Thermal Spray and Multiphase Flow Laboratories
Department of Mechanical and Industrial Engineering

Numerical Study of Suspension Injection in Plasma Spraying Process


Dr. Fadhel Ben Ettouil

Dr. Ali Dolatabadi


Dr. Mamoun Medraj, Concordia University




Thermal barrier coatings (TBC) are layer systems deposited on substrate to protect components from high temperature or to reduce thermal loss for maximum utilisation of energy by operating at optimum allowable temperature limits. Four primary constituents compose a thermal insulation system:

- the ceramic top-coat; i.e., the ceramic TBC, which is commonly manufactured using air plasma spray process

- the substrate materials, most commonly a superalloy

- an aluminum containing bond-coat (BC) located between the metallic substrate and the ceramic TBC

- a thermally grown oxide (TGO), predominantly α-alumina that growths between the ceramic TBC and the BC.



Figure 1 : Schematic of the structure of a thermal barrier coating with a temperature profile

Thermal spray coatings in general and more specifically thermal barrier coatings (TBC's) are unavoidable in several industrial sectors to protect load bearing substrates from severe temperature and chemcial environments, mainly in the aerospace industry and aircraft engine. the following figure details the parts of the aircraft engine using plasma spray coatings.


Figure 2 : The parts of an aircraft engine using a plasma spray coating


The aim of this work is the generation of sprayed thermal barrier coatings in order to improve part lifetime. APS and SPA coatings will be compared in terms of insulation (thermal conductivity and diffusivity) and life (resistance to shock and thermal cycling)

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