could be reestablished only by a post-treatment of the deposited coatings with atomic oxygen in the RF plasma.

LaMnO 3 powders and coatings have been prepared by reactive suspension plasma spraying (SPS) of MnO 2 powders and LaCl 3 solutions. A 40 kW inductively coupled plasma with an oxygen plasma sheath gas has been used. Water and ethanol have been tested as the liquid phase in the SPS process. High perovskite content (70-90%) has been achieved for both powders and coatings when spraying a suspension of fine MnO 2 powder in a saturated ethanol solution of LaCl3 with a 1:1 molar ratio of La and Mn. Materials obtained by a 1100 °C oven treatment have been used as reference during the study. The reactor pressure was varied from 30 to 80 kPa. Low pressure was found to be necessary to suppress the formation of undesired phases in the powders and coatings obtained. A plasma post treatment of the coatings results in an increase of the perovskite content.

A chromium alloy as used for the metallic bipolar plate of a solid oxide fuel cell was processed by RF-plasma spraying to dense free-standing parts. The plasma spray parameters were successfully adapted for two different types of powder. The layer properties, particularly the porosity and the splat shape were investigated in dependence on the spray angles. All the coatings produced with off-normal spray angles show higher porosity increasing from spray angles of 60° to 30°. The splat orientation changes from parallel to the inclined surfaces to almost perpendicular to the plasma jet axis with shallower angles.