Correction: Wen et al. Fabrication of Dense Gadolinia-Doped Ceria Coatings via Very-Low-Pressure Plasma Spray and Plasma Spray–Physical Vapor Deposition Process. Coatings 2019, 9, 717

Gadolinia-doped ceria (GDC) is a promising electrolyte material for low-temperature solid oxide fuel cells (LT-SOFCs). Many works used ceramic sintering methods to prepare the GDC electrolyte, which was mature and reliable but presented difficulties in rapidly preparing a large area of GDC electrolyte without cracks. The low-pressure plasma spray (LPPS) process has the potential to solve this problem, but few studies have been conducted to date. In this work, submicron GDC powder was agglomerated by a spray drying method to achieve the proper granularity with D50 about 10 μm, and then two dense GDC coatings were fabricated with this agglomerated GDC powder using very-low-pressure plasma spray (VLPPS) and plasma spray–physical vapor deposition (PS-PVD), respectively. The results indicate that the two GDC coatings exhibited similar microstructure but with different densification mechanisms. The VLPPS coating was mainly built up in the form of liquid splats, which had lower mechanical properties due to the lower density and crystallinity, while the PS-PVD coating was co-deposited with the vapor clusters and liquid splats, which had higher density, crystallinity, and mechanical properties. It can therefore be concluded that the GDC coating prepared by PS-PVD is more appropriate for the LT-SOFC application.

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Vapor Phase Deposition Using a Plasma Spray Process

Volume 1: Aircraft Engine; Ceramics; Coal, Biomass and Alternative Fuels; Education; Electric Power; Manufacturing Materials and Metallurgy ◽

10.1115/gt2010-22640 ◽

2010 ◽

Cited By ~ 4

Author(s):

Konstantin von Niessen ◽

Malko Gindrat

Keyword(s):

Plasma Spraying ◽

Thermal Spray ◽

Vapor Phase ◽

Plasma Spray ◽

Vapor Deposition ◽

Physical Vapor Deposition ◽

Low Pressure ◽

Spray Process ◽

Pressure Plasma ◽

Low Pressure Plasma

Plasma spray - physical vapor deposition (PS-PVD) is a low pressure plasma spray technology recently developed by Sulzer Metco AG (Switzerland) to deposit coatings out of the vapor phase. PS-PVD is developed on the basis of the well established low pressure plasma spraying (LPPS) technology. In comparison to conventional vacuum plasma spraying (VPS) and low pressure plasma spraying (LPPS), these new process use a high energy plasma gun operated at a work pressure below 2 mbar. This leads to unconventional plasma jet characteristics which can be used to obtain specific and unique coatings. An important new feature of PS-PVD is the possibility to deposit a coating not only by melting the feed stock material which builds up a layer from liquid splats but also by vaporizing the injected material. Therefore, the PS-PVD process fills the gap between the conventional physical vapor deposition (PVD) technologies and standard thermal spray processes. The possibility to vaporize feedstock material and to produce layers out of the vapor phase results in new and unique coating microstructures. The properties of such coatings are superior to those of thermal spray and electron beam - physical vapor deposition (EB-PVD) coatings. In contrast to EB-PVD, PS-PVD incorporates the vaporized coating material into a supersonic plasma plume. Due to the forced gas stream of the plasma jet, complex shaped parts like multi-airfoil turbine vanes can be coated with columnar thermal barrier coatings using PS-PVD. Even shadowed areas and areas which are not in the line of sight to the coating source can be coated homogeneously. This paper reports on the progress made by Sulzer Metco to develop a thermal spray process to produce coatings out of the vapor phase. Columnar thermal barrier coatings made of Yttria stabilized Zircona (YSZ) are optimized to serve in a turbine engine. This includes coating properties like strain tolerance and erosion resistance but also the coverage of multiple air foils.

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Low-Pressure Plasma-Induced Physical Vapor Deposition of Advanced Thermal Barrier Coatings: Microstructures, Modelling and Mechanisms

Materials Today Physics ◽

10.1016/j.mtphys.2021.100481 ◽

2021 ◽

pp. 100481

Author(s):

Sen-Hui Liu ◽

Juan P. Trelles ◽

Anthony B. Murphy ◽

Wen-Ting He ◽

Jia Shi ◽

...

Keyword(s):

Thermal Barrier Coatings ◽

Vapor Deposition ◽

Physical Vapor Deposition ◽

Low Pressure ◽

Thermal Barrier ◽

Barrier Coatings ◽

Pressure Plasma ◽

Low Pressure Plasma

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Preparation and characterization of aluminum-based coatings deposited by very low-pressure plasma spray

Surface and Coatings Technology ◽

10.1016/j.surfcoat.2019.125034 ◽

2019 ◽

Vol 380 ◽

pp. 125034 ◽

Cited By ~ 1

Author(s):

Xiujuan Fan ◽

Geoffrey Darut ◽

Marie Pierre Planche ◽

Chen Song ◽

Hanlin Liao ◽

...

Keyword(s):

Plasma Spray ◽

Low Pressure ◽

Pressure Plasma ◽

Low Pressure Plasma Spray ◽

Low Pressure Plasma

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Effect of chamber pressure on particle velocities in low pressure plasma spray deposition

Surface and Coatings Technology ◽

10.1016/0257-8972(88)90085-0 ◽

1988 ◽

Vol 34 (1) ◽

pp. 25-31 ◽

Cited By ~ 13

Author(s):

Mark F. Smith ◽

Ronald C. Dykhuizen

Keyword(s):

Plasma Spray ◽

Spray Deposition ◽

Low Pressure ◽

Chamber Pressure ◽

Pressure Plasma ◽

Low Pressure Plasma Spray ◽

Low Pressure Plasma ◽

Particle Velocities

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Microstructure of 316L Stainless Steel Coating Deposited by the Low Pressure Plasma Spray

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.644-650.4888 ◽

2014 ◽

Vol 644-650 ◽

pp. 4888-4891

Author(s):

De Ming Yang ◽

Bo Han Tian

Keyword(s):

Stainless Steel ◽

Plasma Spray ◽

316L Stainless Steel ◽

Low Pressure ◽

Air Plasma ◽

Pressure Plasma ◽

Optical Micrograph ◽

Low Pressure Plasma Spray ◽

Low Pressure Plasma ◽

Stainless Steel Coatings

Original equiaxed 316L stainless steel coatings were successfully deposited by the low pressure plasma spray. For comparison, the coatings of 316L stainless steel with normal lamellar structure were also prepared by the air plasma spray (APS). The microstructures were investigated using optical micrograph (OM). The results show that the microstructures of LPPS 316L stainless steel coatings reveal the fine equiaxed microstructures like the solidified stainless steels,which are significantly different from that of APS coatings with lamellar structures.

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