Thermal Spray Coatings: APS
ZrO2 20YSZ to ZrO2 8YSZ
Properties of thermally sprayed coatings by spray process and coating material. Processes: HVOF (high velocity oxy-fuel), APS (atmospheric plasma spray), wire arc spray, detonation gun, and cold spray. Materials: WC-Co and Cr3C2-NiCr carbide cermets, Al2O3/Al2O3-TiO2/Cr2O3/ZrO2-YSZ oxide ceramics, MCrAlY bond coats, NiCr, Stellite 6, 316L stainless, copper, zinc, aluminum, and specialty alloys. Properties: hardness (HV), bond strength (MPa), porosity (%), oxide content (%), surface roughness Ra (um), deposition efficiency (%), thickness range, max service temperature, wear rate, and application guidance. Per ASM Handbook Vol 5A and Oerlikon Metco/Praxair/Höganäs product data.
| spray process | coating material | application | bond strength mpa max (MPa) | bond strength mpa min (MPa) | bond strength mpa typical (MPa) | deposition efficiency pct max | deposition efficiency pct min | deposition efficiency pct typical (%) | hardness hv max (HV) | hardness hv min (HV) | hardness hv typical (HV) | material category | max service temp c (degC) | porosity pct max (%) | porosity pct min (%) | porosity pct typical (%) | surface roughness ra um max | surface roughness ra um min | surface roughness ra um typical (um) | thickness range um max (um) | thickness range um min (um) | wear rate relative |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| APS | ZrO2 20YSZ | Higher Y2O3 for thermal shock; TBC with improved stability; industrial gas turbines; prolonged high-T exposure | 18 | 5 | 11 | 28 | 10 | 18 | 850 | 550 | 700 | ceramic oxide | 1,300 | 16 | 7 | 11 | 22 | 10 | 15 | 600 | 100 | medium |
| APS | ZrO2 8YSZ | TBC thermal barrier; low thermal conductivity 0.8-1.0 W/mK; gas turbine blades; combustion liners; aviation; k=2.0 W/mK dense vs 0.8 W/mK APS | 20 | 5 | 12 | 28 | 10 | 18 | 900 | 600 | 750 | ceramic oxide | 1,200 | 15 | 7 | 10 | 22 | 10 | 15 | 600 | 100 | medium |
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