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Development of Solution Precursor Plasma Spray (SPPS) Yttrium Aluminum Garnet (YAG) Coatings for Engine Components Using a High Enthalpy Cascaded Arc Gun: Part I

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Abstract

Solution precursor plasma-sprayed (SPPS) yttrium aluminum garnet (YAG) thermal barrier coatings (TBCs) have previously been shown to have higher temperature capability and reduced thermal conductivity compared to state-of-the- art TBCs. This previous work was conducted using a relatively low enthalpy plasma gun (Metco 9 MB) and TBCs were deposited on laboratory specimens. The primary goal of this work was to advance the state of technology readiness of SPPS YAG TBC coatings by using a high enthalpy cascaded arc gun (Sinplex Pro) to produce varied microstructures optimized for specific engine components: a fuel nozzle tip, an annular combustor liner, and turbine ceramic outer air seals. The microstructure and properties of these TBCs have been characterized and shown to be superior to those obtained previously. Based on these favorable results, the processing technology was transferred to solar turbines incorporated. Their process optimization of coatings for the three engine components and the rig and engine testing of the coated components will be described in Part II of this paper.

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Acknowledgments

This material is based upon work supported by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) under the Advanced Manufacturing Office (AMO) Emerging Research Exploration Award Number DE-EE0008307.

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Authors and Affiliations

  1. Solutions Spray Technologies LLC, 270 Middle Turnpike, Storrs, CT, 06269, USA

    Rishi Kumar, Chen Jiang, Maurice Gell & Eric H. Jordan

  2. Solar Turbines Incorporated, 4200 Ruffin Rd, San Diego, CA, 92123, USA

    Brent Cottom

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  1. Rishi Kumar
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  2. Chen Jiang
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  4. Maurice Gell
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Kumar, R., Jiang, C., Cottom, B. et al. Development of Solution Precursor Plasma Spray (SPPS) Yttrium Aluminum Garnet (YAG) Coatings for Engine Components Using a High Enthalpy Cascaded Arc Gun: Part I. J Therm Spray Tech 32, 1482–1504 (2023). https://doi.org/10.1007/s11666-023-01573-7

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