Initial phase hot corrosion mechanism of gas tunnel type plasma sprayed thermal barrier coatings

The hot corrosion resistance of the top layer in TBC is one of the main constructive factors which determines the lifetime of the coatings under critical operating environments. In the present study, 8 wt% yttria stabilized zirconia (8YSZ), lanthanum zirconate (La₂Zr₂O₇) and equal weight percentage of its composite (50%8YSZ + 50% La₂Zr₂O₇) coatings were prepared by using gas tunnel type plasma spray torch at optimum spraying conditions. The hot corrosion performances of the above thermal barrier coatings were examined against 40 wt%V₂O₅–60 wt%Na₂SO₄ corrosive ash at 1173 K for 5 h in open air atmosphere. After hot-corrosion testing, the coating surface was studied using a scanning electron microscope to observe the microstructure and X-ray diffraction techniques were used to identify the phase compositions. The results showed that LaVO₄ and YVO₄ are the main hot corrosion products along with the ZrO₂ phase transformation from tetragonal to monoclinic phases in La₂Zr₂O₇ and 8YSZ coatings respectively. The microstructure and phase formation mechanism of the hot corrosion products varied with each coating and among these, composition of 50%8YSZ + 50%La₂Zr₂O₇ coating exhibited least degradation against V₂O₅–Na₂SO₄ corrosive environment compared to the other coatings.