Three-dimensional simulation of porosity in plasma-sprayed alumina using microtomography and electrochemical impedance spectrometry for finite element modeling of properties

Abstract : Moving from a 2-dimensional to a 3-dimensional (3D) approach to microstructure and properties has been expected eagerly for a long while to result in a dramatic increase in the knowledge of thermally sprayed coatings. To meet these expectations, in the present study, microtomography and electrochemical impedance spectroscopy (EIS) were carried out to simulate the microstructure of plasma-sprayed alumina. As-sprayed and excimer laser-processed deposits were studied. Some unexpected but relevant results, e.g., regarding pore orientation in the coatings, could be obtained. EIS led to the establishment of an equivalent electrical circuit representation of the microstructure which enabled modeling of the insulating properties as a function of interfaces and pore interconnection. The pore interconnection was studied by microtomography. From this 3D simulation, a finite element analysis of Young's modulus properties was developed and compared to experiments. Using this approach, excimer laser surface processing was shown to be an innovative process to modify insulating characteristics of plasma-sprayed alumina.