Preparation of SrZrO3 Thermal Barrier Coating by Solution Precursor Plasma Spray

The solution precursor plasma spray (SPPS) process is capable of depositing highly durable thermal barrier coatings (TBCs). In this study, an aqueous chemical precursor feedstock was injected into the plasma jet to deposit SrZrO3 thermal barrier coating on metal substrate. Taguchi design of experiments was employed to optimize the SPPS process. The thermal characteristics and phase evolution of the SrZrO3 precursor, as well as the influence of various spray parameters on the coating deposition rate, microhardness, microstructure, and phase stability, were investigated. The experimental results showed that, at given spray distance, feedstock flow rate, and atomization pressure, the optimized spray parameters were arc current of 600 A, argon flow rate of 40 L/min, and hydrogen flow rate of 10 L/min. The SrZrO3 coating prepared using the optimized spray parameters had single-pass thickness of 6.0 mu m, porosity of similar to 18%, and microhardness of 6.8 +/- 0.1 GPa. Phase stability studies indicated that the as-sprayed SrZrO3 coating had good phase stability in the temperature range from room temperature to 1400 A degrees C, gradually exhibiting a phase transition from t'-ZrO2 to m-ZrO2 in the SrZrO3 coating at 1450 A degrees C with increasing time, while the SrZrO3 phase did not change.