Spray Pyrolysis-Aerosol Deposition for the Production of Thick Yttria-Stabilized Zirconia Coatings
Abstract
Aerosol deposition (AD) is a coating technique wherein particles are impacted onto a target substrate at reduced pressures, and supersonic particle impact velocities lead to coating consolidation. The limiting step in AD application is often not supersonic deposition operation, but aerosolization of powder particles with the proper size distribution; the translational impact velocity is strongly size‐dependent. It is demonstrated that by directly synthesizing particles in the gas phase, size‐controlled ceramic particles can be injected into AD systems. This in situ formation step obviates the need for particle aerosolization. Ultrasonic spray pyrolysis (USP) is applied to produce yttria‐stabilized zirconia (YSZ), and USP is directly coupled with AD to produce consolidated, thick, YSZ coatings on metal substrates. USP‐AD yields YSZ coatings on stainless steel and aluminum substrates with porosities <0.20, which grow to thicknesses beyond 100 μm. Aerodynamic particle spectrometry and electron microscopy reveal that the depositing particles are 200 nm–1.2 μm in diameter, though each particle is composed of nanocrystalline YSZ. Supporting computational fluid dynamics calculations demonstrate that the YSZ particle impact speeds are above 300 m s −1 . Thermal conductivity measurements demonstrate that USP‐AD coatings have conductivities consistent with those produced from high‐temperature processes.
- Authors:
-
[2];
[2];
[1]
- Univ. of Minnesota, Minneapolis, MN (United States)
- Colorado School of Mines, Golden, CO (United States)
- Univ. of Minnesota, Minneapolis, MN (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Publication Date:
- Research Org.:
- Univ. of Minnesota, Minneapolis, MN (United States); Colorado School of Mines, Golden, CO (United States)
- Sponsoring Org.:
- USDOE Advanced Research Projects Agency - Energy (ARPA-E); National Science Foundation (NSF)
- OSTI Identifier:
- 1820662
- Alternate Identifier(s):
- OSTI ID: 1781160
- Grant/Contract Number:
- AR0001094; AR0000840
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Advanced Engineering Materials
- Additional Journal Information:
- Journal Volume: 23; Journal Issue: 8; Journal ID: ISSN 1438-1656
- Publisher:
- Wiley
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE
Citation Formats
Song, Guanyu, Adamczyk, Jesse, Park, Yensil, Toberer, Eric S., and Hogan, Christopher J. Spray Pyrolysis-Aerosol Deposition for the Production of Thick Yttria-Stabilized Zirconia Coatings. United States: N. p., 2021.
Web. doi:10.1002/adem.202100255.
Song, Guanyu, Adamczyk, Jesse, Park, Yensil, Toberer, Eric S., & Hogan, Christopher J. Spray Pyrolysis-Aerosol Deposition for the Production of Thick Yttria-Stabilized Zirconia Coatings. United States. https://doi.org/10.1002/adem.202100255
Song, Guanyu, Adamczyk, Jesse, Park, Yensil, Toberer, Eric S., and Hogan, Christopher J. Sat .
"Spray Pyrolysis-Aerosol Deposition for the Production of Thick Yttria-Stabilized Zirconia Coatings". United States. https://doi.org/10.1002/adem.202100255. https://www.osti.gov/servlets/purl/1820662.
@article{osti_1820662,
title = {Spray Pyrolysis-Aerosol Deposition for the Production of Thick Yttria-Stabilized Zirconia Coatings},
author = {Song, Guanyu and Adamczyk, Jesse and Park, Yensil and Toberer, Eric S. and Hogan, Christopher J.},
abstractNote = {Aerosol deposition (AD) is a coating technique wherein particles are impacted onto a target substrate at reduced pressures, and supersonic particle impact velocities lead to coating consolidation. The limiting step in AD application is often not supersonic deposition operation, but aerosolization of powder particles with the proper size distribution; the translational impact velocity is strongly size‐dependent. It is demonstrated that by directly synthesizing particles in the gas phase, size‐controlled ceramic particles can be injected into AD systems. This in situ formation step obviates the need for particle aerosolization. Ultrasonic spray pyrolysis (USP) is applied to produce yttria‐stabilized zirconia (YSZ), and USP is directly coupled with AD to produce consolidated, thick, YSZ coatings on metal substrates. USP‐AD yields YSZ coatings on stainless steel and aluminum substrates with porosities <0.20, which grow to thicknesses beyond 100 μm. Aerodynamic particle spectrometry and electron microscopy reveal that the depositing particles are 200 nm–1.2 μm in diameter, though each particle is composed of nanocrystalline YSZ. Supporting computational fluid dynamics calculations demonstrate that the YSZ particle impact speeds are above 300 m s −1 . Thermal conductivity measurements demonstrate that USP‐AD coatings have conductivities consistent with those produced from high‐temperature processes.},
doi = {10.1002/adem.202100255},
journal = {Advanced Engineering Materials},
number = 8,
volume = 23,
place = {United States},
year = {Sat Apr 17 00:00:00 EDT 2021},
month = {Sat Apr 17 00:00:00 EDT 2021}
}
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