Processing of yttria partially stabilized zirconia thermal barrier coatings implementing a high-power laser diode

Several studies have been undertaken recently to adapt yttria partially stabilized zirconia (YPSZ) thermal barrier coating (TBC) characteristics during their manufacturing process. Thermal spraying implementing laser irradiation appears to be a possibility for modifying the coating morphology. This study aims to present the results of in situ (i.e., simultaneous treatment) and a posteriori (i.e., post-treatment) laser treatments implementing a high-power laser diode. In both cases, the coatings underwent atmospheric plasma spraying (APS). Laser irradiation was achieved using a 3 kW, average-power laser diode exhibiting an 848 nm wavelength. Experiments were performed to reach two goals. First, laser post-treatments aimed at building a map of the laser-processing parameter effects on the coating microstructure to estimate the laser-processing parameters, which seem to be suited to the change into in situ coating remelting. Second, in situ coating remelting aimed at quantifying the involved phenomena. In that case, the coating was treated layer by layer as it was manufactured. The input energy effect was studied by varying the scanning velocity (i.e., between 35 and 60 m/min), and consequently the irradiation time (i.e., between 1.8 and 3.1 ms, respectively). Experiments showed that coating thermal conductivity was lowered by more than 20% and that coating resistance to isothermal shocks was increased very significantly.