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Rare Earth Oxide Coating with Controlled Chemistry Using Thermal Spray
Title
Rare Earth Oxide Coating with Controlled Chemistry Using Thermal Spray.
Creator
Singh, Virendra, Seal, Sudipta, Coffey, Kevin, Raghavan, Seetha, Heinrich, Helge, Zhai, Lei, University of Central Florida
Abstract / Description
Cerium oxide (Ceria) at nano scale has gained significant attention due to its numerous technological applications. Ceria in both doped and undoped forms are being explored as oxygen sensor, catalysis, protective coating against UV and corrosion, solid oxide fuel cell (SOFC) electrolyte and newly discovered antioxidant for biomedical applications. Therefore, there is an imminent need of a technology which can provide a cost effective, large scale manufacturing of nanoceria and its subsequent...
Show moreCerium oxide (Ceria) at nano scale has gained significant attention due to its numerous technological applications. Ceria in both doped and undoped forms are being explored as oxygen sensor, catalysis, protective coating against UV and corrosion, solid oxide fuel cell (SOFC) electrolyte and newly discovered antioxidant for biomedical applications. Therefore, there is an imminent need of a technology which can provide a cost effective, large scale manufacturing of nanoceria and its subsequent consolidation, specially using thermal spray.This dissertation aims to develop a scientific understanding towards the development of pure and doped ceria- based coating for a variety of technological applications, from SOFC applications to corrosion resistant coating. Atmospheric plasma spray (APS) and solution precursor plasma spray (SPPS) techniques for the fabrication of nano ceria coating were investigated. For feedstock powder preparation, a spray drying technique was used for the agglomeration of cerium oxide nano particles to achieve high density coating. Deposition efficiencies and coating porosity as a function of processing parameters were analyzed and optimized using a statistical design of experiment model. The coating deposition efficiency was dependent on the plasma temperature and vaporization pressure of the ceria nanoparticles. However, low standoff distance and high carrier gas flow rate were responsible for the improved density upto 86 (&)#177;3%.An alternative novel SPPS technique was studied for a thin film of cerium oxide deposition from various cerium salt precursors in doped and undoped conditions. The SPPS process allows controlling the chemistry of coating at a molecular level. The deposition mechanism by single scan experiments and the effect of various factors on coating microstructure evolution were studied in terms of splats formation. It was found that the precursor salt (nitrate of cerium) with lower thermal decomposition temperatures was suitable for a high density coating. The high concentration and low spray distance significantly improve the splat morphology and reduced porosity (upto 20%). The feasibility of the trivalent cations (Sm 3+ and Gd 3+) doping into cerium oxide lattice in high temperature plasma was discussed and experimentally studied. XRD analysis revealed the nano crystalline characteristic of the coating and lattice expansion due to doping. The extensive transmission electron microscopy, Scanning electron microscopy, X-ray diffraction, X-ray photoelectron spectroscopy and thermo gravimetric were conducted to evaluate the precursors, and coating microstructure.Due to facial switching between Ce4+ and Ce3+ oxidation state, the cerium oxide surface becomes catalytically active. Thus, the APS ceria coatings were investigated for their applicability under extreme environmental conditions (high pressure and temperature). The air plasma sprayed coated 17-4PH steel was subjected to high pressure (10 Kpsi) and temperature (300 oF) corrosive environment. The coated steel showed continuous improvement in the corrosion resistance at 3.5 wt% NaCl at ambient temperature for three months study whereas, high pressure did not reveal a significant role in the corrosion process, and however, one needs to do further research. The ceria coated steel also revealed the improvement in corrosion protection (by 4 times) compared to the bare steel at low pH, 300 oF and 4000 Psi environment. This study projects the importance of cerium oxide coatings, their fabrication, optimization and applications.
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Date Issued
2012
Identifier
CFE0004230, ucf:49023
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0004230
PLASMA PROCESSING FOR RETENTION OF NANOSTRUCTURES
Title
PLASMA PROCESSING FOR RETENTION OF NANOSTRUCTURES.
Creator
Venkatachalapathy, Viswanathan, Seal, Sudipta, University of Central Florida
Abstract / Description
Plasma spray processing is a technique that is used extensively in thermal barrier coatings on gas and steam turbine components, biomedical implants and automotive components. Many processing parameters are involved to achieve a coating with certain functionality. The coating could be required to function as thermal barrier, wear resistant, corrosion resistant or a high temperature oxidation resistant coating. Various parameters, such as, nozzle and electrode design, powder feeding system,...
Show morePlasma spray processing is a technique that is used extensively in thermal barrier coatings on gas and steam turbine components, biomedical implants and automotive components. Many processing parameters are involved to achieve a coating with certain functionality. The coating could be required to function as thermal barrier, wear resistant, corrosion resistant or a high temperature oxidation resistant coating. Various parameters, such as, nozzle and electrode design, powder feeding system, spray distances, substrate temperature and roughness, plasma gas flow rates and others can greatly alter the coating quality and resulting performance. Feedstock (powder or solution precursor) composition and morphology are some of the important variables, which can affect the high end coating applications. The amount of heat a plasma plume has to offer to the particles being processed as a coating depends primarily on the dissociation of the atoms of gaseous mixtures being used to create the plasma and the residence time required for the particle to stay in the flame. The parameters that are conducive for nanostructured retention could be found out if the residence time of the particles in the flame and the available heat in the plume for various gas combinations could be predicted. If the feedstock is a liquid precursor instead of a powder feedstock, the heat that has to be offered by the plasma could be increased by suitable gas combination to achieve a good quality coating. Very little information is available with regard to the selection of process parameters and processing of nano materials feedstock to develop nanostructured coatings using plasma spray. In this study, it has been demonstrated that nano ceramics or ceramic composites either in the form of coatings or bulk free form near net components could be processed using DC plasma spray. For powder feedstock, analytical heat transfer calculations could predict the particle states for a given set of parameters by way of heat input from the plasma to the particles. The parameter selection is rendered easier by means of such calculations. Alumina nano ceramic particles are processed as a coating. During Spray drying, a process of consolidation of nano alumina particles to spherical agglomerates, parameter optimization for complete removal of moisture has been achieved. The parameters are tested for alumina nanoparticles with a plasma torch for the veracity of calculations. The amount of heat transfer from the surface of the agglomerates to the core has been quantified as a function of velocity of particles. Since preparation of nanostructured feedstock for plasma spray is expensive and cumbersome, alternative solution precursor route for direct pyrolysis of precursor to coating has been studied in case of nanocrystalline rare earth oxides. Thus, it has also been shown by this research that nanostructured coatings could be either from a powder feedstock or a solution precursor feedstock. MoSi2-Si3N4, Ni-Al2O3, W-HfC nano ceramic composite systems have been processed as a bulk free form nanocomposite with 60-70% retained nanostructures. The importance of selection of substrates, roughness and the substrate temperature for development of free form bulk components has been highlighted. The improvement in mechanical and high temperature properties associated with having such nanostructured coatings or bulk nanocomposites are revealed. These nanostructured coatings are known for their low thermal conductivity, high wear resistance and can be potentially used as steam and gas turbines coatings for improved thermal efficiency. In summary, bulk nanocomposite through plasma spray processing is a viable alternative to conventional processes such as sintering, HIP for high fracture toughness and hardness applications.
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Date Issued
2007
Identifier
CFE0001680, ucf:47203
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0001680
DEVELOPMENT OF THERMALLY PROCESSED NANOCOMPOSITES WITH CONTROLLED SURFACES
Title
DEVELOPMENT OF THERMALLY PROCESSED NANOCOMPOSITES WITH CONTROLLED SURFACES.
Creator
Georgieva, Petya, Seal, Sudipta, University of Central Florida
Abstract / Description
The ever increasing need for technology development requires the integration of inexpensive, light weight and high strength materials which are able to meet the high standards and specifications for various engineering applications. The intention of this work is to show that the suitable material selection and the utilization of plasma spray processing can be of potential interest to a large number of industrial, biomedical and everyday life applications. This research demonstrates also that...
Show moreThe ever increasing need for technology development requires the integration of inexpensive, light weight and high strength materials which are able to meet the high standards and specifications for various engineering applications. The intention of this work is to show that the suitable material selection and the utilization of plasma spray processing can be of potential interest to a large number of industrial, biomedical and everyday life applications. This research demonstrates also that plasma processing is a promising engineering tool for multifunctional coatings and near-net-shape manufacturing. Further, the theoretical and experimental results are combined in order to explain the mechanisms behind nanostructure retention and enhanced properties. Proper design of experiments, an appropriate material selection and experimental methodology are discussed herein. The experimental conditions were optimized in order to achieve the best materials properties according to their explicit properties and functions. Specific materials were consolidated according to their prospective performance and applications: 1) Plasma spraying of nano-Ceria-stabilized Zirconia free form part for stem cells scaffolds, 2) Plasma spraying of FeCrAlY on Ti-alloy plate, additionally coated with nano-size Hydroxyapatite for bone tissue engineering, 3) Wire-arc spraying of nano-based steel wires for aerospace and automotive applications. The performance and characteristics of all of the developed coatings and free-form-parts are evaluated using state-of-the art characterization techniques.
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Date Issued
2006
Identifier
CFE0001153, ucf:46871
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0001153
EFFECTS OF INTERNAL OXIDATION ON THERMO-MECHANICAL PROPERTIES OF ATMOSPHERIC PLASMA SPRAYED CONICRALY COATINGS
Title
EFFECTS OF INTERNAL OXIDATION ON THERMO-MECHANICAL PROPERTIES OF ATMOSPHERIC PLASMA SPRAYED CONICRALY COATINGS.
Creator
Patterson, Travis, Sohn, Yong-ho, University of Central Florida
Abstract / Description
Thermal barrier coatings (TBC) with MCrAlY (M=Co and/or Ni) bond coats have been widely used in hot sections of gas turbines to protect underlying superalloys from high temperatures, oxidation, and hot corrosion. Deposition of MCrAlY bond coats using atmospheric plasma spray (APS), as oppose to conventionally employed vacuum/low-pressure plasma spray and high velocity oxy-fuel deposition, allows greater flexibility in ability to coat economically and rapidly for parts with complex geometry...
Show moreThermal barrier coatings (TBC) with MCrAlY (M=Co and/or Ni) bond coats have been widely used in hot sections of gas turbines to protect underlying superalloys from high temperatures, oxidation, and hot corrosion. Deposition of MCrAlY bond coats using atmospheric plasma spray (APS), as oppose to conventionally employed vacuum/low-pressure plasma spray and high velocity oxy-fuel deposition, allows greater flexibility in ability to coat economically and rapidly for parts with complex geometry including internal surfaces. There were three objectives of this study. First, relationships between APS spray parameters and coating microstructure was examined to determine optimum spray parameters to deposit APS CoNiCrAlY bond coats. Second, free-standing APS CoNiCrAlY coatings were isothermally oxidized at 1124C for various periods to examine the evolving microstructure of internal oxidation. Third, as a function of time of isothermal oxidation (i.e., internal oxidation), thermal conductivity and coefficient of thermal expansion were measured for free-standing APS CoNiCrAlY bond coats. Thirteen CoNiCrAlY coatings were deposited on steel substrates by APS using the F4-MB plasma torch. APS CoNiCrAlY bond coats were produced by incremental variation in the flow rate of primary (argon) gas from 85 to 165 SCFH and the flow rate of secondary (hydrogen) gas from 9 to 29 SCFH. Optimum coating microstructure was produced by simultaneously increasing the flow rate of both primary and secondary gas, so that the particle temperature is high enough for sufficient melting and the particle velocity is rapid enough for minimum in-flight oxidation. Optimum spray parameters found in this study were employed to deposit free-standing APS CoNiCrAlY coatings that were isothermally oxidized at 1124ºC for 1, 6, 50,100, and 300 hours. Extent of internal oxidation was examined by scanning electron microscopy and image analysis. Internal oxidation occurred by a thickening of oxide scales segregated at the splat boundaries oriented parallel to the coating surfaces. Thermal conductivity and coefficient of thermal expansion (CTE) of the free-standing APS CoNiCrAlY coatings were measured as a function of internal oxidation (i.e., time of oxidation or extent of internal oxidation). Thermal conductivity of free-standing APS CoNiCrAlY was found to decrease with increasing internal oxidation from 28 to 25 W/m-K. This decrease is due to an increase in the amount of internal oxides with lower thermal conductivity (e.g., Al2O3). CTE of free-standing APS CoNiCrAlY, measured in temperature range of 100~500C, was also found to decrease with increasing internal oxidation. Internal oxides have lower CTE than metallic CoNiCrAlY coatings. These evolving properties of APS CoNiCrAlY should be beneficial to the overall performance of TBCs in gas turbine applications.
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Date Issued
2008
Identifier
CFE0002400, ucf:47757
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0002400
Graphene Oxide Reinforcement in Plasma Sprayed Nickel-5%Aluminum Coatings
Title
Graphene Oxide Reinforcement in Plasma Sprayed Nickel-5%Aluminum Coatings.
Creator
Ward, David, Seal, Sudipta, Vaidyanathan, Raj, Heinrich, Helge, Zhai, Lei, University of Central Florida
Abstract / Description
Metallic plasma sprayed coatings are widely used in the aerospace industry for repair on worn engine components. However, the inherent defects in these coatings limit the variety of repairs and reduce the service life of the repaired parts. A potential solution to overcome this problem is to mix small amounts of inexpensive graphene oxide in the powder feedstock. The incredible strength to weight ratio of graphene oxide makes it a viable additive to improve mechanical properties of metallic...
Show moreMetallic plasma sprayed coatings are widely used in the aerospace industry for repair on worn engine components. However, the inherent defects in these coatings limit the variety of repairs and reduce the service life of the repaired parts. A potential solution to overcome this problem is to mix small amounts of inexpensive graphene oxide in the powder feedstock. The incredible strength to weight ratio of graphene oxide makes it a viable additive to improve mechanical properties of metallic plasma sprayed coatings. The powder system chosen for this research is Nickel-5Aluminum since it is a common coating for such repairs. The greatest challenge was retaining graphene oxide, which combusts at 400(&)deg;C, while melting the Nickel above 1450(&)deg;C using a high temperature plasma plume. Graphene oxide was successfully retained in the coatings using either of two configurations: (1) Injecting the graphene oxide powder via solution suspension separately from the metal powder, or (2) Installing a shroud on the front of the plasma gun and backfilling with Argon to inhibit combustion. The uniquely designed solution suspension configuration resulted in a higher deposition efficiency of graphene oxide while the inert shroud configuration had a more homogeneous distribution and retention of graphene oxide in the coatings. The best overall coating was achieved using the inert shroud configuration using a powder mixture containing 2% weight Edge Functionalized Graphene Oxide. Vickers microhardness increased 46% and tensile adhesion strength increased 26% over control samples. This is possible due to the mechanisms of dislocation strengthening and stress transfer previously reported in graphene oxide reinforced Aluminum composites formed by flake powder metallurgy. It was also observed that the energy released by the combustion of graphene oxide helps to uniformly melt the Nickel particles and improve the coating microstructure, allowing for more forgiving spray parameters. The methods developed and results attained in this research open opportunities for graphene oxide to be added as inexpensive reinforcements to other metallic compositions for widespread use in metal matrix composite manufacturing.
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Date Issued
2014
Identifier
CFE0005901, ucf:50857
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0005901
Fatigue Lifetime Approximation based on Quantitative Microstructural Analysis for Air Plasma Sprayed Thermal Barrier Coatings
Title
Fatigue Lifetime Approximation based on Quantitative Microstructural Analysis for Air Plasma Sprayed Thermal Barrier Coatings.
Creator
Bargraser, Carmen, Sohn, Yongho, An, Linan, Heinrich, Helge, University of Central Florida
Abstract / Description
The durability of thermal barrier coatings (TBCs) affects the life of the hot section engine components on which they are applied. Fatigue is the general failure mechanism for such components and is responsible for most unexpected failures; therefore it is desirable to develop lifetime approximation models to ensure reliability and durability.In this study, we first examined the microstructural degradation of air plasma sprayed ZrO2-8wt.%Y2O3 TBCs with a low-pressure plasma sprayed CoNiCrAlY...
Show moreThe durability of thermal barrier coatings (TBCs) affects the life of the hot section engine components on which they are applied. Fatigue is the general failure mechanism for such components and is responsible for most unexpected failures; therefore it is desirable to develop lifetime approximation models to ensure reliability and durability.In this study, we first examined the microstructural degradation of air plasma sprayed ZrO2-8wt.%Y2O3 TBCs with a low-pressure plasma sprayed CoNiCrAlY bond coat on an IN 738LC superalloy substrate. The durability of TBCs were assessed through furnace thermal cyclic tests carried out in air at 1100(&)deg;C with a 1-, 10-, and 50-hour dwell period, preceded by a 10-minute heat-up and followed by a 10-minute forced-air-quench. Failure mechanisms of the TBCs were thoroughly investigated through materials characterization techniques including: X-Ray Diffraction, Scanning Electron Microscopy, and Energy Dispersive X-Ray Spectroscopy.Quantitative microstructural analyses were then carried out to document the growth of the thermally grown oxide (TGO) scale, the depletion of the Al-rich ?-NiAl phase in the bond coat, and the population and growth of micro-cracks near the YSZ/bond coat interface. Trends in the TGO growth and the ?-phase depletion in the bond coat followed those of diffusion-controlled processes(-)parabolic growth of the TGO and exponential depletion of the ?-phase. Formation and propagation of cracks within the YSZ resulted in complete spallation of the YSZ topcoat from the bond-coated superalloy substrate.Evolution in these microstructural features was correlated to the lifetime of TBCs, which showed cracking within the YSZ to be the cause of failure; thus a lifetime approximation model was developed, via modification of Paris Law, based on the experimental data. The model predicted the TBC lifetime within 10% of the experimental lifetime.
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Date Issued
2011
Identifier
CFE0004087, ucf:49145
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0004087
Nanocomposite Coating Mechanics via Piezospectroscopy
Title
Nanocomposite Coating Mechanics via Piezospectroscopy.
Creator
Freihofer, Gregory, Raghavan, Seetha, Gou, Jihua, Bai, Yuanli, Schulzgen, Axel, University of Central Florida
Abstract / Description
Coatings utilizing the piezospectroscopic (PS) effect of alpha alumina could enable on the fly stress sensing for structural health monitoring applications. While the PS effect has been historically utilized in several applications, here by distributing the photo-luminescent material in nanoparticle form within a matrix, a stress sensing coating is created. Parallel to developing PS coatings for stress sensing, the multi-scale mechanics associated with the observed PS response of...
Show moreCoatings utilizing the piezospectroscopic (PS) effect of alpha alumina could enable on the fly stress sensing for structural health monitoring applications. While the PS effect has been historically utilized in several applications, here by distributing the photo-luminescent material in nanoparticle form within a matrix, a stress sensing coating is created. Parallel to developing PS coatings for stress sensing, the multi-scale mechanics associated with the observed PS response of nanocomposites and their coatings has been applied to give material property measurements, providing an understanding of particle reinforced composite behavior.Understanding the nanoparticle-coating-substrate mechanics is essential to interpreting the spectral shifts for stress sensing of structures. In the past, methods to experimentally measure the mechanics of these embedded nano inclusions have been limited, and much of the design of these composites depend on computational modeling and bulk response from mechanical testing. The PS properties of Chromium doped alumina allow for embedded inclusion mechanics to be revisited with unique experimental setups that probe the particles state of stress under applied load to the composite. These experimental investigations of particle mechanics will be compared to the Eshelby theory and its derivative theories in addition to the nanocomposite coating mechanics. This work discovers that simple nanoparticle load transfer theories are adequate for predicting PS properties in an intermediate volume fraction range. With fundamentals of PS nanocomposites established, the approach was applied to selected experiments to prove its validity. In general it was observed that the elastic modulus values calculated from the PS response were similar to that observed from macroscale strain measurements such as a strain gage. When simple damage models were applied to monitor the elastic modulus, it was observed that the rate of decay for the elastic modulus was much higher for the PS measurements than for the strain gage.A novel experiment including high resolution PS maps with secondary strain maps from digital image correlation is reviewed on an open hole tension, composite coupon. The two complementary measurements allow for a unique PS response for every location around the hole with a spatial resolution of 400 microns. Progression of intermediate damage mechanisms was observed before digital image correlation indicated them. Using the PS nanocomposite model, elastic modulus values were calculated. Introducing an elastic degradation model with some plastic deformation allows for estimation of material properties during the progression of failure.This work is part of a continuing effort to understand the mechanics of a stress sensing PS coating. The mechanics were then applied to various experimental data that provided elastic property calculations with high resolution. The significance is in the experimental capture of stress transfer in particulate composites. These findings pave the way for the development of high resolution stress-sensing coatings.
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Date Issued
2014
Identifier
CFE0005614, ucf:50223
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0005614
INVESTIGATION OF PS-PVD AND EB-PVD THERMAL BARRIER COATINGS OVER LIFETIME USING SYNCHROTRON X-RAY DIFFRACTION
Title
INVESTIGATION OF PS-PVD AND EB-PVD THERMAL BARRIER COATINGS OVER LIFETIME USING SYNCHROTRON X-RAY DIFFRACTION.
Creator
Northam, Matthew, Raghavan, Seetha, Ghosh, Ranajay, Vaidyanathan, Raj, University of Central Florida
Abstract / Description
Extreme operating temperatures within the turbine section of jet engines require sophisticated methods of cooling and material protection. Thermal barrier coatings (TBCs) achieve this through a ceramic coating applied to a substrate material (nickel-based superalloy). Electron-beam physical vapor deposition (EB-PVD) is the industry standard coating used on jet engines. By tailoring the microstructure of an emerging deposition method, Plasma-spray physical vapor deposition (PS-PVD), similar...
Show moreExtreme operating temperatures within the turbine section of jet engines require sophisticated methods of cooling and material protection. Thermal barrier coatings (TBCs) achieve this through a ceramic coating applied to a substrate material (nickel-based superalloy). Electron-beam physical vapor deposition (EB-PVD) is the industry standard coating used on jet engines. By tailoring the microstructure of an emerging deposition method, Plasma-spray physical vapor deposition (PS-PVD), similar microstructures to that of EB-PVD coatings can be fabricated, allowing the benefits of strain tolerance to be obtained while improving coating deposition times. This work investigates the strain through depth of uncycled and cycled samples using these coating techniques with synchrotron X-ray diffraction (XRD). In the TGO, room temperature XRD measurements indicated samples of both deposition methods showed similar in-plane compressive stresses after 300 and 600 thermal cycles. In-situ XRD measurements indicated similar high-temperature in-plane and out-of-plane stress in the TGO and no spallation after 600 thermal cycles for both coatings. Tensile in-plane residual stresses were found in the YSZ uncycled PS-PVD samples, similar to APS coatings. PS-PVD samples showed in most cases, higher compressive residual in-plane stress at the YSZ/TGO interface. These results provide valuable insight for optimizing the PS-PVD processing parameters to obtain strain compliance similar to that of EB-PVD. Additionally, external cooling methods used for thermal management in jet engine turbines were investigated. In this work, an additively manufactured lattice structure providing transpiration cooling holes is designed and residual strains are measured within an AM transpiration cooling sample using XRD. Strains within the lattice structure were found to have greater variation than that of the AM solid wall. These results provide valuable insight into the viability of implementing an AM lattice structure in turbine blades for the use of transpiration cooling.
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Date Issued
2019
Identifier
CFE0007844, ucf:52830
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0007844