Thermal Barrier Coatings by Electrophoretic Deposition and evaluation of their durability

Electrophoretic Deposition (EPD) of 8 mol% yttria-stabilized zirconia from a propanol-based suspension were used for the preparation of thick deposits for thermal barrier coating high temperature applications. This work determined a single-layer thickness (for a deposit) near 35 ± 10 µm, achieved by adapting selected EPD parameters such as applied voltage and waveform, deposit time, suspension concentration, and additives. A multi-layer deposition approach followed by a single thermal treatment generated a TBC of total thickness of 200 ± 20 µm. Slow TGO growth at the HX-NiCrAlY / TBC interface as well as coating thermal resistance and thermal shock longevity were demonstrated. This research represents a step forward in developing EPD-based thermal barrier coatings, a technique compatible with complex geometries.