84:(HVOF) combustion flame. Once the solution is injected, the droplets go through several chemical and physical changes and can arrive at the substrate in several different states, from fully melted to unpyrolized. The deposition state can be manipulated through spray parameters and can be used to significantly control coating properties, such as density and strength.
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mismatch between the coating and the substrate during cyclic heating. The generation of these through thickness cracks was systematically explored and found to be caused by the depositing a controlled portion of unpyrolized material in the coating. Superior mechanical properties such as bond strength
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material systems are used to protect components in hot sections of gas turbine and diesel engines. The SPPS process lends itself particularly well to the creation of these TBCs. Studies report the generation of coatings demonstrating superior durability and mechanical properties. Superior durability
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The precursor solution is formulated by dissolving salts (commonly zirconium and yttrium when used to formulate thermal barrier coatings) in a solvent. Once dissolved, the solution is then injected via a pressurized feed system. As with other thermal spray processes, feedstock material is melted and
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The use of a solution precursor was first reported as a coating technology by
Karthikeyan et al. In that work, Karthikeyan showed that the use of a solution precursor was in fact feasible; however, well adhered coatings could not be generated. Further work was reported in 2001, which refined the
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Maurice Gell, Fang Wu, Eric H. Jordan, Nitin P. Padture, Baki M. Cetegen, Liangde Zie, Alper Ozturk, Eric Cao, Amol Jadhav, Dianying Chen, and Xinqin Ma, The
Solution Precursor Plasma Spray Process for Making Highly Durable Thermal Barrier Coatings, Proceedings of GT2005, ASME Turbo Expo
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N. P. Padture, K. W. Schlichting, T. Bhatia, A. Ozturk, B. Cetegen, E. H. Jordan, M. Gell, S. Jiang, T. D. Xiao, P. R. Strutt, E. Garcia , P.Miranzo and M. I. Osendi, "Towards
Durable Thermal Barrier Coatings with Novel Microstructures Deposited by Solution Precursor Plasma Spray",
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to some of the lowest reported values for TBCs. These low thermal conductivities were achieved through the generation of an alternating high-porosity, low-porosity microstructure or the synthesis of a low-conductivity precursor composition with
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X. Q. Ma, T. D. Xiao, J. Roth, L. D. Xie, E. H. Jordan, N. P. Padture, M. Gell, X. Q. Chen, J. R. Price, "Thick
Thermal Barrier Coatings with Controlled Microstructures Using Solution Precursor Plasma Spray Process",
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Liangde Xie, Dianying Chen, Eric H. Jordan, Alper Ozturk, Fang Wu, Xinqing Ma, Baki M. Cetegen and
Maurice Bell, "Formation of Vertical Cracks in Solution- Precursor Plasma- Sprayed Thermal Barrier Coatings",
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Sujatha D. Parukuttyamma, Joshua
Margolis, Haiming Liu, Clare P. Grey, Sanjay Sampath, Herbert Herman, and John B. Parise, "Yttrium Aluminum Garnet (YAG) Films through a Precursor Plasma Spraying Technique",
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L. Xie, X. Ma, E.H. Jordan, N. P. Padture, T. D. Xiao and M. Gell, "Identification of
Coating Deposition Mechanisms in the Solution-Precursor Plasma-Spray Process using Model Spray Experiments",
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Karthikeyan J., Berndt C. C., Tikkanen J., Wang J. Y., King A. H., Herman H., "Nanomaterial
Powders and Deposits Prepared by Flame Spray Processing of Liquid Precursors", 8(1), 1997, p. 61–74.
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Jeganathan
Karthikeyan, Christopher C. Berndt, Sri Reddy, Jenn-Yue Wang, Alexander H. King, and Herbert Herman, "Nanomaterial Deposits Formed by DC Plasma Spraying of Liquid Feedstocks",
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processes. However, instead of injecting a powder into the plasma plume, a liquid precursor is used. The benefits of utilizing the SPPS process include the ability to create unique
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Eric H. Jordan, L. Xie, C. Ma M. Gell, N. Padture, B. Cetegen, J. Roth, T. D. Xiao and P. E. C. Bryant, "Superior
Thermal Barrier Coatings Using Solution Precursor Plasma Spray",
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Amol Jadhav, Nitin Padture, Fang Wu, Eric Jordan , Maurice Gell, "Thick ceramic thermal barrier coatings with high durability deposited using solution-precursor plasma spray",
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Karthikeyan J., Berndt C. C., Tikkanen J., Wang J. Y., King A. H., Herman H, "Preparation of Nanophase Materials by Thermal Spray Processing of Liquid Precursors",
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L. Xie, X. Ma, E.H. Jordan, N. P. Padture, T.D. Xiao and M. Gell, "Highly Durable Thermal Barrier Coatings Made by the Solution Precursor Plasma Spray Process",
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Xinqing Ma, Fang Wu, Jeff Roth, Maurice Gell, Eric Jordan, "Low Thermal Conductivity Thermal Barrier Coating Deposited by the Solution Plasma Spray Process",
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L. Xie, X. Ma, E. H. Jordan, N. P. Padture, T. D. Xiao and M. Gell, "Deposition of Thermal Barrier Coatings Using Solution Precursor Plasma Spray Process",
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is imparted by the creation of controlled through thickness vertical cracks. These cracks only slightly increase coating conductivity while allowing for
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process where a feedstock solution is heated and then deposited onto a substrate. Basic properties of the process are fundamentally similar to other
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E. Bouyer, G. Schiller, M. Muller, and R. H. Heane, "Thermal Plasma Chemical Vapor Deposition of Si-Based Ceramic Coatings from Liquid Precursors",
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without the injection feed problems normally associated with powder systems and flexible, rapid exploration of novel precursor compositions.
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Liangde Xie, Eric H. Jordan and Maurice Gell, "Phase and Microstructural Stability of Precursor Plasma Sprayed Thermal Barrier Coatings",
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films, and silicon ceramic coatings. Since then, extensive research on the technology has been explored in large part by the
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Ozturk, A. and Cetegen B. M., "Modeling of Axially and Transversely Injected Precursor Droplets into a Plasma Environment",
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Most current research on SPPS has examined is application to create thermal barrier coatings (TBCs). These complex
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Padtre, Nitin P., Gell, Maurice, Jordan, Eric H., "Thermal Barrier Coatings for Gas-Turbine Engine Applications",
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The SPPS process is adapted to existing thermal spray systems. Application costs are significantly less than
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and in-plane toughness result from the nanometer sized microstructure that are created by the SPPS process.
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coatings and slightly higher than Air Plasma Spray coatings.
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Other studies have shown that engineered coatings can reduce
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82:high velocity oxygen fuel
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187:Nanostructured Materials
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46:Background
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98:metallic
289:Science
127:dopants
94:ceramic
71:Process
26:) is a
139:EB-PVD
107:stress
103:strain
78:plasma
38:sized
381:2005.
133:Costs
63:and
24:SPPS
111:CTE
57:YAG
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