Porosity–Property Relationships of Plasma‐Sprayed Gd2Zr2O7/YSZ Thermal Barrier Coatings

During the past decade, gadolinium zirconate (Gd₂Zr₂O₇, GZO) has attracted interest as an alternative material to partially yttria‐stabilized zirconia (YSZ) for thermal barrier coatings (TBCs). Despite the well‐known benefits of GZO, such as lower thermal conductivity and superior temperature capability compared to YSZ, processing of GZO via atmospheric plasma spraying (APS) still remains a challenge. Here, we report on APS experiments which were performed to investigate the influence of processing on GZO microstructure and lifetime of GZO/YSZ double‐layer TBCs. Different microstructures of GZO were produced and characterized in terms of porosity, stoichiometry, Young′s modulus, and their effects on the lifetime of YSZ/GZO double‐layer TBCs were discussed. Particle diagnostics were utilized for the optimization of the process parameters with respect to different microstructures of GZO and stoichiometry. It was found that both cumulative porosity of GZO and pore size distribution, which alter the Young′s modulus significantly, govern the lifetime of double layers. In addition, it was shown that the deviation in GZO stoichiometry due to gadolinia evaporation in the investigated range does not display any critical effect on lifetime.