Multilayer GZ/YSZ thermal barrier coating from suspension and solution precursor plasma spray

Leng, K.; Romero, A. Rincon; Curry, N.; Hussain, T.

Abstract

Gas turbines rely on thermal barrier coating (TBC) to thermally insulate the nickel-based superalloys underneath during operation; however, current TBCs, yttria stabilised zirconia (YSZ), limit the operating temperature and hence efficiency. At an operating temperature above 1200 °C, YSZ is susceptible to failure due to phase instability and CMAS (Calcia-Magnesia-Alumina-Silica) attack. Gadolinium zirconates (GZ) could overcome the drawback of YSZ, complementing each other with the multi-layer approach. This study introduces a novel approach utilising axial suspension plasma spray (ASPS) and axial solution precursor plasma spray (ASPPS) to produce a double-layer and a triple-layer TBCs with improved CMAS resistance. The former comprised suspension plasma sprayed GZ and YSZ layers while the latter had an additional dense layer deposited through a solution precursor to minimise the columnar gaps that pre-existed in the SPS GZ layer, thus resisting CMAS infiltration. Both coatings performed similarly in furnace cycling test (FCT) and burner rig testing (BRT). In the CMAS test, the triple-layer coating exhibited better CMAS reactivity, as evidenced by the limited CMAS infiltration observed on the surface.

Citation

Leng, K., Romero, A. R., Curry, N., & Hussain, T. (2024). Multilayer GZ/YSZ thermal barrier coating from suspension and solution precursor plasma spray. Ceramics International, 50(1, Part A), 631-649. https://doi.org/10.1016/j.ceramint.2023.10.142

• Journal Article Type: Article
• Acceptance Date: Oct 16, 2023
• Online Publication Date: Oct 17, 2023
• Publication Date: Jan 1, 2024
• Deposit Date: Feb 5, 2024
• Publicly Available Date: Feb 6, 2024
• Journal: Ceramics International
• Print ISSN: 0272-8842
• Electronic ISSN: 1873-3956
• Publisher: Elsevier
• Peer Reviewed: Peer Reviewed
• Volume: 50
• Issue: 1, Part A
• Pages: 631-649
• DOI: https://doi.org/10.1016/j.ceramint.2023.10.142
• Keywords: Materials Chemistry, Surfaces, Coatings and Films, Process Chemistry and Technology, Ceramics and Composites, Electronic, Optical and Magnetic Materials
• Public URL: https://nottingham-repository.worktribe.com/output/27582785
• Publisher URL: https://www.sciencedirect.com/science/article/pii/S0272884223031899?via%3Dihub
• Additional Information: This article is maintained by: Elsevier; Article Title: Multilayer GZ/YSZ thermal barrier coating from suspension and solution precursor plasma spray; Journal Title: Ceramics International; CrossRef DOI link to publisher maintained version: https://doi.org/10.1016/j.ceramint.2023.10.142; Content Type: article; Copyright: © 2023 The Authors. Published by Elsevier Ltd.