Electrophoretic deposition (EPD) has been used to produce the yttria-stabilized zirconia (YSZ) coatings on metal substrates. Sintering of YSZ with and without doping has been carried out at 1150 °C for 2hrs. The properties of these coatings have been examined in light of thermal barrier applications. For EPD, the green density increases with an initial increase in the HCl concentration and the EPD time. This suggests that particle packing was influenced by a time dependent re-arrangement, in addition to the initial suspension dispersion state. The green density peaks at a electrical conductivity of around 10×10-4 S/m achieved by an 0.5 mM HCl addition for the 20 g/l suspensions with the EPD time of around 8 ~10 minute. For sintered coatings, the HCl concentration had a marked effect on the neck size to grain size ratio of the 8 mol% yttria-stabilized zirconia (8YSZ) coatings. The presence of ZrCl4 and ZrOCl2, and a high concentration of oxygen vacancies at the grain boundaries are believed to promote neck growth in the early stage of sintering at 1150 °C. During sintering of 3 mol% and 8 mol% yttria-stabilized zirconia (3YSZ and 8YSZ) at 1150 ºC for 2hrs, the densification rate substantially increased with a small amount of Fe2O3 addition (0.5 mol%) to the 3YSZ/8YSZ deposits. A more pronounced graingrowth was present in the Fe2O3 doped 8YSZ deposits. The increased Zr4+ diffusion coefficient is mainly responsible to the rapid densification rate of the Fe2O3 doped 3YSZ/8YSZ deposits. A small grain growth observed in the Fe2O3 doped 3YSZ deposits is attributed to the Fe3+ segregation at grain boundary. A small amount of CeO2 doping was found to substantially inhibit the densification rate of the doped 3YSZ deposits with a minor grain growth. Fe2O3 doping reduced the thermal conductivities of 3YSZ/8YSZ. It is found that Rayleigh-type phonon scattering due to the mass difference alone is inadequate to explain the thermal conductivity of Fe2O3 doped YSZ systems. The lattice strain effects due to the ionic radius difference could more effectively reduce thermal conductivity of the Fe2O3-doped 3YSZ. A decrease in the growth rate of the TGO scale with the increasing Fe2O3 additions was observed for the oxidized FeCrAlY metal substrates with the Fe2O3-doped 3YSZ coating, which was found to be attributed to the early formation of the stable and dense α-Al2O3 phase due to the presence of Fe3+ ions.

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Indiana University-Purdue University Indianapolis (IUPUI) / Thermal barrier coatings (TBCs) have been extensively employed as thermal protection in hot sections of gas turbines in aerospace and power generation applications. However, the fabrication of TBCs still needs to improve for better coating quality, such as achieving coating thickness' uniformity. However, several previous studies on the coating thickness prediction and a systematic understanding of the thickness evolution during the deposition process are still missing. This study aims to develop high-fidelity computational models to predict the coating thickness on complex-shaped components. In this work, two types of models, i.e., ray-tracing based and heat transfer based, are developed. For the ray-tracing model, assuming a line-of-sight coating process and considering the shadow effect, validation studies of coating thickness predictions on different shapes, including plate, disc, cylinder, and three-pin components. For the heat transfer model, a heat source following the Gaussian distribution is applied. It has the analogy of the governing equations of the ray-tracing method, thus generating a temperature distribution similar to the ray intensity distribution in the ray-tracing method, with the advantages of high computational efficiency. Then, using a calibrated conversion process, the ray intensity or the temperature profile are converted to the corresponding coating thickness. After validation studies, both models are applied to simulate the coating thickness in a rotary turbine blade. The results show that the simulated validation cases are in good agreement with either the experimental, analytical, or modeling results in the literature. The turbine blade case shows the coating thickness distributions based on rotating speed and deposition time. In summary, the models can simulate the coating thickness in rotary complex-shaped parts, which can be used to design and optimize the coating deposition process.