Hot corrosion behavior of BaLa2Ti3O10 exposed to calcium-magnesium-alumina-silicate at elevated temperatures

Calcium-magnesium-alumina-silicate (CMAS) attack has been regarded as one of the significant failure mechanisms for thermal barrier coatings (TBCs). In this study, CMAS corrosion behavior of BaLa₂Ti₃O₁₀, a novel TBC material, is investigated at 1300?°C and 1350?°C for 0.5?h, 4?h, 12?h and 24?h. Results reveal that BaLa₂Ti₃O₁₀ has high resistance to molten CMAS infiltration, attributable to the formation of a dense reaction layer. X-ray diffraction, scanning electron microscope, energy dispersive spectroscope, transmission electron microscope confirm that the layer consists of apatite, celsian and perovskite phases. With increased corrosion duration, the layer retains good phase stability and the thickness increases. The formation of corrosion products and the reaction layer are discussed according to a dissolution-reprecipitation mechanism and the optical basicity theory.     

Interaction of Gd2Si2O7 with CMAS melts for environmental barrier coatings

Environmental barrier coatings (EBCs) prevent the oxidation of ceramic matrix composites (CMC), which are used as components in gas turbines. However, EBCs deteriorate more rapidly in real environments, molten silicate deposits accelerate the deterioration of EBCs. In this study, high-temperature behavior sintered Gd₂Si₂O₇ with calcia-magnesia-alumina-silica (CMAS) melt at 1400 °C for 0.5, 2, 12, 48, and 100 h was investigated. HT-XRD results showed that at 1300 °C, CMAS and Gd₂Si₂O₇ chemically reacted to form Ca₂Gd₈(SiO₄)₆O₂ (apatite). The reaction layer became thicker as the heat-treatment time increased, and the thickness of the reaction layer has increased following a parabolic curve. With the extension of the reaction time from 0.5 to 100 h, the thickness of the reaction layer increased from approximately 98 to 315 µm. It was confirmed that Ca₂Gd₈(SiO₄)₆O₂ grew vertically on the Gd₂Si₂O₇ surface. Vertical and horizontal cracks were found after reacting at 1400 °C for 100 h, but no interfacial delamination occurred in this study. In addition, the effects of CaO:SiO₂ molar ratios, monosilicates (RE₂SiO₅) and disilicates (RE₂Si₂O₇), heat-treatment time, and cation size were determined and compared with the results of previous studies (Gd₂SiO_5, Yb₂SiO_5, and Er₂Si₂O₇).     

Tailoring the EB-PVD columnar microstructure to mitigate the infiltration of CMAS in 7YSZ thermal barrier coatings

The CMAS associated degradation of 7YSZ TBC layers is one of the serious problems in the aero engines that operate in dusty environments. CMAS infiltrates into TBC at high temperatures and stiffens the TBC which ultimately loses its strain tolerance and gets delaminated. The EB-PVD technique is used to coat TBCs exhibiting a columnar microstructure on parts such as blades and on vanes. By varying the EB-PVD process parameters, columnar morphology and porosity of the 7YSZ coating is changed and its effect on the CMAS infiltration behaviour is studied in detail. Two different TBC pore geometries were created and infiltration experiments were carried out at 1250 °C and 1225 °C for different time intervals. The 7YSZ coating with more ‘feathery’ features has resulted in higher CMAS resistance by at least by a factor of 2 than its less ‘feathery’ counterpart. These results are explained on the basis of a proposed physical model.     

Effects of Yb and Sc co-doping on the thermal properties and CMAS corrosion of garnet-type (Y3-xYbx)(Al5-xScx)O12 ceramics

Thermal barrier coatings with excellent thermal performance and corrosion resistance are essential for improving the performance of aero-engines. In this paper, (Y_3-xYb_x)(Al_5-xSc_x)O₁₂ (x = 0, 0.1, 0.2, 0.3) thermal barrier coating materials were synthesized by a combination of sol-gel method and ball milling refinement method. The thermal properties of the (Y_3-xYb_x)(Al_5-xSc_x)O₁₂ ceramics were significantly improved by increasing Yb and Sc doping content. Among designed ceramics, (Y_2.8Yb_0.2)(Al_4.8Sc_0.2)O₁₂ (YS-YAG) showed the lowest thermal conductivity (1.58 Wm^?1K^?1, at 800 °C) and the highest thermal expansion coefficient (10.7 × 10^?6 K^?1, at 1000 °C). In addition, calcium-magnesium- aluminum -silicate (CMAS) corrosion resistance of YS-YAG was further investigated. It was observed that YS-YAG ceramic effectively prevented CMAS corrosion due to its chemical inertness to CMAS as well as its unique and complex structure. Due to the excellent thermal properties and CMAS corrosion resistance, YS-YAG is considered to be prospective material for thermal barrier coatings.     

Corrosion behavior of air plasma spraying zirconia-based thermal barrier coatings subject to Calcium–Magnesium–Aluminum-Silicate (CMAS) via burner rig test

Three different kinds of thermal barrier coatings (TBCs) — 8YSZ, 38YSZ and a dual-layered (DL) TBCs with pure Y₂O₃ on the top of 8YSZ were produced on nickel-based superalloy substrate by air plasma spraying (APS). The Calcium–Magnesium–Aluminum-Silicate (CMAS) corrosion resistance of these three kinds of coatings were researched via burner rig test at 1350 °C for different durations. The microstructures and phase compositions of the coatings were characterized by SEM, EDS and XRD. With the increase of Y content, TBCs exhibit better performance against CMAS corrosion. The corrosion resistance against CMAS of different TBCs in descending was 8YSZ + Y₂O₃, 38YSZ and 8YSZ, respectively. YSZ diffused from TBCs into the CMAS, and formed Y-lean ZrO₂ in TBCs because of the higher diffusion rate and solubility of Y³⁺ in CMAS than Zr⁴⁺. At the same time, 38YSZ/8YSZ + Y₂O₃ reacts with CAMS to form Ca₄Y₆(SiO₄)₆O/Y_4·67(SiO₄)₃O with dense structure, which can prevent further infiltration of CMAS. The failure of 8YSZ coatings occurred at the interface between the ceramic coating and the thermally grown oxide scale (TGO)/bond coating. During the burner rig test, the Y₂O₃ layer of the DL TBCs peeled off progressively and the 8YSZ layer exposed gradually. DL coatings keep roughly intact and did not meet the failure criteria after 3 h test. 38YSZ coating was partially ablated, the overall thickness of the coating is thinned simultaneously after 2 h. Therefore, 8YSZ + Y₂O₃ dual-layered coating is expected to be a CMAS corrosion-resistant TBC with practical properties.     

Calcium–magnesium–aluminosilicate corrosion behaviors of rare-earth disilicates at 1400 °C

Environmental barrier coatings (EBCs) are used to prevent oxidation of underlying ceramic matrix composite (CMC) structural components in gas turbines. When the siliceous minerals deposit on the surface of EBCs, a glassy melt of calcium–magnesium–aluminosilicate (CMAS) will be formed, leading to the EBCs degradation. In this study, seven rare-earth disilicates (RE₂Si₂O₇, RE = Yb, Lu, La, Gd, Eu, Sc, and Y) were fabricated to analyze their CMAS corrosion behaviors. The results indicated that the RE₂Si₂O₇ could react with the CMAS in the temperature range of 1250–1350 °C. Reaction zones formed at the interfaces. For the Yb₂Si₂O₇, Lu₂Si₂O₇, La₂Si₂O₇, Eu₂Si₂O₇ and Gd₂Si₂O₇, the reaction zones dissolved into the molten CMAS and separated from the RE₂Si₂O₇. As for the Sc₂Si₂O₇ and Y₂Si₂O₇, the reaction zones could stay at the interface. They could effectively block the molten CMAS to penetrate into the RE₂Si₂O₇ and protect them from CMAS corrosion.     

Resistance of 2ZrO2·Y2O3 top coat in thermal/environmental barrier coatings to calcia‐magnesia‐aluminosilicate attack at 1500°C

Internally cooled, hollow SiC‐based ceramic matrix composites (CMCs) components that may replace metallic components in the hot section of future high‐efficiency gas‐turbine engines will require multilayered thermal/environmental barrier coatings (T/EBCs) for insulation and protection. In the T/EBC system, the thermally insulating outermost (top coat) ceramic layer must also provide resistance to attack by molten calcia‐magnesia‐aluminosilicate (CMAS) deposits. The interactions between a potential candidate for top coat made of air‐plasma‐sprayed (APS) 2ZrO₂·Y₂O₃ solid‐solution (ss) ceramic and two different CMASs (sand and fly ash) are investigated at a relevant high temperature of 1500°C. APS 2ZrO₂·Y₂O₃(ss) top coat was found to resist CMAS penetration at 1500°C for 24 hours via reaction products that block CMAS penetration pathways. In situ X‐ray diffraction (XRD) studies have identified the main reaction product to be an Ca‐Y‐Si apatite, and have helped elucidate the proposed mechanism for CMAS attack mitigation. Ex situ electron microscopy and analytical spectroscopy studies have identified the advantageous characteristics of the reaction products in helping the CMAS attack mitigation in the APS 2ZrO₂·Y₂O₃(ss) coating at 1500°C. Finally, the Y³⁺ solubility limit and transport behavior are identified as potential comparative tools for assessing the CMAS resistance ability of top‐coat ceramics.     

Wetting,infiltration and interaction behavior of CMAS towards columnar YSZ coatings deposited by plasma spray physical vapor

Thermal barrier coatings (TBCs) produced by electron beam physical vapor deposition (EB-PVD) or plasma spray (PS) usually suffer from molten calcium-magnesium-alumino-silicate (CMAS) attack. In this study, columnar structured YSZ coatings were fabricated by plasma spray physical vapor deposition (PS-PVD). The coatings were CMAS-infiltrated at 1250?°C for short terms (1, 5, 30?min). The wetting and spreading dynamics of CMAS melt on the coating surface was in-situ investigated using a heating microscope. The results indicate that the spreading evolution of CMAS melt can be described in terms of two stages with varied time intervals and spreading velocities. Besides, the PS-PVD columnar coating (～100?μm thick) was fully penetrated by CMAS melt within 1?min. After the CMAS attack for 30?min, the original feathered-YSZ grains (tetragonal phase) in both PS-PVD and EB-PVD coatings were replaced by globular shaped monoclinic ZrO₂ grains in the interaction regions.     

Microscale fracture mechanisms of HfO2-Si environmental barrier coatings

Environmental barrier coatings (EBCs) play a vital role in protecting advanced turbine components subjected to extreme service environments, where mechanical, thermal and chemical behaviors typically dominate the design criteria. This study focuses on investigating the mechanical properties of individual phases within a HfO₂-Si ceramic matrix composite (CMC) structure through implementation of notched microcantilevers and micropillar splitting experiments. The microcantilever experiments resulted in fracture toughnesses ranging between 1.38–1.52 MPa-m^1/2 for the Si-rich phase and 2.26–2.38 MPa-m^1/2 for the HfO₂-rich phase depending on the method of analysis. From our micropillar splitting experiments, we found fracture toughnesses of 1.13 ± 0.39 MPa-m^1/2 for the Si-rich phase and 1.18 ± 0.26 MPa-m^1/2 for the HfO₂-rich phase. Comparisons with bulk single edge V-notched beams (SEVNBs) suggest the micropillar results are accurate whereas the microcantilever experiments may overestimate K_IC of the Si-rich and HfO₂-rich phases by ?0.2–1.2 MPa-m^1/2, most likely, due to dimensional errors that affect specimen and model compliances.     

Heat-treated lanthanum magnesium hexaaluminate coatings exposed to molten calcium-magnesium-alumino-silicate

LaMgAl₁₁O₁₉ (LMA) coatings usually have a large amount of amorphous phase due to the rapid cooling during spraying, which will not benefit the service lifetime in aeroengine. Fortunately, the thermal cycling lifetime of LMA TBCs can be improved by heat treatment. Moreover, the hot corrosion degradation with calcium-magnesium-alumino-silicate (CMAS) attracts much attention recently. Therefore, to clarify the influence of heat treatment on CMAS corrosion behaviour, plasma-sprayed LMA coatings were isothermally heat-treated and then exposed to CMAS. Results indicate that heat treatment promoted a crystallization of LMA coatings, but the molten CMAS had completely penetrated into LMA coatings along the increased and widened vertical microcracks. It is the isotropic pores that determine the penetration kinetics of CMAS to LMA. CaAl₂Si₂O₈ and MgAl₂O₄ were the predominant reaction products in the superficial layer, while Ca₃La₆(SiO₄)₆ interpenetrated with the residual LMA in the inner layer, forming a corroded bilayer for LMA coatings.     

CMAS corrosion resistance,thermal shock resistance and numerical simulation of novel surface micromesh thermal barrier coatings

Thermal barrier coatings (TBCs) are widely used as insulating layers to protect the underlying metallic structure of gas turbine blades. However, the thermal cycling performance of TBCs is affected by their complex working environments, which may shorten their service life. Previous studies have shown that preparing a mesh structure in the bonding layer can relieve thermal stress and improve the bonding strength, thereby prolonging the service life of TBCs. In this paper, a micromesh structure was prepared on the surface of the bonding layer via wet etching. The microstructure and failure mechanism of the micromesh TBCs after CMAS (CaO-MgO-Al₂O₃-SiO₂) thermal erosion were investigated. Numerical simulation was combined with thermal shock experiments to study the stress distribution of the micromesh-structured TBCs. The results showed that the circular convex structure can effectively improve the CMAS corrosion resistance and thermal shock resistance of TBCs.     

航空发动机用热障涂层的CMAS侵蚀及防护

热障涂层作为航空发动机的关键技术,一旦在使用过程中失效将导致严重的后果。然而,热障涂层在使用过程中不可避免地会接触到钙镁铝硅酸盐(CMAS),引发涂层剥落,使高温合金直接暴露在高温燃气中,带来巨大的危险。因此,热障涂层的CMAS侵蚀及防护问题近年来得到了广泛关注。本文在介绍传统氧化钇稳定氧化锆(YSZ)涂层受CMAS侵蚀现状的基础上,明确了CMAS侵蚀YSZ的化学作用过程,阐明了YSZ涂层的失效机制,比较了不同种类CMAS的侵蚀效果,总结了目前热障涂层抵抗CMAS侵蚀的主要方法,并阐述了基于自损型防护原理开展的新型热障涂层材料的CMAS侵蚀行为研究进展,以期为未来航空发动机用热障涂层陶瓷材料的选择和CMAS防护提供有益参考。