Additive Manufacturing of Columnar Thermal Barrier Coatings by Laser Cladding of Ceramic Feedstock

This study presents a new laser-cladding-based additive manufacturing technique named Clad2Z. Using a robot-mounted confocal powder nozzle with axial infrared laser beam, ceramic columns with a diameter of 450 mu m and an adjustable height are developed. Influence of laser parameters and robot movements on shape and microstructure is analyzed. As an example application, the common material yttria-stabilized zirconia (YSZ) is used to deposit columnar-structured thermal barrier coatings (TBCs). The excellent thermal cycling performance of the Clad2Z samples is demonstrated by burner rig tests and comparing lifetime and failure mechanism with conventional TBC systems.

Automated summary

This study introduces a new laser-cladding-based additive manufacturing technique called Clad2Z, which utilizes a robot-mounted confocal powder nozzle and axial infrared laser beam to develop ceramic columns. The influence of laser parameters and robot movements on shape and microstructure is analyzed, and the excellent thermal cycling performance of Clad2Z samples in terms of thermal barrier coatings is demonstrated through burner rig tests and comparison with conventional TBC systems.