FINAL PROGRAM

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SEPTEMBER 13-14, 2017GE GLOBAL RESEARCH CENTER | NISKAYUNA, NY

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REGISTRATION SCHEDULEDay/Date Hours Location

Tuesday, September 12, 2017 18:00 – 20:00 Lobby, Homewood Suites Schenectady (HQ Hotel)

Wednesday, September 13, 2017 07:30 – 17:00 GE Global Research Center

Thursday, September 14, 2017 07:30 – 16:00 GE Global Research Center

EXHIBIT DATES AND TIMESWednesday, September 13 Thursday, September 14

Morning Refreshment Break: 10:00 – 10:30 Morning Refreshment Break: 10:00 – 10:30 Lunch with Exhibitors: 12:00 – 13:00 Lunch with Exhibitors: 12:00 – 13:00

Afternoon Refreshment Break: 15:00 – 15:30 Afternoon Refreshment Break: 15:00 – 15:30Networking Reception: 17:00 – 18:30

ORGANIZING COMMITTEETechnical Program:

Brian Callen, Oerlikon Metco (Canada)Brian Hazel, Pratt & Whitney (USA)

Luc Leblanc, GE-Fuel Cells (USA)Rogerio Lima, National Research Council of Canada (Canada)

Christian Moreau, Concordia University (Canada)James A. Ruud, GE Global Research (USA)

Filofteia-Laura Toma, Fraunhofer Institute for Material and Beam Technology IWS (Germany)

TSS Expo Committee Liaison:Shari Fowler-Hutchinson, Saint Gobain (USA)

NETWORKINGWelcome Reception with Exhibitors

Wednesday, September 1317:00 – 18:30

Refreshment Breaks with ExhibitorsWednesday, September 13 Thursday, September 14

Morning Refreshment Break: 10:00 – 10:30 Morning Refreshment Break: 10:00 – 10:30Afternoon Refreshment Break: 15:00 – 15:30 Afternoon Refreshment Break: 15:00 – 15:30

Lunch with ExhibitorsWednesday, September 13: 12:00 – 13:00

Thursday, September 14: 12:00 – 13:00

GENERAL INFORMATION

ABOUT THE EVENTThis special symposium is a chance for scientists and engineers interested in the emerging S&STS technologies to address both research challenges and development of industrial applications. The symposium will comprise a bal-anced group of speakers from industry, academia and national laboratories.

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WEDNESDAY, SEPTEMBER 13, 2017Time Activity Presenter Institution

07:15 Shuttle Departs Homewood Suites for GE Global Research Center

08:00 – 08:15 Welcoming Remarks from ASM Thermal Spray Society, Doug Puerta

08:15 – 09:00Keynote Presentation Suspension Thermal Spray Technologies Chair: Christian Moreau, Concordia University

James Ruud GE Global Research

SESSION 1: TBCs Engineered via Suspensions & Solutions Chair: James Ruud, GE Global Research

09:00 – 9:30 The Solution Precursor Plasma Spray Process— Development & Applications Maurice Gell University of

Connecticut

09:30 – 10:00Effect of Coating Microstructure and Bond Coat Surface Preparation on Columnar Suspension Plasma Sprayed Columnar YSZ Thermal Barrier Coatings

Luc Bianchi Safran

10:00 – 10:30 Refreshment Break with Exhibitors

SESSION 2: Suspension Thermal Spraying—Process Control & Reliability Chair: Rogerio Lima, National Research Council of Canada

10:30 – 11:00 Suspension Spraying — Recent Activities of Material, Equipment and Coating Development Junya Kitamura Oerlikon Metco

11:00 – 11:30 New Developments on Suspension Spraying— From Hardware to Coating Solutions Filofteia-Laura Toma Fraunhofer IWS

Dresden

11:30 – 12:00 The Industrialization of Suspension Spraying — Recent Developments and New Potentials Nicholas Curry Treibacher Inustrie AG

12:00 – 13:00 Lunch with Exhibitors

SESSION 3: SPS TBCs—Properties and Testing Chair: Brian Callen, Oerlikon Metco

13:00 – 13:30 Porosity Measurements in Suspension Plasma Sprayed YSZ Coatings by Use of X-Ray Microscopy and NMR Cryoporometry Uta Klement Chalmers University of

Technology

13:30 – 14:00 Processing Effects on Microstructure in Spraying of Suspensions Brian Hazel Pratt & Whitney

14:00 – 14:30 Development of Columnar YSZ Thermal Barrier Coatings with Suspension Plasma Spraying Robert Vassen Forschungszentrum

Jülich GmbH

14:30 – 15:00 Thermal Conductivity & CMAS Resistance of SPS Composite Coatings for Use in Thermal Barrier Coating Systems Christopher Petorak Praxair Surface

Technologies

15:00 – 15:30 Refreshment Break with Exhibitors

SESSION 4: Suspension Engineered Coatings—Fundamentals on Processing Chair: Luc Leblanc, GE-Fuel Cells

15:30 – 16:00Engineering Surface Morphology of Suspension Plasma Sprayed TiO2 Coatings to Control Wetting Behavior and Superhydrophobic Properties

Christian Moreau Concordia University

16:00 – 16:30 High Velocity Flame Spraying (HVSFS) of Nano-structured Coatings and Related Industrial Applications Rainer Gadow University of Stuttgart

16:30 – 17:00 Numerical Study of Suspension HVOF Spray Impinging on Flat and Cylindrical Substrates Ali Dolatabadi Concordia University

17:00 – 18:30 Networking Reception with Exhibitors

18:30 Shuttle Returns Guests to Homewood Suites

TECHNICAL PROGRAM SCHEDULE

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THURSDAY, SEPTEMBER 14, 2017Time Activity Presenter Institution

07:30 Shuttle Departs Homewood Suites for GE Global Research Center

08:15 – 09:00

Keynote Presentation Thermal Spraying Evolution from Micro- to Nano-Structured Coatings Chair: Filofteia-Laura Toma, Fraunhofer Institute for Material and Beam Technology IWS

Pierre Fauchais University of Limoges

SESSION 5: SPS TBCs—Microstructure, Processing & Properties Chair: Filofteia-Laura Toma, Fraunhofer Institute for Material and Beam Technology IWS

09:00 – 09:30 Development of suspension plasma sprayed thermal barrier coatings for Siemens industrial gas turbines Xin-Hai Li Siemens Industrial

Turbomachinery

09:30 – 10:00 Understanding the functional performance of advanced axial suspension plasma sprayed thermal barrier coatings Ashish Ganvir University West

10:00 – 10:30 Refreshment Break with Exhibitors

SESSION 6: Suspension Engineered Coatings—Properties Chair: Christian Moreau, Concordia University

10:30 – 11:00 Axial Suspension Plasma Spraying with High Spray Rate and Wide Process Window Neil Young Northwest Mettech

Corp.

11:00 – 11:30 The Thermal Transport Properties of Suspension and Solution Precursor Plasma Sprayed YSZ coatings

Pawel Sokolowski / Pablo Carpio Cobol

Wroclaw University of Science and Technology /

Universidad Politecnica de Valencia

11:30 – 12:00 Electric Properties of Dense Ceramic Coating Prepared by SPS Process Nobuaki Kato Fujimi Incorporated

12:00 – 13:00 Lunch with ExhibitorsSESSION 7: Suspension Engineered Coatings—New Developments

Chair: Brian Hazel, Pratt & Whitney

13:00 – 13:30 Low K SPS Thermal Barrier Coatings Using Nanostructured YSZ Powders Alan Burgess Spraywerx

Technologies Inc.

13:30 – 14:00Potential of Hybrid Water-stabilized Plasma Torch for High-Throughput Deposition of Tailored Coatings via Suspension/Solution Plasma Spraying

Radek MusalekInstitute of Plasma

Physics of the Czech Academy of Sciences

14:00 – 14:30 Liquid Injection Combustion Spray Leonardo Ajdelsztajn GE Global Research

14:30 – 15:00 TBCs Engineered via Finely-Dispersed-Particle Air Plasma Spray (FAPS): A Possible Alternative to SPS TBCs Rogerio Lima National Research

Council of Canada

15:00 – 15:30 Refreshment Break with Exhibitors

15:30 – 16:30 Roundtable DiscussionModerators: Rogerio Lima and Christian Moreau

16:30 Shuttle Returns Guests to Homewood Suites

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SUSPENSION THERMAL SPRAY TECHNOLOGIESJames RuudGE Global Research

THE SOLUTION PRECURSOR PLASMA SPRAY PROCESS—DEVELOPMENT & APPLICATIONS Dr. Maurice Gell University of Connecticut

The Solution Precursor Plasma Spray (SPPS) pro-cess has been under development for more than 10 years at the University of Connecticut. The first appli-cation was to yttria stabilized zirconia (YSZ) thermal barrier coatings (TBCs). It was demonstrated that the SPPS process produces unique microstructural fea-tures that confer excellent TBC properties, including (a) through-coating-thickness cracks for strain tolerance and increased thermal cyclic durability, (b) ultra-fine splats, <2 microns diameter, that provide improved splat bonding and coating toughness, (c) planar ar-rays of porosity, inter-pass boundaries (IPBs), that re-duce thermal conductivity, and (d) porosity that can be varied over wide ranges from 0 to 40 volume percent. These microstructural features of SPPS YSZ provide a TBC with improved durability and a 50% reduction in thermal conductivity compared to air plasma spray (APS) YSZ.

In the past five years, the University of Connecticut has developed a higher temperature SPPS TBC, yttrium aluminum garnet (YAG). SPPS YAG TBCs have the po-tential to be used at temperatures 200oC greater than YSZ TBCs, based on increased phase stability, sinter resistance and CMAS resistance. SPPS YAG TBCs also exhibit a 50% reduction in elevated temperature (1000-1300oC) thermal conductivity and increased thermal cyclic durability compared to APS YSZ.

Based on these favorable TBC developments, a new company, Solution Spray Technologies (SST) was formed two years ago to further develop and com-mercialize the SPPS Technology. SST has extended the SPPS technology to the deposition of thin (5-25 mi-crons), dense coatings (>95%) for a variety of applica-tions, including environmental barrier coatings, oxygen permeable membranes, fusion reactors, and corrosion and contamination protection applications.

The processing and properties of these thick, po-rous and thin, dense SPPS coatings will be described.

EFFECT OF COATING MICROSTRUCTURE AND BOND COAT SURFACE PREPARATION ON COLUMNAR SUSPENSION PLASMA SPRAYED COLUMNAR YSZ THERMAL BARRIER COATINGS L. Bianchi1, B. Bernard1, A. Quet2, A. Joulia1, A. Malié3, Safran, Magny-Les-Hameaux, France CEA-DAM, Monts, France Safran Aircraft Engines, Châtellerault, France

Suspension Plasma Spraying (SPS) was identified as promising for the enhancement of Thermal Bar-rier Coatings (TBCs) systems used in for gas turbines. Particularly, the emerging columnar microstructure achieved by SPS process is likely to bring extended TBC thermal lifetime compared to APS coatings or even EB-PVD (Electron Beam Physical vapor Deposition) coat-ings. At the same time, SPS process opens the way to a significant decrease of the thermal conductivity com-pared to EB-PVD. Due to the permanent increase of tur-bine working temperature this point becomes one of the main issues for the next generation of gas turbine as well as components cooling in order to maintain the Ni based superalloy at an acceptable working tem-perature. In this presentation, Yttria-Stabilized Zirconia (YSZ) coatings showing different columnar structures, performed using both SPS and EB-PVD processes, were studied. Depending on the columnar microstruc-ture readily adaptable in SPS process, a large range of thermal conductivities can be obtained. At 1100 °C, a decrease from 1.6 W/mK for YSZ EB-PVD coating to around 0.7 W/mK for SPS coatings was shown. The higher content of porosity in case of SPS process im-proves phonon scattering and decreases thermal con-ductivity. Thermal lifetime of YSZ SPS coatings was also studied for different bondcoat composition and surface preparation used especially for EB-PVD top coats. SPS columnar coatings are showing equivalent or even su-perior performances, depending on bondcoat nature and preparation, compared to EB-PVD ones. Thermal cyclic fatigue performance of best SPS coating reached 1000 cycles to failure on AM1 substrates with a γ-(Ni,Pt)Al bond coat. Tests were also performed on AM1 sub-strates with a Pt diffused γ-Ni / γ’-Ni3Al bond coat for which more than 2000 cycles to failure were observed. The high thermal compliance offered by both the co-lumnar structure and the porosity allowed to reach high thermal lifetime resistance promising for a TBC application.

ABSTRACTSAbstracts are organized by presentation time.

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SUSPENSION SPRAYING—RECENT ACTIVITIES OF MATERIAL, EQUIPMENT AND COATING DEVELOPMENT Junya Kitamura, Kazuya Fujimori, Brian Callen, Christian Bauer, and Riston Rocchio-Heller

Suspension spraying, an emerging coating tech-nology, is currently under active development to re-alize improved physical and chemical properties with affordable cost and rapid deposition rate by precise control of micro- and nanoscale-structures. Target ap-plications using oxide ceramics are considered to be various that motivate these activities, such as thermal barrier coatings (TBC) by yttria stabilized zirconia (YSZ) in aerospace and gas turbine industries, erosion resis-tant coatings by yttria against halogen contained plas-ma in semiconductor manufacturing industries, elec-trolyte layers by fully stabilized zirconia for solid oxide fuel cell (SOFC), electrical insulating layers with high heat conduction for electrical vehicles, photo catalytic layers by titanium oxide with high amount of anatase phase and so on.

Although suspension spraying has high potential, a lot of problems to be solved have been identified through previous work by many researchers and en-gineers. Suspension should be mixed homogeneously without agglomeration and have stable feeding with lower viscosity in spite of relatively higher concentra-tion. In order to produce it, dispersants will be one of the key parameters. It also should be stable for a long time during storage, for example a few months and be easily remixed after sedimentation. Particle size will be the most important property to control coating struc-ture. High solids concentration of the suspension is better in terms of economics. However, this will also affect coating structures in some cases.

Recent activities in material, equipment and coating development are discussed in this presenta-tion. Influence of particle size and spray parameters on coating structure has been studied mainly for YSZ and yttria. In addition, the latest status of suspension feeder development will be presented.

NEW DEVELOPMENTS ON SUSPENSION SPRAYING—FROM HARDWARE TO COATING SOLUTIONS F.-L Toma, N. Kulissa, M. Barbosa Fraunhofer IWS, Dresden, Germany A. Potthoff Fraunhofer IKTS, Dresden, Germany

By using suspensions as feedstock for atmo-spheric plasma spraying (APS) and high velocity oxy-fuel spraying (HVOF) coatings with a wide variety of thicknesses, morphologies, and properties can be produced. The economic efficiency of the process depends not only on the development and handling of stable suspensions, but also on the availability of suitable additional system components. The symbio-

sis between these two important factors has allowed, over the last few years, significant advances in terms of deposition efficiency and feed rate in relation to the solid content of the suspension.

For the conventional thermal spraying process, the availability of fused feedstock powder composed of two oxides or more is limited, although for industrial applications coatings with a wide spectra of properties are needed. Suspension spraying is the key to satisfy these requirements by offering tailored compositions in the Cr2O3-TiO2-Al2O3 system. Next to ZrO2, the indi-vidual oxides and binary compositions in the system Cr2O3-TiO2-Al2O3 are the most used ceramic materials for thermally sprayed coating solutions. Cr2O3 coat-ings are characterized by good sliding wear resistance, while Al2O3 coatings show excellent insulation behav-ior and TiO2 has striking corrosion properties. Aim-ing to combine these properties, suspension sprayed coatings containing more than one oxide have been produced, and are promising candidates for applica-tions in off-shore piston-rods or pump sealing seals or hydraulic cylinder rods. In this contribution, new developments on ready-to-spray suspensions with tai-lored composition and on industrial-suitable hardware systems for suspension spraying will be presented. The criteria for the selection of raw materials as well as aspects of the development of binary /ternary sus-pensions to be used in thermal spray will be discussed. Coatings sprayed using the developed suspensions and high velocity oxy fuel flame spraying (SHVOF) will be presented and analyzed in terms of their properties. From the experimental results it was observed that the suspension sprayed coatings showed in most of cases denser microstructure, higher mechanical properties and superior corrosion performances when compared to coatings produced from feedstock powder.

THE INDUSTRIALIZATION OF SUSPENSION SPRAYING—RECENT DEVELOPMENTS AND NEW POTENTIALS Nicholas Curry Treibacher Industrie AG

In the last two years, suspension spraying has gone from being a process under development, to a qualified and industrially accepted coating method. The aerospace certification of suspensions demon-strates the great advances that have been made in the decades since the technique was first developed.

While the first coating applications are entering industrial use, there remains a great deal of scope in the development of the suspension spraying process. In the area of thermal barrier coatings there is the po-tential to further increase coating performance, pro-cessing rate and efficiency. Potentially making the SPS process an effective alternative to traditional air plasma spray coating, not only EB-PVD.

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Further developments of the coating technique are realizing the potential for new applications in fields like wear, erosion and corrosion resistance. In some cases this can be the development of higher perfor-mance replacements for traditional APS and HVOF coatings. Suspensions allow the production of com-posite mixtures of materials that previously could not be sprayed reliably with dry powder techniques. There exists also the potential for combining powders and suspensions of vastly different materials to produce hybrid coatings with improved performance.

This presentation will focus on some of the more recent developments in suspension development and possible directions for future coatings.

POROSITY MEASUREMENTS IN SUSPENSION PLASMA SPRAYED YSZ COATINGS BY USE OF X-RAY MICROSCOPY AND NMR CRYOPOROMETRY U. Klement Chalmers University of Technology, Gothenburg, Sweden

Numerous techniques exist for determining po-rosity in porous materials and the most commonly used methods for determining pore size distributions are image analysis, gas adsorption and mercury intru-sion porosimetry. However, there are also advanced characterization techniques like small and ultra-small angle scattering techniques which provide uniquely useful information on the pore size and pore size dis-tribution of both open and closed pores in size ranges from approximately 1 nm to 10 µm. Due to limitations with the various techniques, it is often valuable and frequently necessary to combine porosity and mor-phological information from different complementary techniques. Here, the porosity of suspension plasma sprayed (SPS) yttria-stabilized zirconia coatings is in-vestigated using hitherto unusual methods such as Nuclear Magnetic Resonance (NMR) cryoporometry and X-ray microscopy (XRM). NMR cryoporometry can be used to measure porosity, pore size distribution and pore geometry in porous material and can mea-sure pore sizes down to a few nanometer. But the tech-nique is restricted to pore sizes of a few hundred nano-meters. The porous material is saturated with a probe liquid and cooled down to complete solidification and thereafter the temperature is slowly raised. The liq-uid will start to melt depending on pore size (smaller pore volumes will start to melt at lower temperature than larger) and when analyzing the fraction of liquid against temperature, it is possible to determine the pore size distribution. XRM is an advanced imaging technique that visualizes the specimen in three dimen-sions using X-ray optics, while rotating the specimen in the X-ray beam. With this technique it is possible to in-vestigate internal features like open and closed pores at a resolution down to 50 nm.

It will be shown that novel techniques such as XRM and NMR cryoporometry provide complementary

data that extends our ability to quantitatively describe the pore space in SPS coatings. Advantages and dis-advantages with the measurement techniques will be discussed.

PROCESSING EFFECTS ON MICROSTRUCTURE IN SPRAYING OF SUSPENSIONS Brian Hazel Pratt & Whitney, East Hartford, Connecticut, USA

Thermal spraying utilizing suspension feedstock is a relatively new method for applying coatings. Sus-pension plasma spraying specifically has demonstrat-ed the ability to produce a range of coating microstruc-tures. The suspension plasma sprayed strain tolerant vertically segmented and columnar structures are of particular interest for application of thermal barrier coatings used gas turbine engines. These strain tol-erant structures are expected to have the ability to withstand the high temperatures and thermal cycling inherent in gas turbine operation. The processing con-ditions selected can greatly influence the details in the strain tolerant structure. The structural differences can include column size, column packing, and density. Selected process parameters will be related to their effect on the resultant microstructure. Furthermore, how these microstructural changes will impact perfor-mance be considered from an industry perspective.

DEVELOPMENT OF COLUMNAR YSZ THERMAL BARRIER COATINGS WITH SUSPENSION PLASMA SPRAYING Dapeng Zhou1, Olivier Guillon1,2, Robert Vaßen1 Forschungszentrum Jülich GmbH, Germany Jülich Aachen Research Alliance: JARA-Energy

Suspension plasma spraying is an attractive and advanced thermal spraying technology especially for the deposition of Thermal Barrier Coatings (TBCs). The use of an axial injection system allows the good pen-etration of the suspension in the center of the plasma plume. It enables the growth of columnar-like struc-tures and hence combines advantages of Electron Beam- Physical Vapor Deposition (EB-PVD) technology with the considerably cheaper Atmospheric Plasma Spraying (APS). At first, the presentation will discuss the effects of spraying conditions (bond coat rough-ness, stand-off distance, input power, and solid load-ing of the suspensions) on the microstructures of Yttria partially Stabilized Zirconia (YSZ) top coats and the de-position efficiency. Coatings deposited on as-sprayed bond coats without additional surface preparation appear to have nicely developed columnar structures. Based on these results, variations of the stand-off dis-tances and yttria content in the coatings were used to manufacture three different columnar structures for tests in a gas burner rig. In these tests, all columnar structured TBCs showed relatively short lifetimes com-pared with porous APS coatings. Indentation measure-ments for Young’s modulus and fracture toughness

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in the columns of the SPS coatings indicated a cor-relation between mechanical properties and lifetime for the SPS samples. A simplified model is presented which correlates mechanical properties and lifetime of SPS coatings. The model allows a further insight on the degradation mechanisms of the SPS TBC systems.

THERMAL CONDUCTIVITY AND CMAS RESISTANCE OF SPS COMPOSITE COATINGS FOR USE IN THERMAL BARRIER COATING SYSTEMS Chris Petorak, Ph.D.Praxair Surface Technologies

Suspension plasma spray (SPS) coatings have demonstrated unique microstructures and properties. While very porous columnar 7wt%YSZ microstructures produced by SPS are thermally compliant and dem-onstrate low thermal conductivity, they lack erosion and CMAS resistance. The following work examines variations in SPS microstructures and composite SPS coatings relative to the coating properties, specifically changes in thermal conductivity and CMAS resistance. Additionally, limited data is correlated with erosion re-sistance and furnace cycle testing (FCT) results.

ENGINEERING SURFACE MORPHOLOGY OF SUSPENSION PLASMA SPRAYED TIO2 COATINGS TO CONTROL WETTING BEHAVIOR AND SUPERHYDROPHOBIC PROPERTIES Navid Sharifi, Fadhel Ben Ettouil, Ali Dolatabadi, Martin Pugh, Christian Moreau * Concordia University, Montreal, QC, Canada

Suspension plasma spraying (SPS) has shown promise for new applications focusing on surface tex-tured coatings including superhydrophobic coatings. Such coatings have a dual-scale hierarchical morphol-ogy or so-called “cauliflower” features on the surface and they demonstrate extreme water repellence and mobility. Superhydrophobic coatings are potential coat-ing solutions to reduce ice formation and accretion on critical components in airplanes, wind mills, etc.

In this study, the effect of critical process param-eters to optimize the performance of these coatings is investigated. It was found that, by carefully designing and controlling the process parameters, one can gen-erate relatively fine and uniform dual-scale (hierarchi-cal) surface textured coatings that, after treatment for lowering their surface energy, show significantly im-proved water repellence and water mobility with water contact angles as high as 170° and sliding angles as low as 1.3°. It is also demonstrated that dual surface tex-ture is essential for having simultaneously improved water repellence and mobility. The results show the significant influence of pre-deposition surface rough-ness, precursor suspension rheology and plasma pow-er on the structure and performance of the developed coatings.

HIGH VELOCITY FLAME SPRAYING (HVSFS) OF NANOSTRUCTURED COATINGS AND RELATED INDUSTRIAL APPLICATIONS R. Gadow University of Stuttgart, Germany

Various thermal spray technologies including plasma and supersonic flame spraying have shown their potential in the production of dense and well adherent structural and functional coatings on metal, ceramic and even polymer substrates. Thermal spray-ing using liquid precursors or suspensions, containing fine and ultra-fine powder particles enables the devel-opment of coatings with unique microstructure and beneficial features, that significantly differ from con-ventionally sprayed coatings. The potential of these novel coatings is well known and has gained vital inter-est among the scientific and industrial community. It is expected, that thermal spraying with liquid feedstocks will give substantial contributions in numerous indus-trial key applications like biomedicine, energy conver-sion, catalysis, automotive and aerospace engineer-ing. Fabrication routes and processing of solutions and suspension feedstocks containing nano sized par-ticles strongly differ from conventional spray materials preparation.

Especially in case of suspensions, their storage and handling requires distinct expertise. Flame in-teraction of liquids and suspensions as well as coat-ing formation phenomena are key issues to gain the necessary process knowledge. This is required to fully control and shape the liquid feedstock based spray process and raise the technology to an industrial pro-duction level. Novel hard ware components and con-figurations were developed for combustion chamber, spray nozzles and injection systems as well as robot guided component geometry related optimized torch trajectories to manage the heat and mass transfer. The presentation gives an overview about current research activities in hard ware component and process devel-opment and will discuss new coating product develop-ment and industrial applications.

NUMERICAL STUDY OF SUSPENSION HVOF SPRAY IMPINGING ON FLAT AND CYLINDRICAL SUBSTRATES A. Dolatabadi and M. JadidiConcordia University, Montreal, Canada

In thermal spray processes, it is known that sub-strate shape and location have significant effects on particle in-flight behavior and coating quality. In the current work, the suspension high-velocity oxygen-fuel (HVOF) spraying process is modeled using a three-dimensional two-way coupled Eulerian-Lagrangian approach. Flat and cylindrical substrates are placed at different standoff distances and particles characteris-tics near the substrates and upon impact are studied.

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Suspension droplets with predefined size distribu-tion are injected into the combustion chamber and the droplet breakup phenomenon is simulated us-ing Taylor Analogy Breakup model. Furthermore, the eddy dissipation model is used to model the premixed combustion of oxygen-propylene, and non-premixed combustion of oxygen-solvent components. Once the breakup and combustion phenomena are completed, the solid/molten mullite particles are tracked through the domain. It is shown that as the standoff distance increases the particle temperature and velocity de-crease and the particle trajectory deviation becomes more significant compared to the conventional HVOF process. The numerical results presented here is con-sistent with the experimental data in the literature for the same operating conditions.

THERMAL SPRAYING EVOLUTION FROM MICRO- TO NANOSTRUCTURED COATINGS Pierre FauchaisUniversity of Limoges

The thermal spray community has been actively involved in spraying “nano-sized” or “nanostructured” materials for more than 30 years. For these coatings, the splat-to-splat cohesion is generally better and the coating is rather homogeneous with splat sizes below a few micrometers. However, the problem of injecting nano-particles into the core of the high enthalpy plas-ma flow is a complex problem.

First works were devoted to micrometer–sized ag-glomerates with optimized conditions to only partially melt them. Then a liquid containing sub-micrometer sized particles (suspensions plasma spraying: SPS) or reacting elements (solution precursor plasma spray SPPS) was used. The behavior of sub-micrometer sized droplets and then particles in plasma jets was stud-ied to determine the best matching between injection modes and used spray torches. The influence of these parameters on splats formation and layering, with re-sulting coating porosity is an important parameter.

These works required to develop, with more or less success, new measurements to follow droplets and then in-flight particles, splats formation and very low coating porosity characterization.

Main results obtained with suspensions and solu-tions and potential developments will be presented. At last the actual developments of hybrid processes (powders and solution spraying) will be considered.

DEVELOPMENT OF SUSPENSION PLASMA SPRAYED THERMAL BARRIER COATINGS FOR SIEMENS INDUSTRIAL GAS TURBINES Xin-Hai Li Siemens Industrial Turbomachinery AB, Sweden

Development of thermal barrier coating systems (TBCs) for gas turbine applications allowing higher

combustion temperatures or/and a reduced metal temperature is continuously attracting great efforts from both academies and industries since they result in higher fuel efficiency, increasing component life, and lower emissions. Suspension plasma spraying (SPS) which involves deposition of ultrafine droplets of suspension has been demonstrated as a promis-ing process development for advanced TBCs, since it exhibits column-like microstructure, low thermal conductivity, and good cyclic lifetime as compared to conventional systems. Here, potential benefits of SPS TBCs compared to the conventional TBCs such as APS and EBPVD TBCs and possible applications in indus-trial Siemens gas turbines are discussed. An overview of the recent progress and accomplishments, arising from efforts devoted to development of high perfor-mance SPS TBCs in which Siemens has been involved, is given, including results illustrating the different types of the microstructures, behaviour of thermal conductivity, effects of various bondcoats, thermal cy-clic life, effects of process parameters, effects of bond-coat surface treatment, and etc., in comparison with conventional powder-based coatings. TBCs with var-ied architectures and chemistries, besides the conven-tional single 8wt. % yttria stabilized zirconia insulating ceramic layer, are specifically highlighted.

UNDERSTANDING THE FUNCTIONAL PERFORMANCE OF ADVANCED AXIAL SUSPENSION PLASMA SPRAYED THERMAL BARRIER COATINGS Ashish Ganvir, Nicolaie Markocsan, Mohit Gupta, Stefan Björklund, Rosa Calinas, Robert Vassen University West

Axial Suspension Plasma Spraying (ASPS) is a relatively new thermal spaying technique to produce advanced thermal barrier coatings (TBCs). ASPS has shown to be a very promising technique to produce coatings with lower thermal conductivity as well as higher thermal-cyclic lifetime than the state-of-art TBCs used today. In addition ASPS has also shown to have a wide process window which enables the production of variety of microstructures such as highly dense, highly porous, segmented or columnar. These microstructures show very inhomogeneous and wide distribution of microstructural features such as pores, cracks, inter-columnar spacing, grains etc. These features can affect the coatings functional performance and their amount and distribution in the coatings depends not only on the spray parameters but also on the feedstock (suspen-sion) characteristics. Therefore it becomes vital to un-derstand the role of spray parameters and suspension characteristics on microstructure and the influence var-ious microstructural features on coatings performance.

This work aims to study the effect of feedstock and spray conditions on the various microstructural fea-tures and hence on coatings functional performance. Firstly, 8 wt% yttria stabilized zirconia (8YSZ) suspen-

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sions with varied solid loading, particle size distribution and solvent types were prepared to produce different coating microstructures while keeping the same deposi-tion conditions. Secondly, different coating microstruc-tures were produced using the same 8YSZ suspension but with dissimilar spray parameters. Coatings were then evaluated for their thermal conductivity, thermal cyclic fatigue and thermal shock lifetime as well as sin-tering behavior under isothermal exposure conditions. Several experimental characterization techniques were utilized to analyze the as-sprayed and post treated coat-ings. The techniques involved include scanning electron microscopy for microstructure and porosity analysis, X-ray diffraction for phases and crystallite size, mercury infiltration porosimetry for pore-size distribution, mi-cro-indentation for hardness, E-modulus and fracture toughness etc.

Based on the detailed experimental investiga-tion conducted in this work, various factors needed for designing an optimized columnar TBC for gas turbine application are discussed. Along with the suspension viscosity and surface tension, ceramic top coat total po-rosity and pore-size distribution was found to be crucial in designing the optimized TBC.

AXIAL SUSPENSION PLASMA SPRAYING WITH HIGH SPRAY RATE AND WIDE PROCESS WINDOW Zhaolin Tang and Neil Young Northwest Mettech Corp., British Columbia, Canada

Suspension plasma spraying is gaining greater interest for emerging applications such as solid ox-ide fuel cells (SOFCs), plasma erosion resistant coat-ings, and advanced thermal barrier coatings (TBCs). Mettech developed an axial suspension plasma spray technology (ASPS), and demonstrated its capability to overcome the complexities of the process and deliver quality coatings. This paper demonstrates the process window required for industrial production including the spraying angle, stand-of-distance, suspension con-certation and feed rate, and substrate surface rough-ness. The ASPS process with high spray rate was devel-oped, with comparable deposition rate to traditional APS with dry powders. This was possible thanks to the benefit of axial injection and the continuing improve-ment on the process parameters and feedstock sus-pensions. With many years of development, the tech-nology is being introduced into aerospace to replace expensive EB-PVD for durable TBCs.

THE THERMAL TRANSPORT PROPERTIES OF SUSPENSION—AND SOLUTION PRECURSOR PLASMA SPRAYED YSZ COATINGS Paweł Sokołowski1, Pablo Carpio2,3, and Lech Pawłowski3 Wroclaw University of Science and Technology, Wrocław, Poland Institute of Material Science, Valencia, Spain

University of Limoges, Limoges, France The thermal transport properties play an impor-

tant role in Thermal Barrier Coatings (TBC’s) technol-ogy. Recently, due to the development of liquid feed-stock plasma spraying and producing of finely-grained topcoats, the improvement of the insulation proper-ties of TBC’s seems to be possible. This work was done in order to investigate thermal diffusivity and thermal conductivity of Suspension Plasma Sprayed (SPS) and Solution Precursor Plasma Sprayed (SPPS) yttria-sta-bilized zirconia coatings.

The two different liquid feedstock materials, namely suspension and solution, were formulated for coating deposition. In case of SPS the water/ethanol based (50:50) slurries with various solid contents, in range of 5 to 20 wt%, were formulated. The different sets of suspensions based on: (i) in-house ball-milled (dv50≌0.9µm) 8YSZ and (ii) as-produced (dv50≌0.5µm) 14YSZ powder material, were tested. The solution that was applied for SPPS was prepared from zirconium acetate and yttrium nitrate in a stoichiometric ratio in order to obtain 8YSZ. Suspension and solution feed-stocks were then fully-characterized prior to spraying. The plasma spraying was performed by using one set-up that was equipped with a stick-type cathode SG-100 torch and was supplied with Ar+H2 plasma forming gases.

The use of various feedstocks affected the coating growth-up mechanisms and influenced the microstruc-tural features of zirconia coatings. The microstructural characterization was performed by Scanning Electron Miccroscopy (SEM), X-ray Diffraction (XRD) and Electron Back Scatter Diffraction (EBSD). The coating morphol-ogy, porosity, phase composition, grain size as well as the shape of grain were investigated. Finally, the char-acterization of thermal diffusivity of coatings was car-ried out by the means of Laser Flash method and then thermal conductivity was calculated. It was done in or-der to investigate the effect of the coating morphology on thermal transport properties of YSZ topcoats.

ELECTRIC PROPERTIES OF DENSE CERAMIC COATING PREPARED BY SPS PROCESS Nobuaki Kato Fujimi Incorporated

Al2O3 coatings obtained by the plasma spraying is applied for application to application utilizing the elec-trical insulation properties of such electronics devise manufacturing equipment components. Dense ceram-ics coatings sprayed by suspension plasma spraying (SPS) are expected to develop functional applications due to their superior electrical and mechanical prop-erties compared with conventional thermal sprayed coating which has micron size pores.

Fine size materials are more sensitive by process conditions and several factors both of coating pro-cess and suspension properties are being investigated

11

to obtain dense ceramic coating by SPS process. The presentation will focus on electric properties of dense Al2O3 and Y2O3 ceramic coating. Spray conditions, plasma power, gas flow rate and stand-off distance af-fect the coating density, crystal phase, mechanical and electric properties. Mechanism of coating formation by plasma spraying with fine powder suspensions will be discussed based on the findings.

LOW K SPS THERMAL BARRIER COATINGS USING NANOSTRUCTURED YSZ POWDERS Alan Burgess President, Spraywerx Technologies Inc.

Spraywerx Technologies Inc. has demonstrated the ability to produce low k thermal barrier coatings using nanostructured 7wt% yttria stabilized zirconia produced by Innovnano Materias Advancados S.A. A matrix of 6 SPS coatings were sprayed using the Axial III plasma spray system with plasma power and bond coat surface roughness being the key variables in the study. An Accuraspray system was used to monitor in flight particle temperature and velocity for the vari-ous coating parameters. SEM analysis of the resulting coatings was performed to determine crack frequency, porosity and coating morphology. Thermal conductiv-ity of the coatings was performed using the laser flash diffusivity method. The correlation between spray pa-rameters, coating microstructure and thermal conduc-tivity will be presented and discussed.

POTENTIAL OF HYBRID WATER-STABILIZED PLASMA TORCH FOR HIGH-THROUGHPUT DEPOSITION OF TAILORED COATINGS VIA SUSPENSION/SOLUTION PLASMA SPRAYING Radek Musalek, Ph.D. Institute of Plasma Physics of the Czech Academy of Sciences, Prague, Czech Republic

Recently developed hybrid water-argon plasma torch technology combines benefits of both conven-tional gas-stabilization and water-stabilization princi-ples. Thanks to the high enthalpy of the generated plas-ma, this torch may be used for cost-effective spraying with liquid feedstocks at high feed rates (higher than 100 ml/min). Different strategies leading to deposition of coatings with distinguishable tailored microstruc-tures (e.g. strain-tolerant columnar cauliflower-like, extremely porous or dense coatings) will be presented and illustrated on several ceramic coatings (including YSZ, Gadolinium Zirconate, YAG) relevant namely for high temperature applications. Build-up mechanisms and impact of the microstructure on the coatings properties will be discussed.

LIQUID INJECTION COMBUSTION SPRAYLeonardo AjdelsztajnGE Global Research

TBCS ENGINEERED VIA FINELY-DISPERSED-PARTICLE AIR PLASMA SPRAY (FAPS)—A POSSIBLE ALTERNATIVE TO SPS TBCS Rogerio S. Lima, Bruno M. H. Guerreiro and Basil R. Marple National Research Council of Canada

Electron-Beam Physical Vapour Deposition (EB-PVD) is the state-of-the-art processing method to de-posit ZrO2-Y2O3 (YSZ) thermal barrier coatings (TBCs) on the rotating parts of turbine engines (e.g., turbine blades). Suspension Plasma Spray (SPS) is a technol-ogy that has been demonstrating a good potential to replace EB-PVD as the state-of-the at method deposit TBCs on these rotating parts. SPS processing is able to engineer TBCs exhibiting vertically-oriented columnar structures; which are fundamental for the application on the turbine blades. Although SPS is a promising process, there are still security concerns on the flam-mability issues related to the use of alcohol-based suspensions.

In this work, YSZ TBCs were manufactured via conventional Air Plasma Spray (APS), Suspension Plas-ma Spray (SPS) and an additional technology hereby termed Finely-dispersed-particle Air Plasma Spray (FAPS). The FAPS processing employs the exact same classification of finely dispersed particles as used in SPS; however, whereas SPS uses a liquid medium, in the case of FAPS the particles are fed conventionally via a carrier gas into the plasma spray torch by using a newly developed powder feeder for fine (suspension-like) particles (NRC patented technology). These finely dispersed YSZ particles consist of irregularly shaped (fluffy-like) agglomerates made from individual nano-sized particles. By using FAPS, the flammability issues related to SPS processing are not applied. Besides, FAPS processing is able to produce the desired verti-cally-oriented columnar structured TBCs.

For this study, both SPS and FAPS YSZ TBCs ex-hibited porous and vertically-cracked microstruc-tures. The conventional APS YSZ TBC microstructure exhibited the traditional lamellar morphology. Elastic modulus and hardness values of the as-sprayed and heat-treated (1300 °C-10h) YSZ TBCs were evaluated via instrumented indentation. Thermal conductivity values were measured at room temperature (RT) and 1300 °C. Microstructures and phase analysis were in-vestigated via scanning electron microscope (SEM) and X-ray diffraction (XRD).

Axial Injection—The Superior Solution for SPS

Tel.: 604-987-1668 Email: Info@mettech.com Website: www.mettech.com

Columnar SPS Coatings Dense SPS Coatings

13EXHIBIT DATES AND TIMESWednesday, September 13

10:00 – 18:30Morning Break with Exhibitors: 10:00 – 10:30

Lunch with Exhibitors: 12:00 – 13:00Afternoon Break with Exhibitors: 15:00 – 15:30

Networking Reception/Dinner with Exhibitors: 17:00 – 18:30

Thursday, September 1410:00 – 13:30

Morning Break with Exhibitors: 10:00 – 10:30Lunch with Exhibitors: 12:00 – 13:00

Afternoon Break with Exhibitors: 15:00 – 15:30

SHOW DIRECTORY

Thank you to our Sponsors!

14

EXHIBITOR LIST 2 Hayden Corporation 4 Mettech 8 Precision Surfaces International, Inc. 1 Progressive Surface, Inc.

3 Proton OnSite 6 Saint-Gobain 5 Treibacher Industrie Incorporated 7 Zircar Zirconia, Inc.

Tabletop # Exhibitor Tabletop # Exhibitor

Progressive Surface, Inc.Tabletop #1Progressive Surface designs and builds integrated ther-mal spray systems and surface treatment equipment. We build turnkey systems for conventional plasma, HVOF, combustion and our 100HE High Enthalpy plas-ma. The 100HE is exceptional at spraying standard plasma coatings as well as suspension plasma spray (SPS) and solution precursor (SPPS) coatings.www.progressivesurface.com

Hayden CorporationTabletop #2Hayden Corporation provides Tough Coatings for harsh environments. Services include Laser Cladding, Ther-mal Spray and Fused Coating services for protection and restoration of machine components. We are the only full-service supplier in the Northeast. Processes include HVOF, Plasma, Wire Spray, Fusing, Cladding, Grinding and Milling.www.haydencorp.com

Proton OnSiteTabletop #3Proton OnSite is now a part of Nel Hydrogen- the world’s largest hydrogen Electrolyzer manufacturer. Our advanced PEM and Alkaline electrolysis systems coupled with uncompromising attention to excellence and quality, enables us to deliver, install and support gas generation units for material processing operations worldwide.www.protononsite.com

MettechTabletop #4Mettech manufactures and sells our world-renowned Axial III plasma torch, Nanofeed suspension feeder and parts from our Vancouver, Canada facilities. We part-ner with our commercial and institutional clients to provide superior solutions in traditional applications as well as in new and exciting fields. www.mettech.com

Treibacher Industrie IncorporatedTabletop #5Treibacher Industrie AG is an international company with over 100 years’ experience in chemistry and metal-lurgy. At its headquarters in Althofen/Austria Treibach-er Industrie AG develops and manufactures ferro alloys for the steel and foundry industries, powders for the carbide industry, materials for high performance ce-ramics, fine chemicals and special alloys.www.treibacher.com/en

Saint GobainTabletop #6Saint-Gobain is a world class manufacturer of consum-ables and equipment for the thermal spray industry. We offer a complete line of ceramic powders, Rokide(R) rods, flexible cords, EBPVD ingots, flame spray and plasma spray equipment. www.coatingsolutions.saint-gobain.com

Zircar ZirconiaTabletop #7Manufacturer of “Zircar Process” Oxide Ceramic Fibers and Powders for Use in Thermal Spray TechnologiesZircarzirconia.com

Precision SurfacesTabletop #8Precision Surfaces International, Inc. is a unique source of products for grinding and polishing in the Thermal Spray industry, both for production applications and in the metallurgical laboratory. These products include all of the 3M Diamond Superfinishing Abrasives and a complete offering of metallurgical laboratory equip-ment and consumables.www.psidragon.com

COMPANY DESCRIPTIONS

Because there may have been some late changes in booth assignments, some exhibitors may have a different booth number than was shown on their invitations and advertising. Please check this Directory for the most-up-to-date listings, as well as onsite signage.

Reasonable precautions have been taken to avoid errors in and omissions from this Directory, but ASM International does not guarantee listings herein and shall not be responsible for errors in or omission in this Directory.

EXHIBITOR LIST

Onlinemonitoringof thermal sprayprocesses forthe shop floor.

ITSC2O18INTERNATIONAL THERMAL SPRAYCONFERENCE AND EXPOSITION

www.asminternational.org/itsc

Organized by:

Co-located with:

May 7-10, 2018

SAVE THE DATE!

Gaylord Palms Resort & Convention Center

Orlando, Florida, USA