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Title: Behavior of yttria-stabilized zirconia (YSZ) during laser direct energy deposition of an Inconel 625-YSZ cermet

Abstract

Thermal barrier coatings (TBC) are regularly used today to protect and extend the service life of several superalloys which are extensively used in high temperature applications. The existing TBCs are typically between 0.1 to 0.5 mm in thickness, are deposited on metal substrates using plasma spray or electron beam vapor deposition, and can reduce temperatures at the substrate surface by up to 300 °C. For greater temperature reductions there is a need for thicker TBCs. The building of thick TBCs has to date been stymied by poor adhesion, and cracking during deposition. It has been suggested that a functionally graded approach may reduce the residual stresses which result in these defects. To date there have been few reports on the deposition of ceramic or cermet coatings using laser AM and none have reported on the phase stability of ceramic particles post-deposition. This article is a first report on the phase stability of ceramic particles following the compositional segregation of elements during deposition using a powder feed additive manufacturing process. Functionally graded (FG), thick TBCs (>3 mm) consisting of Inconel 625 (IN625) and yttria-partially stabilized zirconia (8YSZ) were deposited on an A516 steel substrate via laser direct energy deposition (LDED). Goodmore » interfaces were observed between the bond coat (BC) and first cermet layer and between the graded cermet layers. However, cermet layers deposited with 10 wt.% or more YSZ developed a thin layer of YSZ on the surface. The thin layer of YSZ greatly hindered additional deposition of new cermet layers. In cermet layers that did exhibit good interfaces, fine, re-solidified, YSZ particles were homogenously distributed within the Inconel 625 matrix. The YSZ particles exhibited a tetragonal lattice structure and were depleted of yttrium. In contrast, the thin YSZ layer formed on a cermet surface showed no yttrium depletion.« less

Authors:
 [1];  [2];  [3];  [4];  [4];  [1]
  1. National Energy Technology Lab. (NETL), Albany, OR (United States)
  2. National Energy Technology Lab. (NETL), Albany, OR (United States); Leidos Research Support Team, Pittsburgh, PA (United States)
  3. National Energy Technology Lab. (NETL), Albany, OR (United States); Oregon State Univ., Corvallis, OR (United States)
  4. DM3D Technology, LLC, Auburn Hills, MI (United States)
Publication Date:
Research Org.:
National Energy Technology Laboratory (NETL), Albany, OR (United States)
Sponsoring Org.:
USDOE Office of Fossil Energy (FE)
OSTI Identifier:
1635623
Alternate Identifier(s):
OSTI ID: 1574522
Resource Type:
Journal Article: Accepted Manuscript
Journal Name:
Additive Manufacturing
Additional Journal Information:
Journal Volume: 31; Journal ID: ISSN 2214-8604
Publisher:
Elsevier
Country of Publication:
United States
Language:
English
Subject:
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CHEMISTRY; Multi-material additive manufacturing; Phase stability of YSZ; Ceramic additive manufacturing; Compositional stability; Functionally graded materials; Thick thermal barrier coatings

Citation Formats

Rao, Harish, Oleksak, Richard P., Favara, Kory, Harooni, Arshad, Dutta, Bhaskar, and Maurice, David. Behavior of yttria-stabilized zirconia (YSZ) during laser direct energy deposition of an Inconel 625-YSZ cermet. United States: N. p., 2019. Web. doi:10.1016/j.addma.2019.100932.
Rao, Harish, Oleksak, Richard P., Favara, Kory, Harooni, Arshad, Dutta, Bhaskar, & Maurice, David. Behavior of yttria-stabilized zirconia (YSZ) during laser direct energy deposition of an Inconel 625-YSZ cermet. United States. https://doi.org/10.1016/j.addma.2019.100932
Rao, Harish, Oleksak, Richard P., Favara, Kory, Harooni, Arshad, Dutta, Bhaskar, and Maurice, David. Sun . "Behavior of yttria-stabilized zirconia (YSZ) during laser direct energy deposition of an Inconel 625-YSZ cermet". United States. https://doi.org/10.1016/j.addma.2019.100932. https://www.osti.gov/servlets/purl/1635623.
@article{osti_1635623,
title = {Behavior of yttria-stabilized zirconia (YSZ) during laser direct energy deposition of an Inconel 625-YSZ cermet},
author = {Rao, Harish and Oleksak, Richard P. and Favara, Kory and Harooni, Arshad and Dutta, Bhaskar and Maurice, David},
abstractNote = {Thermal barrier coatings (TBC) are regularly used today to protect and extend the service life of several superalloys which are extensively used in high temperature applications. The existing TBCs are typically between 0.1 to 0.5 mm in thickness, are deposited on metal substrates using plasma spray or electron beam vapor deposition, and can reduce temperatures at the substrate surface by up to 300 °C. For greater temperature reductions there is a need for thicker TBCs. The building of thick TBCs has to date been stymied by poor adhesion, and cracking during deposition. It has been suggested that a functionally graded approach may reduce the residual stresses which result in these defects. To date there have been few reports on the deposition of ceramic or cermet coatings using laser AM and none have reported on the phase stability of ceramic particles post-deposition. This article is a first report on the phase stability of ceramic particles following the compositional segregation of elements during deposition using a powder feed additive manufacturing process. Functionally graded (FG), thick TBCs (>3 mm) consisting of Inconel 625 (IN625) and yttria-partially stabilized zirconia (8YSZ) were deposited on an A516 steel substrate via laser direct energy deposition (LDED). Good interfaces were observed between the bond coat (BC) and first cermet layer and between the graded cermet layers. However, cermet layers deposited with 10 wt.% or more YSZ developed a thin layer of YSZ on the surface. The thin layer of YSZ greatly hindered additional deposition of new cermet layers. In cermet layers that did exhibit good interfaces, fine, re-solidified, YSZ particles were homogenously distributed within the Inconel 625 matrix. The YSZ particles exhibited a tetragonal lattice structure and were depleted of yttrium. In contrast, the thin YSZ layer formed on a cermet surface showed no yttrium depletion.},
doi = {10.1016/j.addma.2019.100932},
url = {https://www.osti.gov/biblio/1635623}, journal = {Additive Manufacturing},
issn = {2214-8604},
number = ,
volume = 31,
place = {United States},
year = {2019},
month = {11}
}

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