Plasma spray deposition of ultra high temperature ceramics

An innovative, proprietary methodology was developed to produce, by plasma spraying deposition, a ceramic composite containing SiC particles dispersed in a ZrB2 matrix. With such a technique both coatings and free standing parts were fabricated. In spite of the well known difficulty to obtain plasma sprayed coatings containing SiC, characterisation results evidenced that the used process did not affect the phase composition. Thermal and mechanical behaviour of the obtained material have been extensively characterized, in order to assess its applicability to specific space missions. In a first phase, tests were carried out on laboratory scale samples. Scope of the second phase of the activity, which is currently running, is the validation of the developed material in simulated operative conditions, by demonstrative components testing in a PWT (plasma wind tunnel) facility. A preliminary test campaign has been successfully completed, demonstrating that UHTC plasma sprayed coatings are able to withstand high temperature oxidising conditions.