Deposition of ceramic thermal barrier coatings by gas flow sputtering

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The project "deposition of ceramic thermal barrier coatings by gas flow sputtering" is intended to study the suitability of gas flow sputtering for applications in gas turbines. Although the gas flow sputtering technique has a comparably low deposition rate, it is considerably more cost-efficient than the EB-PVD method. Coatings produced by gas flow sputtering have a microstructure similar to that of EB-PVD-coatings and should thus be superior to APS coatings with respect to their life time. Furthermore, the microstructure can be controlled within a wide range. So far, no systematic investigations of the dependence of the microstructure on the process parameters have been published. In the first project phase, the parameter influence on the process has been determined using a simplified model system. Promising microstructures were identified. Furthermore, first results on damage and failure during thermal cycling were obtained, showing that damage is determined by the microstructure of the TGO and by the stiffness and sintering of the thermal barrier coating. In the newly proposed project phase, the interplay of these parameters and their influence on the coating life time will be investigated in detail.