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A Study on YSZ Abradable Seal Coatings Prepared by Atmospheric Plasma Spray and Mixed Solution Precursor Plasma Spray

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Abstract

The yttria-stabilized zirconia (YSZ) ceramic has been proved to be a promising material for abradable seal coatings. In this research, abradable seal coatings named C-YSZ and M-YSZ were prepared by applying the conventional plasma spraying method with improved nanostructured powders and by the mixed solution precursor plasma spraying technique, respectively. A study on the microstructure, mechanical properties, oxidation resistance and hot corrosion resistance was conducted on both C-YSZ and M-YSZ coatings by using scanning electron microscopy, transmission electron microscopy, muffle furnace and x-ray diffractometer. The results show that the C-YSZ coating presents larger-size pores with denser YSZ structures and grains showing size larger than 100 nm distributed around the pores compared with M-YSZ, in which the pores are much smaller and the grain size is 20-30 nm. As a result, the M-YSZ coating displays lower hardness and bond strength compared with C-YSZ. The oxidation tests show that the M-YSZ coating possesses better oxidation resistance due to the nanostructure topcoat compared with C-YSZ. However, the hot corrosion tests indicate that both the C-YSZ coating and the M-YSZ coating fail to present ideal hot corrosion resistance.

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Acknowledgements

We gratefully acknowledge support from the National Key Research and Development Program of China (No. 2018YFC1902401) and the National Natural Science Foundation of China (No. 51671180). This work is also supported by Key Deployment Projects of the Chinese Academy of Sciences (ZDRW-CN-2019-01) and Projects of the Innovation Academy for Green Manufacture, Chinese Academy of Sciences (IAGM 2020DB04, IAGM 2020C22).

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Authors and Affiliations

  1. State Key Laboratory of Multiphase Complex Systems, Key laboratory of Science and Technology on Particle Materials, Institute of Process Engineering, Chinese Academy of Sciences, Beijing, 100190, China

    Xiaoming Sun, Lingzhong Du, Hao Lan, Huifeng Zhang, Chuanbing Huang, Maoqiao Xiang, Fen Yue & Weigang Zhang

  2. Innovation Academy for Green Manufacture, Chinese Academy of Sciences, Beijing, 100190, China

    Xiaoming Sun, Lingzhong Du & Hao Lan

  3. University of Chinese Academy of Sciences, Beijing, 100049, China

    Xiaoming Sun & Weigang Zhang

  4. Experimental Teaching and Equipment Management Center, Qufu Normal University, Shandong, 273165, China

    Zhiang Liu

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  1. Xiaoming Sun
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Sun, X., Liu, Z., Du, L. et al. A Study on YSZ Abradable Seal Coatings Prepared by Atmospheric Plasma Spray and Mixed Solution Precursor Plasma Spray. J Therm Spray Tech 30, 1199–1212 (2021). https://doi.org/10.1007/s11666-021-01178-y

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