First Steps towards Understanding the Deposition Mechanisms of YSZ-Polyester Composite Powders via Atmospheric Plasma Spraying (APS)

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Andre Liberati, andre.liberati@unilim.fr; Erwan Bussy, erwan.bussy@etu.unilim.fr; Anouck Anglade, anouck.anglade@etu.unilim.fr; Jerome Pohier, jerome.pohier@safrangroup.com;
Guillaume Fradet, guillaume.fradet@safrangroup.com; Alain Denoirjean, alain.denoirjean@unilim.fr; 

Abradable coatings are critical in the compressor and turbine sections of turbine engines, to minimize clearance between blade tips and the casing, and to protect turbine blades from potential contact damage. Ceramic-polymer coatings such as YSZ-polymer are typically plasma sprayed in the hot sections of turbine engines. In this case, the ceramic provides structural integrity to the coating at elevated temperatures, while the polymer acts as a porosity generator, that ensures desired abradability of the coating. But while these composite coatings have become industrial standards, the corresponding deposition mechanisms are not well documented. Notably, the effect of the spraying parameters on the individual feedstock constituents and on the ensuing coating are not well established. This work aims to explore the effect of the main spraying parameters on the deposition of a composite YSZ-polyester powder via splat tests and the observation of individual splats via Focused Ion Beam Scanning Electron Microscopy (FIB SEM). These results were correlated with spray diagnostics (particle velocity and temperature), measured with an Accuraspray system.

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Erscheinungsdatum

March 2026

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