Advanced Ceramics Progress

Advanced Ceramics Progress

Optimization of Microhardness in Nanostructured Thermal Barrier Coatings Using Spark Plasma Sintering (SPS) and Taguchi Design

Document Type : Original Research Article

Authors
kaveh Kolahgar Azari 1
Ali Alizadeh 2
Hossein Momeni 3
Angela Maria Gallardo Lopez 4
1 PhD Student of Materials Engineering, Materials and Manufacturing Technologies Complex, Malek Ashtar University of Technology, Tehran, Iran.
2 Professor, Materials and Manufacturing Technologies Complex, Malek Ashtar University of Technology, Tehtan, Iran.
3 Associate Professor, Materials and Manufacturing Technologies Complex, Malek Ashtar University of Technology, Tehtan, Iran.
4 Professor, Department of Condensed Matter Physics, University of Seville, Seville, Spain.
10.30501/acp.2024.476831.1162
Abstract
In this study, nanostructured thermal barrier coatings (TBCs) were fabricated using the Spark Plasma Sintering (SPS) method on an Inconel 713 LC superalloy substrate. These coatings were compared to those produced by Atmospheric Plasma Spray (APS) in terms of mechanical properties. The aim of this study was to investigate and optimize the process parameters to improve the microhardness of these coatings. Key parameters, such as temperature, pressure, and holding time, were optimized using the Taguchi design of experiments (L9). The results showed that SPS coatings exhibited significantly higher hardness compared to APS coatings, due to a notable reduction in porosity and increased density. The highest microhardness achieved for SPS coatings was 700 HV at a temperature of 1080°C, a pressure of 25 MPa, and a holding time of 6 minutes. In contrast, APS coatings demonstrated lower hardness, primarily due to higher porosity and lower density. This study highlights that precise control of process parameters in the SPS method can produce coatings with enhanced mechanical properties, making them suitable for high-temperature applications in aerospace and power generation industries. Furthermore, the Taguchi method effectively reduced the number of experiments and improved process efficiency.
Keywords
SPS
Microhardness
Nanostructured Thermal Barrier Coatings
APS
Taguchi Design
Subjects
  1. Iqbal, A. A., & Lim, M. J. (2023). A relationship of porosity and mechanical properties of spark plasma sintered scandia stabilized zirconia thermal barrier coating. Results in Engineering, 19, 101263. https://doi.org/10.1016/j.rineng.2023.101263
  2. Jonnalagadda, K. P. (2019). Thermal barrier coatings: failure mechanisms and life prediction (Doctoral dissertation, Linköping University Electronic Press). https://doi.org/10.3384/diss.diva-154777 
  3. Kruzel, R., Dembiczak, T., & Wachowicz, J. (2023). Optimization of Spark Plasma Sintering Technology by Taguchi Method in the Production of a Wide Range of Materials. Materials, 16(16), 5539. https://doi.org/10.3390/ma16165539
  4. Kumar, D., & Pandey, K. N. (2017). Optimization of the process parameters in generic thermal barrier coatings using the Taguchi method and grey relational analysis. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, 231(7), 600-610. https://doi.org/10.1177/1464420715602727 
  5. Le Godec, Y., & Le Floch, S. (2023). Recent developments of high-pressure spark plasma sintering: an overview of current applications, challenges and future directions. Materials, 16(3), 997. https://doi.org/10.3390/ma16030997
  6. Li, X., Zhang, W., & Cai, X. (2024). Mechanical evaluation of thermal barrier coatings by indentation: A review. Journal of Materials Research and Technology. https://doi.org/10.1016/j.jmrt.2024.04.258
  7. Liu, B., Liu, Y., Zhu, C., Xiang, H., Chen, H., Sun, L., ... & Zhou, Y. (2019). Advances on strategies for searching for next generation thermal barrier coating materials. Journal of Materials Science & Technology, 35(5), 833-851. https://doi.org/10.1016/j.jmst.2018.11.016
  8. Liu, H., Wei, Y., Liang, L., Wang, Y., Song, J., Long, H., & Liu, Y. (2020). Microstructure observation and nanoindentation size effect characterization for micron-/nano-grain TBCs. Coatings, 10(4), 345. https://doi.org/10.3390/coatings10040345
  9. Lóh, N. J., Simão, L., Jiusti, J., De Noni Jr, A., & Montedo, O. R. K. (2017). Effect of temperature and holding time on the densification of alumina obtained by two-step sintering. Ceramics International, 43(11), 8269-8275. https://doi.org/10.1016/j.ceramint.2017.03.159
  10. Nowakowska, M., Łatka, L., Sokołowski, P., Szala, M., Toma, F. L., & Walczak, M. (2022). Investigation into microstructure and mechanical properties effects on sliding wear and cavitation erosion of Al2O3–TiO2 coatings sprayed by APS, SPS and S-HVOF. Wear, 508, 204462. https://doi.org/10.1016/j.wear.2022.204462
  11. Samani, T., (2015), Plasma deposition of nanostructured MCrAlY/YSZ multilayer thermal barrier coatings on Inconel738 superalloy. Master's Thesis, Materials and Energy Research Center.(in Persian). https://ganj.irandoc.ac.ir//#/articles/b22fe252fb6b05408d57e2dc27fdcb92
  12. Thakare, J. G., Pandey, C., Mahapatra, M. M., & Mulik, R. S. (2021). Thermal barrier coatings—A state of the art review. Metals and Materials International, 27, 1947-1968. https://doi.org/10.1007/s12540-020-00705-w
  13. Zhang, X., Cocks, A. C., Okajima, Y., Takeno, K., & Torigoe, T. (2021). An image-based model for the sintering of air plasma sprayed thermal barrier coatings. Acta Materialia, 206, 116649. https://doi.org/10.1016/j.actamat.2021.116649

  • Receive Date 04 September 2024
  • Revise Date 30 September 2024
  • Accept Date 26 November 2024