Thermal Cycling and Flame Thermal Shocking Failure Mechanism of Tetragonal Yttria-stabilized Zirconia TBCs Prepared on High Temperature Alloys by Suspension Plasma Spraying

doi:10.11901/1005.3093.2023.471

Chinese Journal of Materials Research

2024, Vol. 38

Issue (9): 691-700 DOI: 10.11901/1005.3093.2023.471

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Thermal Cycling and Flame Thermal Shocking Failure Mechanism of Tetragonal Yttria-stabilized Zirconia TBCs Prepared on High Temperature Alloys by Suspension Plasma Spraying

HUANG Di¹^,², NIU Yunsong¹^,³, LI Shuai¹, DONG Zhihong¹^,², BAO Zebin¹^,²(

), ZHU Shenglong¹^,²

1 Shi -Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
2 School of Materials Science and Engineering, University of Science and Technology of China, Shenyang 110016, China
3 University of Science and Technology Beijing, State Key Laboratory for Advanced Metals and Materials, Beijing 100083, China

Cite this article:

HUANG Di, NIU Yunsong, LI Shuai, DONG Zhihong, BAO Zebin, ZHU Shenglong. Thermal Cycling and Flame Thermal Shocking Failure Mechanism of Tetragonal Yttria-stabilized Zirconia TBCs Prepared on High Temperature Alloys by Suspension Plasma Spraying. Chinese Journal of Materials Research, 2024, 38(9): 691-700.

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Abstract

In this paper, thermal barrier ceramic coatings (TBCs) with columnar-like structure were prepared on high temperature alloys N5 and DZ411 by suspension plasma spraying, using tetragonal yttria stabilization zirconia (YSZ) powder as raw material. The failure behavior of TBCs was assessed by thermal cycling test (i.e. furnace heating to 1100^oC for 60 min. and then air cooling for 10 min. as one cycle), and flame thermal shocking test (i.e. quick flame heating to 1300^oC and then compressed air cooling to below 300^oC as one cycle) respectively. The results show that the coatings have excellent resistance to thermal cycling and flame thermal shocking, and the phase composition of ceramic coatings maintains tetragonal crystallographic structure after all the tests. The failure mechanism of TBCs in thermal cycling and flame thermal shocking is different. Delamination failure occurs at the interface between the ceramic layer and thermal grown oxides (TGO) during thermal cycling, caused by the mismatch of different thermal expansion coefficient. Besides, the main failure source of TBCs during flame thermal shocking is severe internal oxidation of bond coat due to the formation of hot channel, which is converted from gaps between columnar.

Key words: surface and interface in the materials suspension plasma spraying thermal barrier coatings thermal cycle thermal shock failure mechanism

Received: 19 September 2023

ZTFLH:

TG174.45

Fund: National Natural Science Foundation of China(51671202, 52301116);Fundamental Science Center for Aviation and Gas Turbine Engines(P2021-A-IV-002-001);National Science and Technology Major Project(J2019-IV-0006-0074);the Key Research Program of the Chinese Academy of Sciences(ZDRW-CN-2021-2-2)

Corresponding Authors: BAO Zebin, Tel: (024)23881473, E-mail: zbbao@imr.ac.cn

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	HUANG Di
	NIU Yunsong
	LI Shuai
	DONG Zhihong
	BAO Zebin
	ZHU Shenglong

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https://www.cjmr.org/EN/10.11901/1005.3093.2023.471 OR https://www.cjmr.org/EN/Y2024/V38/I9/691

Table 1 Chemical composition of N5 and DZ411 superalloy (mass fraction, %)

Table 2 Parameters of suspension plasma spraying

Fig.1 Surface microstructure (a) and morphology (b) of the as-sprayed ceramic layer and high-magnification images in column (c, d)

Fig.2 XRD pattern of as-sprayed ceramic layer

Fig.3 Cross-section images of TC (a), intact TGO region (b) and inter-column high-magnification (c, d) after failure at 1100^oC thermal cycling

Fig.4 Line scanning results of TGO region

Fig.5 10°~80° (a) and 72°~76° (b) XRD pattens in as-sprayed and thermally cycling of ceramic layer

Fig.6 Microstructure of TBCs after 5000 times (a, c, e) and 10000 times (b, d, f) of thermal shock

Fig.7 10°~80° (a) and 72°~76° (b) XRD pattens in as-sprayed and after 10000 times thermal shock ceramic layer

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