Effects of ion beam assisted deposition, beam sharing and pivoting in EB-PVD processing of graded thermal barrier coatings

The development of advanced thermal barrier coatings of yttria stabilized zirconia (YSZ) that exhibit lower thermal conductivity through better control of electron beam-physical vapor deposition (EB-PVD) processing is of prime interest to both the aerospace and power industries. Recently, processing technology was developed to create graded TBCs by coupling ion beam assisted deposition (IBAD) with substrate pivoting in the alumina-YSZ system. The Electron Beam-1200 kW (EB-1200) PVD system was used to deposit a variety of TBC coatings with micron layered microstructures and reduced thermal conductivity of 1.5 W/mK. The use of IBAD produced fully stoichiometric coatings at a reduced substrate temperature of 600 °C and a reduced oxygen background pressure of 0.1 Pa. In addition to the process technology, the results of Direct Simulation Monte Carlo plume modeling and spectroscopic characterization of the PVD plumes are presented.