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Processing-Microstructure-Property Relations in Anisotropic Thermal Sprayed Composites

Published online by Cambridge University Press:  26 February 2011

Weiguang Chi ,
Vasudevan Srinivasan ,
Atin Sharma ,
Sanjay Sampath  and
Richard Gambino
Weiguang Chi
Affiliation:
wchi@ic.sunysb.edu, State University of New York at Stony Brook, Materials Science and Engineering, Heavy Engineering 130, Stony Brook, NY, 11794, United States, 631-216-2538
Vasudevan Srinivasan
Affiliation:
vsriniva@ic.sunysb.edu, Stony Brook University, Materials Science and Engineering, Stony Brook, NY, 11794, United States
Atin Sharma
Affiliation:
atsharma@ic.sunysb.edu, Stony Brook University, Materials Science and Engineering, Stony Brook, NY, 11794, United States
Sanjay Sampath
Affiliation:
ssampath@ms.cc.sunysb.edu, Stony Brook University, Materials Science and Engineering, Stony Brook, NY, 11794, United States
Richard Gambino
Affiliation:
rgambino@ms.cc.sunysb.edu, Stony Brook University, Materials Science and Engineering, Stony Brook, NY, 11794, United States
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Abstract

Thermal spray is a significantly advanced but inherently complex deposition process that involves successive impingement of molten droplets on a substrate to form coating with a ¡°brick-wall¡± layered structure. The anisotropic microstructure of coatings is very sensitive to processing conditions and has significant influence on the properties. This study aims to understand the processing-microstructure-thermal property correlation of thermally sprayed coatings. Thermal transport properties of three coating systems forming composites with pores (yttria stabilized zirconia (YSZ) -Air), a second phase (Mo-Mo2C) and a graded material (YSZ-NiCrAlY) are interpreted from the point of view of microstructure and chemical composition. In the case of YSZ-Air composite, results indicate that porosity contribution from 20-35% decreases the thermal conductivity by 50-70% of the bulk value. For the intrinsic composite of Mo and Mo2C, which coexist as stable phases, thermal conductivity increases significantly with 1.75wt% carbon addition since it reduces formation of MoO2 during processing, but decreases with 3.5wt% carbon addition. This is attributed to larger carbide retention in the latter. For the discrete layered and graded composites of YSZ-NiCrAlY, which are made up of varying fractions of these two constituents, thermal conductivity decreases sharply up to 40wt% YSZ and then more gradually with increasing YSZ content. This paper examines these experimental findings by treating the these complex coatings as multiphase composites.

Keywords

compositemicrostructurethermal conductivity
Type
Research Article
Information
MRS Online Proceedings Library (OPL) , Volume 977: Symposium FF – Processing-Structure-Mechanical Property Relations in Composite Materials , 2006 , 977-FF04-15
Copyright
Copyright © Materials Research Society 2007

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