Tribo-performance of plasma-sprayed nanostructured yttria-stabilized zirconia coatings using Taguchi’s experimental design

Abstract

Plasma-sprayed thermal barrier coatings are frequently subjected to impacts by solid particles, which induce surface erosion. This article depicts the solid particle erosion response of plasma sprayed nanostructured yttria-stabilized zirconia (YSZ) coatings on Inconel 718 substrates. The influence of five operating parameters i.e. impact velocity, erodent size, erodent temperature, impingement angle, and stand-off distance with four different level each, on performance output (i.e. erosion rate) are studied using Taguchi’s L₁₆ orthogonal array design. Out of the five parameters, impact velocity has been found to be most significant factor followed by erodent temperature and impingement angle influencing erosion. Maximum erosion takes place at an impingement angle of ∼60° showing the semi-ductile response of the coating to solid particle erosion. The morphology of the eroded surface also showed micro-cutting and small crater formation in the binder matrix caused by the repetitive impacts of erodent particles. It was observed that coating with nano-YSZ grains exhibited higher erosion resistance compared to conventional YSZ coating.

Keywords

Erosion nanozones plasma spraying Taguchi experimental design

Get full access to this article

View all access options for this article.

References

Gell

. Applying nanostructured materials to future gas turbine engines. JOM 1994; 46(10): 30–34.

Chawla

Sidhu

Puri

. Performance of plasma sprayed nanostructured and conventional coatings. J Aust Ceram Soc 2008; 44(2): 56–62.

Lima

Marple

. Thermal spray coatings engineered from nanostructured ceramic agglomerated powders for structural, thermal barrier and biomedical applications: A review. J Therm Spray Technol 2007; 16(1): 40–63.

Guo

Zhou

. Microstructure and thermal properties of plasma sprayed thermal barrier coatings from nanostructured YSZ. J Therm Spray Technol 2010; 19(6): 1186–1194.

Chen

Zhou

Ding

. Investigation of the thermomechanical properties of a plasma-sprayed nanostructured zirconia coating. J Eur Ceram Soc 2003; 23(9): 1449–1455.

Finnie

. Some reflections on the past and future of erosion. Wear 1995; 186–187: 1–10.

Usmani S and Sampath S. Erosion studies on duplex and graded ceramic overlay coatings. JOM 1996; 48(11): 51--54.

Stolarski TA. Tribology in machine design. UK: Heiman Newnes, 1990.

Kivikytö-Reponen P. Correlation of material characteristics and wear of powder metallurgical metal matrix composites. Doctoral Theses in Materials and Earth Sciences, Helsinki University of Technology, Espoo.

10.

Acharya

Dikshit

Mishra

. Erosive wear behaviour of redmud filled metal matrix composite. J Reinf Plast Compos 2008; 27(2): 145–145.

11.

Mishra

Das

Satapathy

. Erosion wear analysis of plasma sprayed ceramic coating using the Taguchi technique. Tribol Trans 2009; 52: 401–404.

12.

Drensky

Hamed

Tabakoff

. Experimental investigation of polymer matrix reinforced composite erosion characteristics. Wear 2011; 270: 146–151.

13.

Sahu

Satapathy

Mishra

. Tribo-performance analysis of fly ash–aluminum coatings using experimental design and ANN. Tribol Trans 2010; 53: 533–542.

14.

Sahu

Satapathy

Patnaik

. Development, characterization and erosion wear response of plasma sprayed fly ash–aluminum coatings. Mater Des 2010; 31: 1165–1173.

15.

Nicholls

Deakin

Rickerby

. A comparison between the erosion behaviour of thermal spray and electron beam physical vapour deposition thermal barrier coatings. Wear 1999; 235: 352–361.

16.

Janos

Lugscheider

Remer

. Effect of thermal aging on the erosion resistance of air plasma sprayed zirconia thermal barrier coating. Surf Coat Technol 1999; 113: 278–285.

17.

Kosel TH. ASM hand book: Friction, lubrication, and wear technology. Metals Park, OH: ASM, 1992, pp.371–372.

18.

Sahin

. The prediction of wear resistance model for the metal matrix composites. Wear 2005; 258: 1717–1722.

19.

Prasad

Das

Jha

. Factors controlling the abrasive wear response of zinc based alloys silicon carbide particle composite. Compos Part A: Appl Sci Manuf 1997; 28A: 301–308.

20.

Sahoo R, Mantry S, Sahoo TK, et al. Effect of microstructural variation on erosion wear behaviour of Ti-6Al-4V alloy. Tribol Trans 2013. DOI: 10.1080/10402004.2013.767400.

21.

Taguchi

. Introduction to quality engineering, Tokyo: Asian Productivity Organization, 1990.

22.

Yang

Tarn

. Design optimization of cutting parameters for turning operations based on the Taguchi method. J Mater Process Technol 1998; 84: 121–129.

23.

Phadke MS. Quality engineering using robust design. AT&T, Bell Laboratories report. New Jersey: Prentice-Hall International Editions, 1989.

24.

JuaÂ rez

Lamas

Lascalea

. Synthesis of nanocrystalline zirconia powders for TZP ceramics by a nitrate-citrate combustion route. J Eur Ceram Soc 2000; 20: 133–138.

25.

Viswanathan

Rea

Vaidya

. Role of spray drying of nanoagglomerates in morphology evolution in nanostructured APS coatings. J Am Ceram Soc 2008; 91(2): 379–386.

26.

Mantry S, Mishra BK and Chakraborty M. Parametric appraisal of process parameters for adhesion of plasma sprayed nanostructured YSZ coatings using Taguchi’s experimental design. Scient World J Article No. 527491.

27.

Ruff

Ives

. Measurement of solid particle velocity in erosive wear. Wear 1975; 36: 195–199.

28.

Pierlot

Pawlowski

Bigan

. Design of experiments in thermal spraying: A review. Surf Coat Technol 2008; 202: 4483–4490.

29.

Mantry

Mishra

Debasish

. Erosive wear analysis of plasma sprayed cermet coatings using copper slag & aluminium. Tribol Trans 2013; 56: 196–202.