Surface & Coatings Technology 208 (2012) 87–91 Contents lists available at SciVerse ScienceDirect Surface & Coatings Technology journal homepage: www.elsevier.com/locate/surfcoat Thermal diffusivity and conductivity of yttria stabilized zirconia coatings obtained by suspension plasma spraying☆ Leszek Łatka a, b, Andrea Cattini a, c, Lech Pawłowski a,⁎, Stephan Valette a, Bernard Pateyron a, Jean-Pierre Lecompte a, Rishi Kumar d, Alain Denoirjean a a SPCTS, University of Limoges, UMR CNRS 7315, F-87068 Limoges, France Faculty of Mechanics, Wrocław University of Technology, Pl-50371 Wrocław, Poland Department of Materials and Environmental Engineering, University of Modena and Reggio Emilia, I-41125 Modena, Italy d Indian Institute of Technology, Bombay, 400076 Mumbai, India b c a r t i c l e i n f o Article history: Received 22 June 2012 Accepted in revised form 8 August 2012 Available online 18 August 2012 Keywords: Suspension plasma spraying Thermal conductivity Yttria stabilized zirconia coatings a b s t r a c t Plasma generated by SG-100 torch was applied to spray suspension formulated with the use of ZrO2 + 8 wt.% Y2O3 (8YSZ) solid phase. The solids have the mean size of about 4.5 μm and were obtained by milling commercial Metco 204NS powder. The suspension was formulated with the use of 20 wt.% of solid phase, 40 wt.% water and 40 wt.% of ethanol. The plasma spray parameters were optimized with the electric power equal to 40 kW, working gases composition Ar—45 slpm and H2—5 slpm, spray distance varying from 40 to 60 mm and torch linear speed with regard to substrate varying from 300 to 500 mm/s. The coatings of the thickness ranging from 51 to 106 μm, were sprayed onto stainless steel substrates. The porosity of the samples was found, with the help of image analysis of metallographically prepared cross-sections of the samples, to be in the range of 8–12%. Thermal diffusivity was measured with the use of the commercial NanoFlash system in the temperature range from room temperature to 523 K. The measurements were made with the use of the coatings sprayed on the substrate and the 2-layers numerical model was applied to determine thermal diffusivity of the coatings. The diffusivity was in the range 0.196 × 10 −6 to 0.352 × 10 −6 m2/s in room temperature depending on the spray parameters. The obtained data were then associated with the literature data on density, specific heat and experimental porosity to find thermal conductivity which was in the range of 0.47 to 0.86 W/(mK) at room temperature depending on the spray run. © 2012 Elsevier B.V. All rights reserved. 1. Introduction Suspension thermal spraying is a new family of coating deposition methods which use a slurry with fine (nanometric or submicrometric) solids instead of coarse powder. The suspension plasma spraying seems to have been the most studied by now [1,2]. During the deposition process, the slurry's liquid evaporates after injection to the plasma jet and the solids may agglomerate, melt and impact the substrate to form a coating. The method of slurry introduction to the torches with radial feedstock injectors, being the most popular in research and industrial applications, may be realized by: (i) an atomizer; or, (ii) a nozzle (mechanical injector). The injection mode influences strongly the sprayed coatings' microstructure. The fine grained microstructure is characteristic for the coatings sprayed with the use of an atomizer ☆ A part of the paper was presented at ITSC 2012, Houston, Texas, USA, 21–24 May 2012. ⁎ Corresponding author. Tel.: +33 587 50 24 12. E-mail address: lech.pawlowski@unilim.fr (L. Pawłowski). 0257-8972/$ – see front matter © 2012 Elsevier B.V. All rights reserved. http://dx.doi.org/10.1016/j.surfcoat.2012.08.014 [3]. On the other hand, the injection through a nozzle results in a two-zone-microstructure which has been analyzed recently [4]. Partly stabilized zirconia has been applied for 4 decades as a thermal barrier coating (TBC) [5,6]. The progress in the technology of thermal barriers concerns the choice of thermal insulating materials which includes pyrochlores, hexaaluminates, and perovskites [7]. Thermal properties of new materials such as lanthana doped yttria stabilized zirconia was tested by Rauf et al. [8] and samarium zirconate having a pyrochloric structure—by Yu et al. [9]. Another axis of TBC development is related to new technology. In fact, solution plasma spraying of yttria stabilized zirconia was tested by Jordan et al. [10] and suspension plasma spraying of a similar material was tested by Bacciochini et al. [11] and Kozerski et al. [12]. The present paper is devoted to the experimental characterization of thermal diffusivity of yttria stabilized zirconia sprayed using varying operational parameters. Thermal diffusivity data are subsequently a basis for the determination of thermal conductivity verified by the numerical simulations of the experiments. The experiments were carried out to understand the influence of operational spray parameters on thermal conductivity and the measurements of diffusivity were carried out in relatively low temperatures. L. Łatka et al. / Surface & Coatings Technology 208 (2012) 87–91 88 Table 2 Results of thickness and porosity characterizations of suspension plasma sprayed YSZ coatings. 10 µm Fig. 1. SEM (secondary electrons) micrographs of 8YSZ powder used to formulate the suspension. Run Thickness, mean value [μm] Thickness, standard deviation, [μm] Porosity [%] 1 2 3 4 5 100 106 53.6 51.1 59.7 0.9 1.5 0.9 2.9 4.5 9 8 9 10 12 and analyzed using scanning electron microscope Philips 515 (Eindhoven, Netherlands) with the use of secondary electron detectors. X-ray diffraction patterns were obtained with a D8 Advance diffractometer equipped with a fast linear detector Lynxeye and using monochromatic Cu Kα1 radiation. The typical recording conditions are reported elsewhere [12]. The DIFFRAC+ suite of the program was used for the preliminary crystal phase analysis and TOPAS V4.1 for a Rietveld method study of sprayed deposits. 2.4. Determination of coatings thickness and porosity 2. Experimental methods The initial powder of 8YSZ was the commercially available, Metco 204NS. The powders were ball milled for 2 h and their initial mean diameter of dvs = 38 μm was reduced to 4.5 μm as shown by the measurements of laser granulometry. The morphology of milled powder is shown in Fig. 1. The suspensions used for the spray experiments were formulated with the use of 20 wt.% of powder, 40 wt.% of water and 40 wt.% of ethanol. The suspension feed rate was equal to about 39 g/min in all experiments and the static pressure in a pneumatic container was about 0.03 MPa. The suspension was introduced via internal injection mode using a continuous-stream injector (with an internal diameter of 0.5 mm) installed inside the anode-nozzle of the plasma torch. 2.2. Plasma spraying The torch used for plasma spraying was the SG-100 (Praxair S.T., Indianapolis, IN, USA) DC single cathode torch animated by linear movement in the face of substrates installed on a rotating swivel. The working gases were a mixture of Ar + H2 (45 + 5 slpm) and applied electric power was constant and equal to 40 kW. After each scan of the torch along the swivel, the deposition was interrupted and coatings were cooled down to temperatures (measured using a pyrometer) of about 60–80 °C. The variable spray parameters and other experimental details are given in Table 1. The coatings were sprayed onto stainless steel cylindrical substrates and sand blasted prior to deposition. The bond coatings were not applied. 2.3. Structure and microstructure characterization The powder was analyzed using a field emission scanning electron microscope Jeol JSM‐7400. The coatings were prepared metallographically Table 1 Variable spray parameters and coating temperatures. Run 1 2 3 4 5 Torch linear speed [mm/s] 300 500 400 300 500 Spray distance [mm] 40 40 50 60 60 Maximum surface temp. [°C] 570–690 490–650 460–530 410–570 380–460 Metallographically prepared samples were observed using an optical microscope Nikon Eclipse LV100. The thicknesses of coatings were found from 15 measurements in different regions of coatings. The porosity was determined from the image analysis. The SEM images having 10,000× magnifications were used to this end. The software used for the analysis was the Image J public domain program [13]. The results of thickness and porosity characterizations are collected in Table 2. 2.5. Thermal diffusivity measurements The samples submitted to thermal diffusivity measurements were coated with a thin graphite layer deposited onto zirconia coatings. The measurements were made using LFA 447 NanoFlash® Flash Lamp System. The setup enables the measurements in the temperature range from room temperature to 250 °C in air. The measurements were made by applying the software developed for 2-layer samples. Thermal diffusivity can be calculated from the well-known expression, developed for a single layer configuration [14]: 2 α¼ 0:1388·d t 0:5 ð1Þ in which a is the thermal diffusivity, d is the sample thickness and t0.5 is the half rise time. The value of t0.5 corresponds to 50% of the Back face signal-sample YSZ-1 2.5 Electrical signal [V] 2.1. Suspension preparation 2 1.5 1 0.5 0 0 200 t 0.5 400 600 800 1000 Time [ms] Fig. 2. Experimental evolution of the electrical signal collected by an infrared detector at the back face of the sample sprayed in run 1 during the measurement of thermal diffusivity by the flash method at room temperature. L. Łatka et al. / Surface & Coatings Technology 208 (2012) 87–91 89 Table 3 Thermal dilatation and specific heat values used in calculations of thermal conductivity of YSZ coatings [20,21]. Temperature [K] Specific heat cp [J/(kg·K)] ΔL L [1/1] 298 323 373 423 473 523 438 453 480 501 518 531 4.2606 × 10−5 2.5646 × 10−4 6.8840 × 10−4 1.1262 × 10−3 1.5702 × 10−3 2.0206 × 10−3 Thermal dilatation sample's back face temperature rise (see Fig. 2). The measurements of thermal diffusivity were made for the YSZ coatings on stainless steel substrates. In this case a “double layer” mode of the setup was chosen, in which there is one unknown thermal diffusivity value (of the tested coating). During the experiment the model of Cowan including 2 layers was used [15,16]. The necessary data input included properties such as density ρ, specific heat cp (for both types of materials) and thermal diffusivity or substrate. The model of Cowan includes the possibility of heat loss from both the front and back face of the sample. In addition, it was also assumed that the energy pulse was rectangular in shape and of relatively short duration (pulse time, tp b b t0.5). In fact, in these experiments, the duration of the pulse tp is equal to 0.18 ms and t0.5 is longer than 300 ms (see Fig. 2). Thermal conductivity was calculated from following equation: ρ300 1 þ 3·ΔL L ðT Þ ð2Þ in which λ is the thermal conductivity, a is the thermal diffusivity, cp is the specific heat, ρ300 is the apparent density in room temperature, and ΔL/L is the thermal dilatation. The density used in the calculations was corrected for porosity as in following expression: ρ300 ¼ ρ0 ð1−P Þ Fig. 4. SEM (secondary electrons) of the cross-section of 8YSZ coating sprayed in run 3. 2.7. Verification of thermal conductivity The thermal diffusivity experiments were simulated using COMSOL Multiphysics 3.4 Client software. There were 2 layers, for the substrate and coating and the virtual layer, which was the TCR (thermal contact resistance) layer. The heat conduction equation has the following form: 2.6. Thermal conductivity determination λðT Þ ¼ α ðT Þ·cp ðT Þ· 10 µm ð3Þ in which ρ0 is the density of tetragonal phase YSZ, being the major phase in the sprayed coatings [15], and is equal to 6050 kg/m 3 and P is the porosity. The specific heat was calculated from the Kopp–Neumann law by taking into account the chemical composition of the powder used as a spray. Table 3 shows all the values of specific heat and thermal dilatation in the temperature in which diffusivity was being measured. Thermal diffusivity of used stainless steel substrates was measured experimentally in the temperatures of interest and was found to match well with the literature data. ρcp ∂T þ ∇ð−λ∇T Þ ¼ A ∂t ð4Þ where T is the temperature, cp is the specific heat, ρ is the density and A is the heat production rate per unit time and unit volume. The heat conduction equation was solved numerically for cylindrical coordinates. The temperature vs. time response was collected in point on the top of the coating surface (Fig. 3). The boundary condition on the side of the substrate included heat production by the Xenon lamp pulse which is described by a heat flux q: q ¼ q0 þ hðT ext −T Þ ð5Þ in which q0 is a flux generated by the lamp and Text is the external temperature. Finally the thermal contact resistance (TCR) between the substrate and coating was considered. The value was taken to be in the range of TCR = 1.5 × 10 −4–2.5 × 10 −4 m 2K/W after [17]. The results of the simulations were the temperature evolution of the rear side of irradiated samples. These evolutions were fitted to the experimental curves (such as this shown in Fig. 2) with the use of the least squares method [18] by changing thermal conductivity until high correlation was reached. Fig. 3. Axial symmetry model used in the simulation. L. Łatka et al. / Surface & Coatings Technology 208 (2012) 87–91 Table 4 Calculation of the content of phases and lattice parameters using the Rietveld method of YSZ coatings suspension plasma sprayed in different runs. Sample Tetragonal zirconia Monoclinic zirconia Content, wt.% a, Å c, Å Content, wt.% a, b, Å c, Å and γ, ° 1 89.2 3.6147 5.1650 10.8 2 90.4 3.6144 5.1657 9.6 3 91.6 3.6157 5.1634 8.4 4 92.6 3.6159 5.1630 7.4 5 92.9 3.6159 5.1629 7.1 5.172 5.206 5.171 5.204 5.167 5.207 5.168 5.207 5.170 5.204 5.319 99.12 5.318 99.11 5.318 99.15 5.318 99.16 5.318 99.13 YSZ-1 YSZ-2 300 350 YSZ-3 YSZ-4 YSZ-5 1.2 Thermal conductivity [W/m.K] 90 1 0.8 0.6 0.4 0.2 0 250 400 450 500 550 Temperature [K] 3. Results Fig. 6. Thermal conductivity of 8YSZ coatings suspension plasma sprayed in different experimental runs. 3.1. Microstructure The suspension plasma coatings surface shows generally fine grains having a spherical form and well molten large lamellae (Fig. 4). The cross section shows relatively well molten lamellae and some porosity between them. It is possible to distinguish the small grains inside the lamellae. Some of them have vertical cracks, which could have been generated by the relaxation of thermal stress after deposition. All the suspension plasma sprayed coatings were tetragonal and 89 to 93 wt.% and the residual phase was monoclinic zirconia (see Table 4). 3.2. Thermal diffusivity measurements Thermal diffusivity data are shown in Fig. 5. The samples sprayed in run 2 have the greatest diffusivity and the lowest—the samples sprayed in the run 4. Thermal diffusivity is greatest for the less porous sample (see Table 2) and the porosity, in turn, decreases with the decrease of the spray distance (see Table 1). 3.3. Thermal conductivity Thermal conductivity was calculated with the use of Eq. (2) using the specific heat and thermal expansion data collected in Table 3. The results are shown in Fig. 6. The calculated values of thermal conductivity are in the range of 0.5 to 1.0 W/(mK) in the discussed temperatures. The thermal conductivity data were verified with the use of simulation of thermal diffusivity experiments. The thermophysical YSZ-2 YSZ-3 YSZ-4 YSZ-5 4. Discussion The suspension plasma spray technique needs more careful optimization of processing parameters and, in particular, the deposition rate is lower than that obtained at the conventional coarse powder spraying. The suspension sprayed yttria stabilized zirconia has a two-zone-microstructure characteristic for suspension sprayed coatings which was discussed in Ref. [4]. Such a microstructure is characterized by a presence of large, well-molten grains and by small, fine particles, which are more or less sintered. The processing parameters of suspension preparation were improved with regard to the previous paper presented in Ref. [12] and the distribution of the initial fine powder was narrower and monomodal. Consequently, the resulting Back face temperature -sample YSZ -1 0.35 299.6 299.4 0.3 Temperature [K] Thermal diffusivity [m2/S] x 10-6 YSZ-1 0.4 properties of the coating were the same as those used in the determination of thermal conductivity and the data for the substrate were found in the database. The initial values of the thermal conductivity of the coating were taken from the experiments. The simulations enabled us to find the temperature of the back side after the lamp pulse (see Fig. 7). Theses curves were compared with curves obtained experimentally, such as those shown e.g. in Fig. 2. The comparison started by setting the minimum and maximum values of the temperature and electric signal evolution as equal. Then, the simulated temperature curve was adjusted to the experimental one by changing thermal conductivity in the simulation until the shapes of curves were identical. The fitting was made with the least squares method to reach high correlation. The results of the fitting are shown in Table 5. Thermal conductivity found in the fitting process corresponded fairly well to the experimental data found in Eq. (2). 0.25 0.2 0.15 299.2 299 298.8 298.6 298.4 298.2 0.1 250 350 450 550 Temperature [K] Fig. 5. Thermal diffusivity of 8YSZ coating suspension plasma sprayed in different experimental runs. The curves show the experimental data and standard deviations. 298 0 200 400 600 800 1000 Time [ms] Fig. 7. Simulation of temperature evolution of the back face of the sample sprayed in run 1 after lamp pulse at room temperature. L. Łatka et al. / Surface & Coatings Technology 208 (2012) 87–91 Table 5 Thermal conductivity of YSZ coatings obtained by fitting the simulated curves to experimental ones. Temperature T [K] 298 R2 323 R2 373 R2 423 R2 473 R2 523 R2 Thermal conductivity [W/(m·K)] Correlation coefficient [1/1] Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 0.8 0.9987 0.8 0.9966 0.8 0.9953 0.8 0.9965 0.9 0.9979 0.9 0.9992 0.9 0.9952 0.9 0.9976 0.9 0.9982 0.9 0.9973 1.0 0.9946 1.0 0.9969 0.7 0.9972 0.6 0.9989 0.7 0.9944 0.7 0.9969 0.7 0.9981 0.9 0.9965 0.5 0.9959 0.5 0.9976 0.5 0.9972 0.5 0.9963 0.6 0.9975 0.6 0.9971 0.5 0.9979 0.5 0.9964 0.6 0.9988 0.6 0.9971 0.6 0.9958 0.7 0.9985 coatings were denser and more homogenous (see Fig. 4). The careful analysis of the microstructure enables us however to distinguish the small grains inside the larger lamellae and the micro-porosity. This micro-porosity may explain low thermal conductivity such as that observed for the sample sprayed in experimental run 4 (see Fig. 6). This value is much lower than the conductivity λ = 0.69 W/(mK) observed for the 8YSZ samples of suspension plasma sprayed previously which have had a porosity of 17% which is much greater than that of 10% found for the samples sprayed in run 4 (see Table 2). The influence of micro-porosity on thermal conductivity is confirmed by the data presented by Raghavan et al. [22] for 8YSZ having cubic and tetragonal structures and a crystal size of 83 nm is about 2 W/(mK) in similar range of temperatures. These authors showed also that thermal conductivity of conventional APS coatings used for thermal barriers was about 1.2 W/(mK) for high density coatings and about 0.9 W/ (mK) for low density coatings. On the other side, thermal conductivity for EB PVD zirconia coatings was above 1.5 W/(mK) in the same temperatures. In general, thermal diffusivity and thermal conductivity are lower for the samples sprayed from a larger distance and having greater porosity (see Figs. 5 and 6 and Table 2). Mechanical properties of the coatings are discussed elsewhere [19]. 5. Conclusions 8YSZ coatings were obtained using suspension plasma spraying. The solid phase in the suspension with a mean size of 4.5 μm was obtained by milling coarse Metco 204NS powder. The fine solids were mixed with 40 wt.% water and 40 wt.% of ethanol to obtain a suspension. The plasma spray parameters were optimized by keeping constant the electric power and working gases composition and varying the spray distance and torch scan linear speed. The porosity of the samples was found to be in the range of 8–12%. Thermal diffusivity was measured with the use of the commercial NanoFlash system in the temperature range from room temperature to 300 °C. The measurements were made with the use of the coatings sprayed on the substrate and the 2-layer numerical model was developed to determine thermal 91 diffusivity of the coatings. The diffusivity was in the range of 0.196× 10−6 to 0.352 × 10 −6 m 2/s in room temperature depending on the spray parameters. The obtained data were then associated with the literature data on density, specific heat and experimental porosity to find thermal conductivity which was in the range of 0.47 to 0.86 W/(mK) at room temperature depending on the spray run. The obtained results were successfully verified by applying a numerical simulation of the experiment of thermal diffusivity. The small values of conductivity are explained by the micro-porosity of the coatings. Further studies on thermophysical properties will be carried out in higher temperatures of up to 1200 °C. Acknowledgments The part of the study was financed by the Ministry of Science and Higher Education of Poland, Grant NN503 134138. The French Embassy in Poland financed the stay of Mr. Łatka in France. The foundation “Perenne” supported the stay of Mr. Rishi Kumar in France. 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