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Processing and Structural Stability of Nanocrystalline Thermal Barrier Coatings
Jech, David ; Ctibor, Pavel (referee) ; Ziegelheim, Jindřich (referee) ; Švejcar, Jiří (advisor)
Complex thermal barrier coating systems are one the most efficient high-temperature surface treatments which open up practical applications in land-based turbines and air jet engines. In the case of most exposed rotor and stator jet engine components, the combination of thermal barrier coatings together with the inner cooling system made it possible to increase working temperature by several tens of degrees of Celsius. Nevertheless, it is very difficult to achieve any further increase in working temperature by using the conventional thermal barrier coatings based on the ZrO2-Y2O3 ceramic top coat and the MCrAlY metallic bond coat, which currently work at their material limits. The working temperature inside the combustion chamber of the jet engine is proportional to engine’s efficiency and inversely proportional to fuel consumption and production of undesirable CO2 emission. Therefore, a considerable effort has recently been devoted to research and development of new types of ceramic coatings that can withstand long term extreme working conditions. New design approaches of multi-layer composite thermal barrier coating systems can sustain the required trend of increasing working temperature of jet engines mainly because of possibility of optimization of high-temperature durability and long lifetime. The theoretical part of thesis provides a fundamental overview of thermal barrier coatings, their properties, deposition technologies and testing methods. The experimental part is focused on optimization of deposition parameters of conventional ZrO2-Y2O3 / MCrAlY thermal barrier coatings prepared by means of atmospheric plasma spraying. Furthermore, a novel multi-layer thermal barrier coating system based on ZrO2-Y2O3-Al2O3-SiO2 / ZrO2-Y2O3 / MCrAlY, which contains amorphous and/or nanocrystalline regions, is developed, tested and characterized as well. Structural stability, phase transformations and growth of the thermally grown oxide in both conventional and experimental systems after high-temperature isothermal oxidation, cyclic oxidation and burner-rig tests were evaluated by means light microscopy, scanning electron microscopy with energy-dispersive microanalysis and X-ray diffraction. In comparison with the conventional thermal barrier coatings, the novel multi-layered systems have lower thermal conductivity, slower thermally grown oxide kinetic, better structural stability, and generally higher lifetime in all high-temperature tests.
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Processing and Structural Stability of Nanocrystalline Thermal Barrier Coatings
Jech, David ; Ctibor, Pavel (referee) ; Ziegelheim, Jindřich (referee) ; Švejcar, Jiří (advisor)
Complex thermal barrier coating systems are one the most efficient high-temperature surface treatments which open up practical applications in land-based turbines and air jet engines. In the case of most exposed rotor and stator jet engine components, the combination of thermal barrier coatings together with the inner cooling system made it possible to increase working temperature by several tens of degrees of Celsius. Nevertheless, it is very difficult to achieve any further increase in working temperature by using the conventional thermal barrier coatings based on the ZrO2-Y2O3 ceramic top coat and the MCrAlY metallic bond coat, which currently work at their material limits. The working temperature inside the combustion chamber of the jet engine is proportional to engine’s efficiency and inversely proportional to fuel consumption and production of undesirable CO2 emission. Therefore, a considerable effort has recently been devoted to research and development of new types of ceramic coatings that can withstand long term extreme working conditions. New design approaches of multi-layer composite thermal barrier coating systems can sustain the required trend of increasing working temperature of jet engines mainly because of possibility of optimization of high-temperature durability and long lifetime. The theoretical part of thesis provides a fundamental overview of thermal barrier coatings, their properties, deposition technologies and testing methods. The experimental part is focused on optimization of deposition parameters of conventional ZrO2-Y2O3 / MCrAlY thermal barrier coatings prepared by means of atmospheric plasma spraying. Furthermore, a novel multi-layer thermal barrier coating system based on ZrO2-Y2O3-Al2O3-SiO2 / ZrO2-Y2O3 / MCrAlY, which contains amorphous and/or nanocrystalline regions, is developed, tested and characterized as well. Structural stability, phase transformations and growth of the thermally grown oxide in both conventional and experimental systems after high-temperature isothermal oxidation, cyclic oxidation and burner-rig tests were evaluated by means light microscopy, scanning electron microscopy with energy-dispersive microanalysis and X-ray diffraction. In comparison with the conventional thermal barrier coatings, the novel multi-layered systems have lower thermal conductivity, slower thermally grown oxide kinetic, better structural stability, and generally higher lifetime in all high-temperature tests.
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Suspension plasma spraying of sub-stoichiometric titania by hybrid water/argon stabilized plasma torch
Mušálek, Radek ; Ctibor, Pavel ; Medřický, Jan ; Tesař, Tomáš ; Kotlan, Jiří ; Lukáč, František
In this study, suspension plasma spraying of sub-stoichiometric titania was attempted using hybrid water/argon stabilized plasma torch (WSP-H). Porous coatings with fine cauliflower-like columnar microstructure were successfully deposited in two separate experiments with different power levels of the plasma torch. In both cases, high solid-load content (40 wt. %) of the water-based suspension resulted in considerable coating thickness increase per deposition cycle. Coating annealing and partial remelting of the surface asperities were also achieved by additional pass of plasma torch in front of the coating surface. According to X-ray diffraction, all coatings consisted dominantly of rutile phase. Detailed microscopic observation of the as-sprayed and annealed deposits showed that the local coloration of the coating (ranging from dark blue to beige) was driven by the local overheating of the rough coating surface which could also promote the oxygen intake. Moreover, sample annealing was also observed to increase the sample reflectivity as observed by UV-VIS-NIR scanning spectrophotometry
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Mechanical properties of plasma sprayed layers of NiAl10 and NiAl40 on AZ91 alloy
Kubatík, Tomáš František ; Brodil, R. ; Ctibor, Pavel ; Průša, F. ; Brožek, Vlastimil
In this work, plasma coatings of NiAl10 and NiAl40 on magnesium alloy AZ91 substrate were prepared by the hybrid plasma spraying system WSP®-H 500. The both plasma sprayed coatings of NiAl10 and NiAl40 have metallurgical bond. The thicknesses of microstructures in the cross-section of NiAl10 and NiAl40 plasma sprayed coatings prepared by 9 passes were 374 and 440 μm respectively. Adhesion test of plasma sprayed layers was performed using a modified ASTM C 633 standard. The tensile adhesion strength values are 24.7 MPa for NiAl10 coatings and 12.3 MPa for NiAl40 coatings. Abrasion resistance according to Slurry Abrasion Response (SAR) test of NiAl40 layers had similar values (0.12 g/cm2)in a comparison with the uncoated AZ91 (0.126 g/cm2). Layers NiAl10 had greater weight losses (0.175 g/cm2) than uncoated AZ91. Microhardness of plasma coating of NiAl40 is several times greater than microhardnesses of plasma coating of NiAl10 and uncoated substrate AZ91
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Tungsten coatings and free standing parts
Brožek, Vlastimil ; Ctibor, Pavel ; Matějíček, Jiří ; Mušálek, Radek ; Weiss, Z.
Tungsten powders, 20 – 100 µm in size, were melted in the jet of thermal plasma generated by a water-stabilized spray system WSP®. The molten tungsten was deposited on steel and graphite or boron nitride substrates, whereas the spray-ability itself was tested as well as cohesion with other substrates. One of the goals of this experimentation was to gain skills for covering variously shaped walls of nuclear fusion devices (Tokamaks). Also spraying of free-standing tungsten bodies was realized, by means of substrates easily machainable-out after deposition, as graphite and BN. Other option consists of covering a tungsten mesh or plates armored with tungsten wires. Protection of tungsten against oxidation in the plasma jet was a problem to be solved – the best results were gained with shroud gas, Ar with 7% hydrogen, and simultaneous placement of the substrates into graphite cells. The whole spray process was maintained to avoid temperatures over 700°C at which the oxidation is
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Ceramo-metallic materials of the Ti-B-C and Ti-B-N systems
Brožek, V. ; Doležal, J. ; Novák, M. ; Ctibor, Pavel ; Kolman, Blahoslav Jan
Products prepared by the sintering of titanium and boron carbide powder and by the sintering of titanium and boron nitride powder were studied. The sintering was performed at 2,000 °C under the pressure of 6 GPa in a high-pressure apparatus of BELT-type with sufficient holding time to reach thermodynamic equilibrium. The results of chemical and phase composition analyses were compared with thermodynamic prediction of possible reactions in the system. We proved the preferential formation of borides TiB and TiB2 prior to the carbides or nitrides formation. The products, which may be considered Ti-(TiB,TiB2)-TiN or Ti-(TiB,TiB2)-TiC cermets, were analysed in order to determine their microstructure, phase and chemical composition and their influence on mechanical properties such as hardness or elastic modulus. This work precedes similar study which will be performed using the same powders processed by plasma spraying, which enables to stabilize high-temperature phases by rapid cooling.
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Microstructure and performance of titanium oxide coatings sprayed by oxygen-acetylene flame
Ctibor, Pavel ; Štengl, Václav ; Zahálka, F. ; Murafa, Nataliya
TiO2 nano-powders were agglomerated by a spray drying process for applying to thermal spraying. A conventional oxygen-acetylene flame torch was used to deposit porous partially nanostructured TiO2 coatings. Steel substrates were used as a support for tested samples. Scanning Electron Microscopy, X-ray microanalysis and X-ray diffraction were performed to study the morphology and the crystalline phases of the titania coatings. Optical bandgap and kinetics of the acetone decomposition was studied too. The best results were obtained for the powder which is available as a commercial spray feedstock. This powder seems to be most resistant against the reducing atmosphere in the jet of combustive gasses.
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Tungsten cermets with zirconium and hafnium carbides
Brožek, Vlastimil ; Ctibor, Pavel ; Matušek, M. ; Sedláček, J.
Cermets with tungsten matrix and functional components of ZrC and HfC with absolutely highest meeting points are materials with good properties at high temperature exposure. Tungsten based cermets with 10, 20 and 30 % of the functional component were prepared by two different procedures and their properties were compared. The first series of the samples was manufactured by powder metallurgy. A homogenized and preformed mixture of powders was sintered at 2000°C and pressure 6 GPa by hot-pressing technique in the apparatus of BELT-type. The second series was prepared by plasma spraying with water-stabilized plasma WSP® by two different procedures. In the first case the powders of W and ZrC (or W and HfC) were injected into the plasma jet by two separate feeders. The feeding distance 25 to 75 mm was affected by different kinetic parameters, different size distribution and density. The second case represents deposition of pre-spheroidized powder mixtures prepared by spray drying
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Plasmachemical synthesis of borides, carbides and nitrides of transition metals
Brožek, Vlastimil ; Ctibor, Pavel
For technical practice the most important are up to now borides of titanium and zirconium, carbides of boron, calcium, silicium, titanium, zirconium, hafnium, aluminum and chromium. Nitrides of boron, silicium and titanium. Besides of tungssten carbide, any of the mentioned compounds is proced presently in the Czech Republic, however the know-how and suitable conditions are existing. The contribution describes possibilities of the processing of the mentioned materials to functional layers or thin-walled shaped parts by plasmachemical methods.
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