Phase structure and thermal conductivities of Er2O3 stabilized ZrO2 toughened Gd2Zr2O7 ceramics for thermal barrier coatings

3.5 mol% Er₂O₃ stabilized ZrO₂ (ErSZ) and Gd₂Zr₂O₇ powders were produced by a chemical co-precipitation and calcination method, and ErSZ was used to toughen Gd₂Zr₂O₇. The phase structure, toughness and thermal conductivities of ErSZ toughened Gd₂Zr₂O₇ ceramics were investigated. When the ErSZ content was below 15 mol%, the compound consisted of pyrochlore phase, the ordering degree of which decreased with the increase of the ErSZ content. High ErSZ doping led to the formation of metastable tetragonal (t′) phase in the compound. The addition of ErSZ in Gd₂Zr₂O₇ benefited its toughness, mainly attributable to the presence of t′ phase in the compound. With the increase of the ErSZ content in the compound, the thermal conductivity first decreased and then showed an upward tendency, and 10 mol% ErSZ toughened Gd₂Zr₂O₇ exhibited the lowest thermal conductivity.     

Preparation of nanostructured Gd2Zr2O7-LaPO4 thermal barrier coatings and their calcium-magnesium-alumina-silicate (CMAS) resistance

Nanostructured 30 mol% LaPO₄ doped Gd₂Zr₂O₇ (Gd₂Zr₂O₇-LaPO₄) thermal barrier coatings (TBCs) were produced by air plasma spraying (APS). The coatings consist of Gd₂Zr₂O₇ and LaPO₄ phases, with desirable chemical composition and obvious nanozones embedded in the coating microstructure. Calcium-magnesium-alumina- silicate (CMAS) corrosion tests were carried out at 1250 °C for 1–8 h to study the corrosion resistance of the coatings. Results indicated that the nanostructured Gd₂Zr₂O₇-LaPO₄ TBCs reveals high resistance to penetration by the CMAS melt. During corrosion tests, an impervious crystalline reaction layer consisting of Gd-La-P apatite, anorthite, spinel and tetragonal ZrO₂ phases forms on the coating surfaces. The layer is stable at high temperatures and has significant effect on preventing further infiltration of the molten CMAS into the coatings. Furthermore, the porous nanozones could gather the penetrated molten CMAS like as an absorbent, which benefits the CMAS resistance of the coatings.     

Marked reduction in the thermal conductivity of (La0.2Gd0.2Y0.2Yb0.2Er0.2)2Zr2O7 high-entropy ceramics by substituting Zr4+ with Ti4+

The (La_0.2Gd_0.2Y_0.2Yb_0.2Er_0.2)₂(Zr_1-xTi_x)₂O₇ (x = 0–0.5) high-entropy ceramics were successfully prepared by a solid state reaction method and their structures and thermo-physical properties were investigated. It was found that the high-entropy ceramics demonstrate pure pyrochlore phase with the composition of x = 0.1–0.5, while (La_0.2Gd_0.2Y_0.2Yb_0.2Er_0.2)₂Zr₂O₇ shows the defective fluorite structure. The sintered high-entropy ceramics are dense and the grain boundaries are clean. The grain size of high-entropy ceramics increases with the Ti⁴⁺ content. The average thermal expansion coefficients of the (La_0.2Gd_0.2Y_0.2Yb_0.2Er_0.2)₂(Zr_1-xTi_x)₂O₇ high-entropy ceramics range from 10.65 × 10^?6 K^?1 to 10.84 × 10^?6 K^?1. Importantly, the substitution of Zr⁴⁺ with Ti⁴⁺ resulted in a remarkable decrease in thermal conductivity of (La_0.2Gd_0.2Y_0.2Yb_0.2Er_0.2)₂(Zr_1-xTi_x)₂O₇ high-entropy ceramics. It reduced from 1.66 W m^?1 K^?1 to 1.20 W m^?1 K^?1, which should be ascribed to the synergistic effects of mass disorder, size disorder, mixed configuration entropy value and rattlers.     

Influence of Yb Substitution for La on Thermophysical Property of La2AlTaO7 Ceramics

The (La_1−xYb_x)₂AlTaO₇ ceramics were synthesized by pressureless sintering process at 1600 °C for 10 h in air. The crystal phase, microstructure and thermophysical properties were investigated. Results show that pure (La_1−xYb_x)₂AlTaO₇ cermics with single weberite structure are prepared successfully. Owing to the reduction of crystal-lattice tolerance-factor, the thermal conductivity of (La_1−xYb_x)₂AlTaO₇ (x>0) ceramics increases with increasing Yb₂O₃ fraction at identical temperatures, which is lower than that of La₂AlTaO₇. Due to the relatively high electro-negativity of Yb element, the addition of Yb₂O₃ increases the thermal expansion coefficient of (La_1−xYb_x)₂AlTaO₇ ceramics.     

Influence of Gd2O3 addition on thermophysical properties of La2Ce2O7 ceramics for thermal barrier coatings

In order to develop new candidate ceramic materials for thermal barrier coatings (La_1?xGd_x)₂Ce₂O₇ ceramics were prepared by pressureless-sintering at 1600 °C for 10 h in air. The phase structure, micro-morphology and thermophysical properties of (La_1?xGd_x)₂Ce₂O₇ ceramics were investigated, respectively. XRD results revealed that pure (La_1?xGd_x)₂Ce₂O₇ ceramics with defect fluorite structure were synthesized and SEM showed that their microstructures were dense and no other phases existed among the particles. With the increasing temperature, their thermal expansion coefficients increased, while the thermal conductivities decreased. The thermophysical results indicated that thermal expansion coefficients of these ceramics were higher than that of 8YSZ, and their thermal conductivities were much lower than that of 8YSZ. The lower thermal conductivities of these ceramics were mainly attributed to more oxygen vacancies and substitution atoms. These results imply that the (La_1?xGd_x)₂Ce₂O₇ ceramics can be explored as candidate materials for the ceramic layer in TBC system.     

Thermo-physical and mechanical properties of Yb2O3 and Sc2O3 co-doped Gd2Zr2O7 ceramics

Ceramic materials for the thermal barrier coating (TBC) application of Gd₂Zr₂O₇ (GZO), (Gd_0.94Yb_0.06)₂Zr₂O₇ (GYb_0.06Z), (Gd_0.925Sc_0.075)₂Zr₂O₇ (GSc_0.075Z), (Gd_0.865Sc_0.075Yb_0.06)₂Zr₂O₇ (GSc_0.075Yb_0.06Z), and (Gd_0.8Sc_0.1Yb_0.1)₂Zr₂O₇ (GSc_0.1Yb_0.1Z) were successfully synthesized by chemical co-precipitation. The effects of the doping of Sc₂O₃ and Yb₂O₃ on the phases, thermo-physical and mechanical properties of the ceramics were investigated. The results show that both Yb₂O₃ and Sc₂O₃ doping promoted the phase transition of GZO from pyrochlore to fluorite. All the Sc₂O₃-doped samples exhibited enhanced fracture toughness, as compared to the undoped sample. Furthermore, the GSc_0.075Yb_0.06Z sample revealed a thermal conductivity of ~0.8 W/mK at 1200 °C, which was nearly 30% lower than that of the undoped sample. The associated mechanisms related to the effects of the doping on the thermophysical and mechanical properties are discussed.     

Influence of ytterbium- and samarium-oxides codoping on structure and thermal conductivity of zirconate ceramics

To increase operating temperature and improve performance of gas-turbine engines, it is urgently needed to develop new thermal barrier oxides with a lower thermal conductivity than 6–8 wt.% yttria-stabilized zirconia. (Yb_xSm_1?x)₂Zr₂O₇ (0 ≤ x ≤ 1.0) ceramics were synthesized by pressureless-sintered at 1700 °C for 10 h in air. The relative density, phase structure, morphology and thermal diffusivity coefficients of (Yb_xSm_1?x)₂Zr₂O₇ ceramics were investigated by the Archimedes method, X-ray diffraction, scanning electron microscopy and laser-flash method. Sm₂Zr₂O₇ and (Yb_0.1Sm_0.9)₂Zr₂O₇ ceramics exhibit a pyrochlore structure, while (Yb_xSm_1?x)₂Zr₂O₇ (0.3 ≤ x ≤1.0) ceramics have a defect fluorite-type structure. The thermal conductivities of (Yb_xSm_1?x)₂Zr₂O₇ ceramics first gradually decrease with increasing temperature, and then increase slightly above 800 °C due to the increased radiation contribution. YbSmZr₂O₇ ceramics have the lowest thermal conductivity over the entire temperature range, which is caused by the reduction of cation mean free path in ytterbium–samarium zirconate system.     

Evolution of hot corrosion resistance of YSZ,Gd2Zr2O7, and Gd2Zr2O7 + YSZ composite thermal barrier coatings in Na2SO4 + V2O5 at 1050 °C

This paper compares the hot corrosion performance of yttria stabilized zirconia (YSZ), Gd₂Zr₂O₇, and YSZ + Gd₂Zr₂O₇ composite coatings in the presence of molten mixture of Na₂SO₄ + V₂O₅ at 1050 °C. These YSZ and rare earth zirconate coatings were prepared by atmospheric plasma spray (APS). Chemical interaction is found to be the major corrosive mechanism for the deterioration of these coatings. Characterizations using X-ray diffraction (XRD) and scanning electron microscope (SEM) indicate that in the case of YSZ, the reaction between NaVO₃ and Y₂O₃ produces YVO₄ and leads to the transformation of tetragonal ZrO₂ to monoclinic ZrO₂. For the Gd₂Zr₂O₇ + YSZ composite coating, by the formation of GdVO₄, the amount of YVO₄ formed on the YSZ + Gd₂Zr₂O₇ composite coating is significantly reduced. Molten salt also reacts with Gd₂Zr₂O₇ to form GdVO₄. Under a temperature of 1050 °C, Gd₂Zr₂O₇ based coatings are more stable, both thermally and chemically, than YSZ, and exhibit a better hot corrosion resistance.     

Gd2Zr2O7 and Nd2Zr2O7 pyrochlore prepared by aqueous chemical synthesis

Pyrochlore structured Gd₂Zr₂O₇ and Nd₂Zr₂O₇ are produced via complex precipitation processing. A suite of characterization techniques, including FTIR, Raman, X-ray and electron diffraction, TEM, SEM as well as nitrogen sorption are employed to investigate the structural and grain size evolution of the synthesized and calcined powder. Results show that Gd₂Zr₂O₇ with the pyrochlore structure are produced after calcination at 1400 °C for 12 h while Nd₂Zr₂O₇ has already formed the pyrochlore structure at 1200 °C. This method allows the formation of dense materials at relatively low temperature, with bulk densities over 92% of the theoretical values achieved after sintering at 1400 °C for 50 h. This unique aqueous synthetic method provides a simple pathway to produce pyrochlore lanthanide zirconate without using either organic solvent and/or mechanical milling procedures, making the synthesis protocol an attractive potential scale-up production of highly refractory ceramics.     

Improvement on the phase stability,mechanical properties and thermal insulation of Y2O3-stabilized ZrO2 by Gd2O3 and Yb2O3 co-doping

Gd₂O₃ and Yb₂O₃ co-doped 3.5 mol% Y₂O₃–ZrO₂ and conventional 3.5 mol% Y₂O₃–ZrO₂ (YSZ) powders were synthesized by solid state reaction. The objective of this study was to improve the phase stability, mechanical properties and thermal insulation of YSZ. After heat treatment at 1500 °C for 10 h, 1 mol% Gd₂O₃–1 mol% Yb₂O₃ co-doped YSZ (1Gd1Yb-YSZ) had higher resistance to destabilization of metastable tetragonal phase than YSZ. The hardness of 5 mol% Gd₂O₃–1 mol% Yb₂O₃ co-doped YSZ (5Gd1Yb-YSZ) was higher than that of YSZ. Compared with YSZ, 1Gd1Yb-YSZ and 5Gd1Yb-YSZ exhibited lower thermal conductivity and shorter phonon mean free path. At 1300 °C, the thermal conductivity of 5Gd1Yb-YSZ was 1.23 W/m K, nearly 25% lower than that of YSZ (1.62 W/m K). Gd₂O₃ and Yb₂O₃ co-doped YSZ can be explored as a candidate material for thermal barrier coating applications.     

In situ characterizations of mechanical behaviors of freestanding (Gd0.9Yb0.1)2Zr2O7 coatings by bending tests under different temperatures based on digital image correlation

It is important to investigate the high-temperature mechanical properties and failure mechanisms of Gd₂Zr₂O₇ ceramic materials for the development of novel thermal barrier coatings. Freestanding (Gd_0.9Yb_0.1)₂Zr₂O₇ (GYbZ) coatings were prepared by supersonic plasma sprayed technique. A modified high-temperature in situ experimental system (up to 1500 °C) with the aid of digital image correlation technique was used to evaluate the fracture strength and flexural modulus of GYbZ coatings using three-point bending tests, and the fracture toughness was studied by single edge notched beam experiments. In addition, the extended finite element analysis was used to estimate the critical energy release rate of GYbZ coatings through the aforementioned experimental data. The effect of test temperature on the mechanical properties, cracking and fracture morphology of freestanding GYbZ coatings was discussed under bending loads. The results are useful for understanding high-temperature failure mechanisms of multilayered GYbZ thermal barrier coatings.     

Phase stability and thermal conductivity of RE2O3 (RE=La,Nd, Gd,Yb) and Yb2O3 co-doped Y2O3 stabilized ZrO2 ceramics

Y₂O₃ stabilized ZrO₂ (YSZ) has been considered as the material of choice for thermal barrier coatings (TBCs), but it becomes unstable at high temperatures and its thermal conductivity needs to be further reduced. In this study, 1 mol% RE₂O₃ (RE=La, Nd, Gd, Yb) and 1 mol% Yb₂O₃ co-doped YSZ (1RE1Yb–YSZ) were fabricated to obtain improved phase stability and reduced thermal conductivity. For 1RE1Yb–YSZ ceramics, the phase stability of metastable tetragonal (t′) phase increased with decreasing RE³⁺ size, mainly attributable to the reduced driving force for t′ phase partitioning. The thermal conductivity of 1RE1Yb–YSZ was lower than that of YSZ, with the value decreasing with the increase of the RE³⁺ size mainly due to the increased elastic field in the lattice, but 1La1Yb–YSZ exhibited undesirably high thermal conductivity. By considering the comprehensive properties, 1Gd1Yb–YSZ ceramic could be a good potential material for TBC applications.     

Effect of multi-component rare-earth doping on maintaining structure stability of RE2Zr2O7 (RE = La,Sm, Gd,Y, Yb) coatings under thermal cycling

Inspired by the high entropy effects of high-entropy components, a novel high-entropy rare-earth zirconate (La_1/5Gd_1/5Y_1/5Sm_1/5Yb_1/5)₂Zr₂O₇ (HEC-LZ) was designed and successfully synthesized in this work. In addition, two binary rare-earth doped zirconates (RE-LZ), (La_1/3Sm_1/3Yb_1/3)₂Zr₂O₇ (LSYZ) and (La_1/3Gd_1/3Y_1/3)₂Zr₂O₇ (LGYZ), were proposed using the same rare-earth elements for comparison. The thermal barrier coatings with LZ-based ceramic top layer were prepared by spray granulation, solid-phase synthesis and atmospheric plasma spraying techniques. The as-synthesized LZ-based ceramics are all dominated by the pyrochlore phase. Under 1000 °C, the thermal cycling performances of the three coatings were studied. The microstructure evolution and crack expansion during the failure process were investigated in detail. The strengthening mechanism and the cause of coating spallation are proposed in combination with mechanical properties and thermal matching analysis. The results showed that compared with the undoped LZ coating, the thermal shock life of LGYZ coating, LSYZ coating and HEC-LZ coating is improved by nearly 46%, 27% and 57%, respectively. Due to the characteristics of high randomness, HEC-LZ ceramic has a large lattice distortion than RE-LZ ceramics, resulting in a higher coefficient of thermal expansion and fracture toughness, which contributes to maintaining the structure stability of coatings under thermal stress.     

Characterisation of the microstructure and thermal properties of Nd2Zr2O7 and Nd2Zr2O7/YSZ thermal barrier coatings

The microstructure of following thermal barrier coatings (TBC) was characterised in this paper: monolayer coatings Nd₂Zr₂O₇ and 8YSZ; a double ceramic layered (DCL) coating. Coatings were characterised by thicknesses that did not exceed 300 μm and porosities of approx. 5%. The chemical and phase composition analysis of the DCL layers revealed an external Nd₂Zr₂O₇ ceramic layer approx. 80 μm thick, a transitional zone approx. 120 μm thick and an internal 8YSZ layer 100 μm thick. For the case of the monolayer coating, the Nd₂Zr₂O₇ pyrochlore phase was the only one-phase component. The surface topography of both TBC systems was typical for plasma sprayed coatings, and compressive stress state had a value of approx. 5–10 MPa. Measurements of the thermal parameters, i.e., thermal diffusivity, point to considerably better insulative properties for both new types of layers when compared to the standard 8YSZ layers.     

Phase structure and thermophysical properties of co-doped La2Zr2O7 ceramics for thermal barrier coatings

La₂Zr₂O₇ has high melting point, low thermal conductivity and relatively high thermal expansion which make it suitable for application as high-temperature thermal barrier coatings. Ceramics including La₂Zr₂O₇, (La_0.7Yb_0.3)₂(Zr_0.7Ce_0.3)₂O₇ and (La_0.2Yb_0.8)₂(Zr_0.7Ce_0.3)₂O₇ were synthesized by solid state reaction. The effects of co-doping on the phase structure and thermophysical properties of La₂Zr₂O₇ were investigated. The phase structures of these ceramics were identified by X-ray diffraction, showing that the La₂Zr₂O₇ ceramic has a pyrochlore structure while the co-doped ceramics (La_0.7Yb_0.3)₂(Zr_0.7Ce_0.3)₂O₇ and the (La_0.2Yb_0.8)₂(Zr_0.7Ce_0.3)₂O₇ exhibit a defect fluorite structure, which is mainly determined by ionic radius ratio r(A_av.³⁺)/r(B_av.⁴⁺). The measurements for thermal expansion coefficient and thermal conductivity of these ceramics from ambient temperature to 1200 °C show that the co-doped ceramics (La_0.7Yb_0.3)₂(Zr_0.7Ce_0.3)₂O₇ and (La_0.2Yb_0.8)₂(Zr_0.7Ce_0.3)₂O₇ have a larger thermal expansion coefficient and a lower thermal conductivity than La₂Zr₂O₇, and the (La_0.2Yb_0.8)₂(Zr_0.7Ce_0.3)₂O₇ shows the more excellent thermophysical properties than (La_0.7Yb_0.3)₂(Zr_0.7Ce_0.3)₂O₇ due to the increase of Yb₂O₃ content.     

Hot corrosion behavior of V2O5-coated Gd2Zr2O7 ceramic in air at 700–850 °C

Gd₂Zr₂O₇ ceramic was prepared by solid state reaction at 1650 °C for 10 h in air, and exhibited a defect fluorite-type structure. Reaction between molten V₂O₅ and Gd₂Zr₂O₇ ceramic was investigated at temperatures ranging from 700 to 850 °C using an X-ray diffractometer (XRD) and scanning electron microscopy (SEM). Molten V₂O₅ reacted with Gd₂Zr₂O₇ to form ZrV₂O₇ and GdVO₄ at 700 °C; however, in a temperature range of 750–850 °C, molten V₂O₅ reacted with Gd₂Zr₂O₇ to form GdVO₄ and m-ZrO₂. Two different reactions observed at 700 °C and 750–850 °C could be explained based on the thermal instability of ZrV₂O₇.     

Synthesis and thermal stability of Re2Zr2O7, (Re = La,Gd) and La2(Zr1−xCex)2O7−δ compounds under reducing and oxidant atmospheres for thermal barrier coatings

Rare-earth zirconates and cerates have attracted particular interest for thermal barrier coating (TBC) applications due to their advantageous thermal properties, such as a low conductivity and efficient phase stability at elevated temperatures. This study focuses on synthesising La₂Zr₂O₇, Gd₂Zr₂O₇, La₂Ce₂O_7?γ and La₂(Zr_0.7Ce_0.3)O_7?γ compounds via two soft chemistry processes, alkoxide and citrate synthesis. Thermal analysis, X-ray diffraction (XRD) and scanning electron microscope observations were used to analyse the powder after calcinations under air. Chemical reactivity tests under a reducing atmosphere were performed at 1400 °C and investigated by XRD analysis. It was found that the lanthanum and gadolinium zirconates are the most stable and interesting materials under an Ar_(g)/3%H_2(g) atmosphere.     

High capacity immobilization of U3O8 in Gd2Zr2O7 ceramics via appropriate occupation designs

An optimal occupation of U⁴⁺ and U⁶⁺ in Gd₂Zr₂O₇ is necessary for a really high immobilization capacity of U₃O₈ in Gd₂Zr₂O₇ based waste forms. Based on four kinds of occupation methods, a series of U₃O₈-doped Gd₂Zr₂O₇ compositions have been synthesized. The effects of U₃O₈ content on the phase and microstructure evolution of Gd₂Zr₂O₇ pyrochlore waste forms were investigated. Detailed XRD analysis show that the four sets of samples exhibit a single defect fluorite structure within the range of 0<x≤0.4, 0<x≤0.66, 0<x≤0.6 and 0<x≤1, respectively. The highest solubility of U₃O₈ is about 82.29 wt% when the occupation design (U⁴⁺ and U⁶⁺ substitute for Gd and Zr, respectively) was employed. It was found that the cell parameters of compounds in Set A (Gd_2–3x(U⁴⁺_xU⁶⁺_2x)Zr₂O_7+7x/2) decrease with increasing _x, while those of the other compositions increase. Moreover, the uranium are almost homogeneously distributed in all samples.     

Influence of Yb3+ doping on phase stability and thermophysical properties of (Y1-xYbx)3Al5O12 under high temperature

In this work, Yb³⁺ was selected to replace the Y³⁺ in yttrium aluminum garnet (YAG) in order to reduce its thermal conductivity under high temperature. A series of (Y_1-xYb_x)₃Al₅O₁₂ (x=0, 0.1, 0.2, 0.3, 0.4) ceramics were prepared by solid-state reaction at 1600 °C for 10 h. The microstructure, thermophysical properties and phase stability under high temperature were investigated. The results showed that all the Yb doped (Y_1-xYb_x)₃Al₅O₁₂ ceramics were comprised of a single garnet-type Y₃Al₅O₁₂ phase. The thermal conductivities of (Y_1-xYb_x)₃Al₅O₁₂ ceramics firstly decreased and subsequently increased with Yb ions concentration rising from room temperature to 1200 °C. (Y_0.7Yb_0.3)₃Al₅O₁₂ had the lowest thermal conductivity among investigated specimens, which was about 1.62 W m⁻¹ K⁻¹ at 1000 °C, around 30% lower than that of pure YAG (2.3 W m⁻¹ K⁻¹, 1000 °C). Yb had almost no effect on the coefficients of thermal expansion (CTEs) of (Y_1-xYb_x)₃Al₅O₁₂ ceramics and the CTE was approximate 10.7×10⁻⁶ K⁻¹ at 1200 °C. In addition, (Y_0.7Yb_0.3)₃Al₅O₁₂ ceramic remained good phase stability when heating from room temperature to 1450 °C.     

Comparison of hot corrosion resistance of Sm2Zr2O7 and (Sm0.5Sc0.5)2Zr2O7 ceramics in Na2SO4+V2O5 molten salt

Sm₂Zr₂O₇ and (Sm_0.5Sc_0.5)₂Zr₂O₇ ceramics were fabricated by a chemical co-precipitation and calcination method, and their hot corrosion behaviors in Na₂SO₄+V₂O₅ molten salt were investigated. Hot corrosion tests were carried at 700 °C, 800 °C and 900 °C for 4 h, and corroded surfaces were investigated using X-ray diffractometer and scanning electron microscopy. The corrosion products of Sm₂Zr₂O₇ ceramics were composed of SmVO₄ and monoclinic-ZrO₂, while those of (Sm_0.5Sc_0.5)₂Zr₂O₇ ceramic consisted of SmVO₄ and Zr₅Sc₂O₁₃. Considering the fact that Zr₅Sc₂O₁₃ is more desirable than monoclinic-ZrO₂ for thermal barrier coating applications, (Sm_0.5Sc_0.5)₂Zr₂O₇ showed better corrosion resistance to Na₂SO₄+V₂O₅ salt than Sm₂Zr₂O₇. The hot corrosion mechanisms of Sm₂Zr₂O₇ and (Sm_0.5Sc_0.5)₂Zr₂O₇ in Na₂SO₄+ V₂O₅ salt were discussed in detail.