Microstructural Analysis and Transport Properties of Thermally Sprayed Multiple-Layer Ceramic Coatings
Abstract
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.
- Authors:
-
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Cummins Inc., Columbus, IN (United States)
- Stony Brook Univ., NY (United States)
- Publication Date:
- 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)
- OSTI Identifier:
- 1423044
- Grant/Contract Number:
- AC05-00OR22725
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Journal of Thermal Spray Technology
- Additional Journal Information:
- Journal Volume: 27; Journal Issue: 3; Journal ID: ISSN 1059-9630
- Publisher:
- Springer
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE; 42 ENGINEERING; TBC; thermal barrier coatings; thermal diffusivity
Citation Formats
Wang, Hsin, Muralidharan, Govindarajan, Leonard, Donovan N., Haynes, J. Allen, Porter, Wallace D., England, Roger D., Hays, Michael, Dwivedi, Gopal, and Sampath, Sanjay. Microstructural Analysis and Transport Properties of Thermally Sprayed Multiple-Layer Ceramic Coatings. United States: N. p., 2018.
Web. doi:10.1007/s11666-017-0680-0.
Wang, Hsin, Muralidharan, Govindarajan, Leonard, Donovan N., Haynes, J. Allen, Porter, Wallace D., England, Roger D., Hays, Michael, Dwivedi, Gopal, & Sampath, Sanjay. Microstructural Analysis and Transport Properties of Thermally Sprayed Multiple-Layer Ceramic Coatings. United States. https://doi.org/10.1007/s11666-017-0680-0
Wang, Hsin, Muralidharan, Govindarajan, Leonard, Donovan N., Haynes, J. Allen, Porter, Wallace D., England, Roger D., Hays, Michael, Dwivedi, Gopal, and Sampath, Sanjay. Thu .
"Microstructural Analysis and Transport Properties of Thermally Sprayed Multiple-Layer Ceramic Coatings". United States. https://doi.org/10.1007/s11666-017-0680-0. https://www.osti.gov/servlets/purl/1423044.
@article{osti_1423044,
title = {Microstructural Analysis and Transport Properties of Thermally Sprayed Multiple-Layer Ceramic Coatings},
author = {Wang, Hsin and Muralidharan, Govindarajan and Leonard, Donovan N. and Haynes, J. Allen and Porter, Wallace D. and England, Roger D. and Hays, Michael and Dwivedi, Gopal and Sampath, Sanjay},
abstractNote = {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.},
doi = {10.1007/s11666-017-0680-0},
journal = {Journal of Thermal Spray Technology},
number = 3,
volume = 27,
place = {United States},
year = {Thu Jan 04 00:00:00 EST 2018},
month = {Thu Jan 04 00:00:00 EST 2018}
}
Web of Science
Works referenced in this record:
The effect of thermal barrier coatings on diesel engine performance
journal, May 2002
- Hejwowski, T.; Weroński, A.
- Vacuum, Vol. 65, Issue 3-4
Processing-Microstructure-Property Relations in Anisotropic Thermal Sprayed Composites
journal, January 2006
- Chi, Weiguang; Srinivasan, Vasudevan; Sharma, Atin
- MRS Proceedings, Vol. 977
Flash Method of Determining Thermal Diffusivity, Heat Capacity, and Thermal Conductivity
journal, September 1961
- Parker, W. J.; Jenkins, R. J.; Butler, C. P.
- Journal of Applied Physics, Vol. 32, Issue 9
Development of a Thermal Transport Database for Air Plasma Sprayed ZrO2-Y2O3 Thermal Barrier Coatings
journal, February 2010
- Wang, Hsin; Dinwiddie, Ralph B.; Porter, Wallace D.
- Journal of Thermal Spray Technology, Vol. 19, Issue 5
The behavior of ceramic thermal barrier coatings on diesel engine combustion zone components
journal, January 1987
- Levy, Alan; Macadam, Stuart
- Surface and Coatings Technology, Vol. 30, Issue 1
Synthesis and Characterization of Grading Profiles in Plasma Sprayed NiCrAlY-Zirconia FGMs
journal, May 1999
- Sampath, S.; Smith, W. C.; Jewett, T. J.
- Materials Science Forum, Vol. 308-311
Current status of thermal barrier coatings — An overview
journal, January 1987
- Miller, Robert A.
- Surface and Coatings Technology, Vol. 30, Issue 1
Overview of thermal barrier coatings in diesel engines
journal, March 1997
- Yonushonis, T. M.
- Journal of Thermal Spray Technology, Vol. 6, Issue 1
Delamination of multilayer thermal barrier coatings
journal, July 1999
- Choi, Sung Ryul; Hutchinson, John W.; Evans, A. G.
- Mechanics of Materials, Vol. 31, Issue 7
Temperature and Finite Pulse‐Time Effects in the Flash Method for Measuring Thermal Diffusivity
journal, July 1963
- Cape, J. A.; Lehman, G. W.
- Journal of Applied Physics, Vol. 34, Issue 7
Thermal Barrier Coatings for Gas-Turbine Engine Applications
journal, April 2002
- Padture, N. P.
- Science, Vol. 296, Issue 5566
Thermal conductivities of YSZ/Al2O3 composites
journal, November 2010
- Yang, Fan; Zhao, Xiaofeng; Xiao, Ping
- Journal of the European Ceramic Society, Vol. 30, Issue 15
Works referencing / citing this record:
Self-Enhancing Thermal Insulation Performance of Bimodal-Structured Thermal Barrier Coating
journal, September 2018
- Zhang, Wei-Wei; Li, Guang-Rong; Zhang, Qiang
- Journal of Thermal Spray Technology, Vol. 27, Issue 7