Ih. Jung et al., A study of the microstructure of yttria-stabilized zirconia deposited by inductively coupled plasma spraying, J THERM SPR, 9(4), 2000, pp. 463-477
Zirconia stabilized with 20 wt.% yttria was deposited to a thick free-stand
ing type, similar to7 mm, by (inductively coupled plasma spraying) (ICPS),
The spheroidization of particles and the microstructure of deposits were an
alyzed. Spheroidization fraction dependence on spray parameters such as par
ticle size, H-2 gas mixing quantity, and probe position was studied. Effect
s of parameters on the spheroidization of particles were analyzed by ANOVA
(analysis of variance) (ANOVA). ANOVA results showed that the spheroidizati
on fraction largely depend on H-2 gas mixing quantity and particle size, an
d there are also some dependence on probe position and H-2 gas mixing quant
ity. After melting, particles kept their chemical composition homogeneously
from the center to their surface without segregation or evaporation. The d
egree of deformation of the diameter of the splat over the diameter of the
spheroidized particle was approximately 320% and splat thickness in the dep
osit varies between 2 mum and 3 mum depending on the deposition condition.
The yttrium concentration gradient of the interlayer boundary appeared line
ar in the range of 0.5 to 1 mum. X-ray diffraction analysis and a transmiss
ion electron microscope (TEM) micrograph showed that low yttrium content pa
rticles resulted in tetragonal phase in deposit. The major characteristics
of the microstructure of the thick free-standing deposit and solidification
mode were studied. Microstructure of the bottom part of the deposit repres
ented equiaxed or cellular structure. Equiaxed small grains prevailed when
the droplets were quenched rapidly on substrate. The middle part of the dep
osit showed large columnar grains, of about 100 mum thick and 300 mum long.
This may be due to high substrate or deposit temperatures and results in r
ecrystallization and grain growth.
The effects of the parameters, such as H-2 gas mixing quantity, particle si
ze, spraying distance, and probe position, on the microstructure of the dep
osits were evaluated. The H-2 gas mixing quantity of Ar/H-2 = 120/20 L/min
compared to Ar/H-2 = 120/10 L/min resulted in larger grain size and thicker
cellular in chill. Grain shapes were affected by the heat removal rate fro
m the deposit to its surrounding. Deposition with larger particle size show
ed heterogeneous grain size, insufficient particle melting, and incomplete
recrystallization, The effect of probe position was less than the others.