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This study aims to investigate the influence of spray distance on the microstructure and thermal shock resistance of “feather-like” structured thermal barrier coatings. The “feather-like” ZrO2-7wt. % Y2O3 (7YSZ) thermal barrier coatings were prepared at spray distances of 650, 950and 1250 mm by plasma spray-physical vapor deposition (PS-PVD) technology. Characterization tecniques such as X-CT (Industrial CT) and scanning electron microscopy (SEM) were utilized to examine the growth evolution, porosity, and microstructure of the “feather-like” structured thermal barrier coatings. Additionally, the thermal shock resistance of the “feather-like” structured coatings prepared at different spray distances was compared and tested at a temperature of 1250 ℃, aiming to explore the influence of spray distance on the thermal shock resistance of the coatings. The results indicate that the “feather-like” structured coatings are composed of nanoscale secondary columnar crystals and their interstices, interdendritic pores between “feather-like” structures, and micro-nano solid particles distributed on the “feather-like” dendrites. Along the growth direction of the coating, the “cauliflower-like” head gradually enlarged, and the spacing between the “feather-like” structures sequentially increased, leading to the evolution of the coating from a dense structure to a porous one. As the spray distance increased, the “cauliflower-like” head on the coating surface also gradually enlarged, accompanied by an increase in roughness and porosity. Ultimately, the thermal shock resistance lifespan of the “feather-like” 7YSZ coating increased with the spray distance, reaching 193 cycles (spray distance 650 mm), 230 cycles (spray distance 950 mm), and 347 cycles(spray distance 1250 mm), respectively. This improvement is attributed to the increased porosity of the coating with increasing spray distance, which endows the “feather-like” 7YSZ coating with higher strain tolerance, thereby facilitating the release of thermal stress for the coating's thermal shock resistance.

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Effect of Spray Distance on Microstructure and Thermal Shock Resistance of “Feather-Like” Structured 7YSZ Thermal Barrier Coating Prepared by Plasma Spray Physical Vapor Deposition

  • 会议论文

  • 发表日期：

    2026年

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  • Wenlong Chen,
  • Li Guo,
  • Qiuling Huang,
  • Min Liu,
  • Xuezhang Liu

摘要

This study aims to investigate the influence of spray distance on the microstructure and thermal shock resistance of “feather-like” structured thermal barrier coatings. The “feather-like” ZrO2-7wt. % Y2O3 (7YSZ) thermal barrier coatings were prepared at spray distances of 650, 950and 1250 mm by plasma spray-physical vapor deposition (PS-PVD) technology. Characterization tecniques such as X-CT (Industrial CT) and scanning electron microscopy (SEM) were utilized to examine the growth evolution, porosity, and microstructure of the “feather-like” structured thermal barrier coatings. Additionally, the thermal shock resistance of the “feather-like” structured coatings prepared at different spray distances was compared and tested at a temperature of 1250 ℃, aiming to explore the influence of spray distance on the thermal shock resistance of the coatings. The results indicate that the “feather-like” structured coatings are composed of nanoscale secondary columnar crystals and their interstices, interdendritic pores between “feather-like” structures, and micro-nano solid particles distributed on the “feather-like” dendrites. Along the growth direction of the coating, the “cauliflower-like” head gradually enlarged, and the spacing between the “feather-like” structures sequentially increased, leading to the evolution of the coating from a dense structure to a porous one. As the spray distance increased, the “cauliflower-like” head on the coating surface also gradually enlarged, accompanied by an increase in roughness and porosity. Ultimately, the thermal shock resistance lifespan of the “feather-like” 7YSZ coating increased with the spray distance, reaching 193 cycles (spray distance 650 mm), 230 cycles (spray distance 950 mm), and 347 cycles(spray distance 1250 mm), respectively. This improvement is attributed to the increased porosity of the coating with increasing spray distance, which endows the “feather-like” 7YSZ coating with higher strain tolerance, thereby facilitating the release of thermal stress for the coating's thermal shock resistance.