Air-plasma-sprayed thermal barrier coatings that are resistant to high-temperature attack by glassy deposits

Thermal barrier coatings (TBCs) used in gas-turbine engines afford higher operating temperatures, resulting in enhanced efficiencies and performance. However, at these high operating temperatures, environmentally ingested airborne sand/ash particles melt on the hot TBC surfaces and form calcium–magnesium–aluminosilicate (CMAS) glass deposits. The molten CMAS glass penetrates the TBCs, leading to loss of strain tolerance and TBC failure. Here we demonstrate the use of the commercial manufacturing method of air-plasma-spray (APS) to fabricate CMAS-resistant yttria-stabilized zirconia (YSZ)-based TBCs containing Al and Ti in solid solution. Results from thermal stability studies of these new TBCs and CMAS/TBC interaction experiments are presented, together with a discussion of the CMAS mitigation mechanisms. The ubiquity of airborne sand/ash particles and the ever-increasing demand for higher operating temperatures in future high efficiency/performance gas-turbine engines will necessitate CMAS resistance in all hot-section components of those engines. In this context the versatility, ease of processing, and low cost offered by the APS method has broad implications for the design and fabrication of next-generation CMAS-resistant TBCs for future engines.