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Title: Microstructural Analysis and Transport Properties of Thermally Sprayed Multiple-Layer Ceramic Coatings

In this paper, multilayer, graded ceramic/metal coatings were prepared by an air plasma spray method on Ti-6Al-4V, 4140 steel and graphite substrates. The coatings were designed to provide thermal barriers for diesel engine pistons to operate at higher temperatures with improved thermal efficiency and cleaner emissions. A systematic, progressive variation in the mixture of yttria-stabilized zirconia and bondcoat alloys (NiCoCrAlYHfSi) was designed to provide better thermal expansion match with the substrate and to improve thermal shock resistance and cycle life. Heat transfer through the layers was evaluated by a flash diffusivity technique based on a model of one-dimensional heat flow. The aging effect of the as-sprayed coatings was captured during diffusivity measurements, which included one heating and cooling cycle. The hysteresis of thermal diffusivity due to aging was not observed after 100-h annealing at 800 °C. The measurements of coatings on substrate and freestanding coatings allowed the influence of interface resistance to be evaluated. Finally, the microstructure of the multilayer coating was examined using scanning electron microscope and electron probe microanalysis.
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  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  2. Cummins Inc., Columbus, IN (United States)
  3. Stony Brook Univ., NY (United States)
Publication Date:
Grant/Contract Number:
Accepted Manuscript
Journal Name:
Journal of Thermal Spray Technology
Additional Journal Information:
Journal Volume: 27; Journal Issue: 3; Journal ID: ISSN 1059-9630
Research Org:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Cummins Inc., Columbus, IN (United States)
Sponsoring Org:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Vehicle Technologies Office (EE-3V)
Country of Publication:
United States
36 MATERIALS SCIENCE; 42 ENGINEERING; TBC; thermal barrier coatings; thermal diffusivity
OSTI Identifier: