Performance-Tunable Thermal Barrier Coating for Carbon Fiber-Reinforced Plastic Composite Materials via Flame Spraying

Abstract

Thermal barrier coatings (TBCs) are essential for improving the heat resistance of materials operating in high-temperature environments. This paper proposes a new method for manufacturing double-layered TBC with graded porosity for carbon fiber-reinforced plastic (CFRP) composites. The TBC was created by a flame spraying process, consisting of relatively dense and porous layers: (1) a dense layer was produced by spraying yttria-stabilized zirconia (YSZ) particles directly onto neat carbon fabric substrate and (2) a porous layer was prepared by co-spraying YSZ particles with sacrificial polyetheretherketone (PEEK) particles. The porosity of the porous layer was controlled by varying a PEEK injection distance (D) and a PEEK feed rate (R). The correlation between porosity and thermal conductivity of the TBC layer was investigated to assess its thermal barrier performance. The TBC was fabricated with the D of 5 cm and the R of 1.0 g/min, and double-layered/CFRP composites were manufactured using partially cured CFRP and vacuum forming. The 660-μm-thick TBC with 34% porosity and 0.27 W/m？K thermal conductivity protected the CFRP substrate remarkably under the subjected torch at 500°C, as the TBC layer reduced the surface temperature of CFRP beyond (TCFRP) 230°C. Thermomechanical analysis, following thermal shock tests, revealed that the double-layered TBC/CFRP composite retained 87% and 75% of its pristine flexural strength and modulus, respectively, while the neat CFRP composite was completely burnt out. This study explored the application of flame spray technology to develop highly effective double-layered TBCs with tunable porosity to maximize their thermal barrier performances. All results from the current study provide new insights into the design and development of CFRP composites and, by extension, TBCs for fiber composites, which will benefit a wide range of lightweight high-temperature applications.