Journal Home > Volume 12 , Issue 7
Journal of Advanced Ceramics 2023, 12(7): 1317-1330 https://doi.org/10.26599/JAC.2023.9220750
Research Article | Open Access | Issue | Published: 25 May 2023

Tailoring sintering-resistant thermal barrier coatings by considering critical healing width of two-dimensional interlamellar pores

Show Author's Information Guang-Rong Li,  Tao Liu,  Xiao-Tao Luo,  Guan-Jun Yang,  Chang-Jiu Li( )
State Key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, Xi’an Jiaotong University, Xi’an 710049, China
Keywords:
grain growth, thermal barrier coatings (TBCs), air plasma spraying (APS), multiple connections, sintering-resistant structure
Cite this article:
Li G-R, Liu T, Luo X-T, et al. Tailoring sintering-resistant thermal barrier coatings by considering critical healing width of two-dimensional interlamellar pores. Journal of Advanced Ceramics, 2023, 12(7): 1317-1330. https://doi.org/10.26599/JAC.2023.9220750
Download citation
EndNote(RIS)
BibTeX

1114

Views

197

Downloads

Citations

0

Crossref

0

WoS

0

Scopus

0

CSCD

Abstract Full text About this article

Large degradation in thermal insulation and strain tolerance is a main headache and a primary cause of the failure for plasma-sprayed thermal barrier coatings (TBCs) during service. One mechanism behind such degradation is the healing of interlamellar pores formed by multiple connections between edges of a pore, which significantly speeds up healing during thermal exposure. The objective of this study is to obtain sintering-resistant TBCs by tailoring the width of interlamellar pores to avoid multiple connections. Firstly, the mechanism responsible for the multiple connections was revealed. The splat surfaces before and after thermal treatments were characterized via an atomic force microscope (AFM). The roughening of the pore surface occurs during thermal exposure, along with the grain growth inside the splats. Consequently, the local surface height increases, which causes multiple connections and healing of the interlamellar pores. Secondly, critical widths of the interlamellar pores for avoiding the multiple connections during thermal exposure are established by correlating the extent of surface roughening with the growth of individual grains. The height increase of the splat surface and the growth of the grain size (D) were found to increase with the exposure temperature and duration. A relationship linking the height increase and the growth of the grain size induced by thermal exposure in plasma-sprayed ceramic splats was obtained. Finally, composite TBCs were prepared to form wide interlamellar pores in the coatings. Using this design, the increases in the thermal conductivity (λ) and the elastic modulus (E) can be prevented to a large extent. Thus, sintering-resistant TBCs that maintain high thermal insulation and strain tolerance, even after long thermal exposure, can be created.


menu
Abstract
Full text
Outline
About this article

Tailoring sintering-resistant thermal barrier coatings by considering critical healing width of two-dimensional interlamellar pores

Show Author's information Guang-Rong Li, Tao Liu, Xiao-Tao Luo, Guan-Jun Yang, Chang-Jiu Li( )
State Key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, Xi’an Jiaotong University, Xi’an 710049, China

Abstract

Large degradation in thermal insulation and strain tolerance is a main headache and a primary cause of the failure for plasma-sprayed thermal barrier coatings (TBCs) during service. One mechanism behind such degradation is the healing of interlamellar pores formed by multiple connections between edges of a pore, which significantly speeds up healing during thermal exposure. The objective of this study is to obtain sintering-resistant TBCs by tailoring the width of interlamellar pores to avoid multiple connections. Firstly, the mechanism responsible for the multiple connections was revealed. The splat surfaces before and after thermal treatments were characterized via an atomic force microscope (AFM). The roughening of the pore surface occurs during thermal exposure, along with the grain growth inside the splats. Consequently, the local surface height increases, which causes multiple connections and healing of the interlamellar pores. Secondly, critical widths of the interlamellar pores for avoiding the multiple connections during thermal exposure are established by correlating the extent of surface roughening with the growth of individual grains. The height increase of the splat surface and the growth of the grain size (D) were found to increase with the exposure temperature and duration. A relationship linking the height increase and the growth of the grain size induced by thermal exposure in plasma-sprayed ceramic splats was obtained. Finally, composite TBCs were prepared to form wide interlamellar pores in the coatings. Using this design, the increases in the thermal conductivity (λ) and the elastic modulus (E) can be prevented to a large extent. Thus, sintering-resistant TBCs that maintain high thermal insulation and strain tolerance, even after long thermal exposure, can be created.

Keywords: grain growth, thermal barrier coatings (TBCs), air plasma spraying (APS), multiple connections, sintering-resistant structure

References(55)

[1]
Wei ZY, Meng GH, Chen L, et al. Progress in ceramic materials and structure design toward advanced thermal barrier coatings. J Adv Ceram 2022, 11: 985–1068.
DOI Google Scholar
[2]
Kim K, Kim D, Park K, et al. Methodology for predicting the life of plasma-sprayed thermal barrier coating system considering oxidation-induced damage. J Mater Sci Technol 2022, 105: 45–56.
DOI Google Scholar
[3]
Deng SX, He G, Yang ZC, et al. Calcium–magnesium–alumina–silicate (CMAS) resistant high entropy ceramic (Y0.2Gd0.2Er0.2Yb0.2Lu0.2)2Zr2O7 for thermal barrier coatings. J Mater Sci Technol 2022, 107: 259–265.
DOI Google Scholar
[4]
Chen L, Li BH, Guo J, et al. High-entropy perovskite RETa3O9 ceramics for high-temperature environmental/thermal barrier coatings. J Adv Ceram 2022, 11: 556–569.
DOI Google Scholar
[5]
Guo L, Li BW, Cheng YX, et al. Composition optimization, high-temperature stability, and thermal cycling performance of Sc-doped Gd2Zr2O7 thermal barrier coatings: Theoretical and experimental studies. J Adv Ceram 2022, 11: 454–469.
DOI Google Scholar
[6]
Huang MZ, Liang J, Zhang P, et al. Opaque Gd2Zr2O7/GdMnO3 thermal barrier materials for thermal radiation shielding: The effect of polaron excitation. J Mater Sci Technol 2022, 100: 67–74.
DOI Google Scholar
[7]
Li GR, Tang CH, Yang GJ. Dynamic-stiffening-induced aggravated cracking behavior driven by metal-substrate-constraint in a coating/substrate system. J Mater Sci Technol 2021, 65: 154–163.
DOI Google Scholar
[8]
Shinozaki M, Clyne TW. A methodology, based on sintering-induced stiffening, for prediction of the spallation lifetime of plasma-sprayed coatings. Acta Mater 2013, 61: 579–588.
DOI Google Scholar
[9]
Vassen R, Stuke A, Stöver D. Recent developments in the field of thermal barrier coatings. J Therm Spray Techn 2009, 18: 181–186.
DOI Google Scholar
[10]
Hardwicke CU, Lau YC. Advances in thermal spray coatings for gas turbines and energy generation: A review. J Therm Spray Techn 2013, 22: 564–576.
DOI Google Scholar
[11]
Mondal K, Nuñez L, Downey CM, et al. Thermal barrier coatings overview: Design, manufacturing, and applications in high-temperature industries. Ind Eng Chem Res 2021, 60: 6061–6077.
DOI Google Scholar
[12]
Tian YS, Chen CZ, Wang DY, et al. Recent developments in zirconia thermal barrier coatings. Surf Rev Lett 2005, 12: 369–378.
DOI Google Scholar
[13]
Paul S, Cipitria A, Tsipas SA, et al. Sintering characteristics of plasma sprayed zirconia coatings containing different stabilisers. Surf Coat Tech 2009, 203: 1069–1074.
DOI Google Scholar
[14]
Chi WG, Sampath S, Wang H. Microstructure–thermal conductivity relationships for plasma-sprayed yttria-stabilized zirconia coatings. J Am Ceram Soc 2008, 91: 2636–2645.
DOI Google Scholar
[15]
Xie H, Xie YC, Yang GJ, et al. Modeling thermal conductivity of thermally sprayed coatings with intrasplat cracks. J Therm Spray Techn 2013, 22: 1328–1336.
DOI Google Scholar
[16]
Tan Y, Shyam A, Choi WB, et al. Anisotropic elastic properties of thermal spray coatings determined via resonant ultrasound spectroscopy. Acta Mater 2010, 58: 5305–5315.
DOI Google Scholar
[17]
Thompson JA, Clyne TW. The effect of heat treatment on the stiffness of zirconia top coats in plasma-sprayed TBCs. Acta Mater 2001, 49: 1565–1575.
DOI Google Scholar
[18]
Wang Z, Kulkarni A, Deshpande S, et al. Effects of pores and interfaces on effective properties of plasma sprayed zirconia coatings. Acta Mater 2003, 51: 5319–5334.
DOI Google Scholar
[19]
Lu XJ, Xiao P. Constrained sintering of YSZ/Al2O3 composite coatings on metal substrates produced from eletrophoretic deposition. J Eur Ceram Soc 2007, 27: 2613–2621.
DOI Google Scholar
[20]
Cernuschi F, Bison PG, Marinetti S, et al. Thermophysical, mechanical and microstructural characterization of aged free-standing plasma-sprayed zirconia coatings. Acta Mater 2008, 56: 4477–4488.
DOI Google Scholar
[21]
Tan Y, Longtin JP, Sampath S, et al. Effect of the starting microstructure on the thermal properties of as-sprayed and thermally exposed plasma-sprayed YSZ coatings. J Am Ceram Soc 2009, 92: 710–716.
DOI Google Scholar
[22]
Ercan B, Bowman KJ, Trice RW, et al. Effect of initial powder morphology on thermal and mechanical properties of stand-alone plasma-sprayed 7 wt.% Y2O3–ZrO2 coatings. Mat Sci Eng A 2006, 435–436: 212–220.
DOI Google Scholar
[23]
Xie L, Dorfman MR, Cipitria A, et al. Properties and performance of high-purity thermal barrier coatings. J Therm Spray Techn 2007, 16: 804–808.
DOI Google Scholar
[24]
Dutton R, Wheeler R, Ravichandran KS, et al. Effect of heat treatment on the thermal conductivity of plasma-sprayed thermal barrier coatings. J Therm Spray Techn 2000, 9: 204–209.
DOI Google Scholar
[25]
Cernuschi F, Lorenzoni L, Ahmaniemi S, et al. Studies of the sintering kinetics of thick thermal barrier coatings by thermal diffusivity measurements. J Eur Ceram Soc 2005, 25: 393–400.
DOI Google Scholar
[26]
Zhu DM, Miller RA. Thermal conductivity and elastic modulus evolution of thermal barrier coatings under high heat flux conditions. J Therm Spray Techn 2000, 9: 175–180.
DOI Google Scholar
[27]
Yang GJ, Chen ZL, Li CX, et al. Microstructural and mechanical property evolutions of plasma-sprayed YSZ coating during high-temperature exposure: Comparison study between 8YSZ and 20YSZ. J Therm Spray Techn 2013, 22: 1294–1302.
DOI Google Scholar
[28]
Choi SR, Zhu DM, Miller RA. Effect of sintering on mechanical properties of plasma-sprayed zirconia-based thermal barrier coatings. J Am Ceram Soc 2005, 88: 2859–2867.
DOI Google Scholar
[29]
Li GR, Xie H, Yang GJ, et al. A comprehensive sintering mechanism for TBCs—Part I: An overall evolution with two-stage kinetics. J Am Ceram Soc 2017, 100: 2176–2189.
DOI Google Scholar
[30]
Liu T, Zhang SL, Luo XT, et al. High heat insulating thermal barrier coating designed with large two-dimensional inter-lamellar pores. J Therm Spray Techn 2016, 25: 222–230.
DOI Google Scholar
[31]
Li GR, Wang LS, Yang GJ. A novel composite-layered coating enabling self-enhancing thermal barrier performance. Scripta Mater 2019, 163: 142–147.
DOI Google Scholar
[32]
Lima RS, Marple BR. Nanostructured YSZ thermal barrier coatings engineered to counteract sintering effects. Mat Sci Eng A 2008, 485: 182–193.
DOI Google Scholar
[33]
Liu T, Luo XT, Chen X, et al. Morphology and size evolution of interlamellar two-dimensional pores in plasma-sprayed La2Zr2O7 coatings during thermal exposure at 1300 ℃. J Therm Spray Techn 2015, 24: 739–748.
DOI Google Scholar
[34]
Li GR, Xie H, Yan GJ, et al. A comprehensive sintering mechanism for TBCs—Part II: Multiscale multipoint interconnection-enhanced initial kinetics. J Am Ceram Soc 2017, 100: 4240–4251.
DOI Google Scholar
[35]
Erk KA, Deschaseaux C, Trice RW. Grain-boundary grooving of plasma-sprayed yttria-stabilized zirconia thermal barrier coatings. J Am Ceram Soc 2006, 89: 1673–1678.
DOI Google Scholar
[36]
Guo SQ, Kagawa Y. Young’s moduli of zirconia top-coat and thermally grown oxide in a plasma-sprayed thermal barrier coating system. Scripta Mater 2004, 50: 1401– 1406.
DOI Google Scholar
[37]
Rätzer-Scheibe HJ, Schulz U. The effects of heat treatment and gas atmosphere on the thermal conductivity of APS and EB-PVD PYSZ thermal barrier coatings. Surf Coat Tech 2007, 201: 7880–7888.
DOI Google Scholar
[38]
Chen S, Zhou X, Cao XQ, et al. Novel thermal barrier coatings based on Mg2SiO4/8YSZ double-ceramic-layer systems deposited by APS. J Alloys Compd 2022, 908: 164442.
DOI Google Scholar
[39]
Zhou X, Song WJ, Yuan JY, et al. Thermophysical properties and cyclic lifetime of plasma sprayed SrAl12O19 for thermal barrier coating applications. J Am Ceram Soc 2020, 103: 5599–5611.
DOI Google Scholar
[40]
Cipitria A, Golosnoy IO, Clyne TW. A sintering model for plasma-sprayed zirconia TBCs. Part I: Free-standing coatings. Acta Mater 2009, 57: 980–992.
DOI Google Scholar
[41]
Liu T, Chen X, Yang GJ, et al. Properties evolution of plasma-sprayed La2Zr2O7 coating induced by pore structure evolution during thermal exposure. Ceram Int 2016, 42: 15485–15492.
DOI Google Scholar
[42]
Xing C, Yi MY, Shan X, et al. Sintering behavior of a nanostructured thermal barrier coating deposited using electro-sprayed particles. J Am Ceram Soc 2020, 103: 7267–7282.
DOI Google Scholar
[43]
Beck PA, Holzworth ML, Hu H. Instantaneous rates of grain growth. Phys Rev 1948, 73: 526–527.
DOI Google Scholar
[44]
Tsoga A, Nikolopoulos P. Surface and grain-boundary energies in yttria-stabilized zirconia (YSZ-8 mol%). J Mater Sci 1996, 31: 5409–5413.
DOI Google Scholar
[45]
Michels A, Krill CE, Ehrhardt H, et al. Modelling the influence of grain-size-dependent solute drag on the kinetics of grain growth in nanocrystalline materials. Acta Mater 1999, 47: 2143–2152.
DOI Google Scholar
[46]
Burke JE. Some factors affecting the rate of grain growth in metals. T Am I Min Met Eng 1949, 180: 73–91.
Google Scholar
[47]
Liu KW, Mücklich F. Thermal stability of nano-RuAl produced by mechanical alloying. Acta Mater 2001, 49: 395–403.
DOI Google Scholar
[48]
Yang P, An YL, Zhao D, et al. Structure evolution, thermal properties and sintering resistance of promising thermal barrier coating material La2(Zr0.75Ce0.25)2O7. Ceram Int 2020, 46: 20652–20663.
DOI Google Scholar
[49]
Huang JB, Wang WZ, Li YJ, et al. A novel strategy to control the microstructure of plasma-sprayed YSZ thermal barrier coatings. Surf Coat Tech 2020, 402: 126304.
DOI Google Scholar
[50]
Trice RW, Su YJ, Mawdsley JR, et al. Effect of heat treatment on phase stability, microstructure, and thermal conductivity of plasma-sprayed YSZ. J Mater Sci 2002, 37: 2359–2365.
Google Scholar
[51]
Li GR, Yang GJ. Understanding of degradation-resistant behavior of nanostructured thermal barrier coatings with bimodal structure. J Mater Sci Technol 2019, 35: 231–238.
DOI Google Scholar
[52]
Huang JB, Chu X, Yang T, et al. Achieving high anti-sintering performance of plasma-sprayed YSZ thermal barrier coatings through pore structure design. Surf Coat Tech 2022, 435: 128259.
DOI Google Scholar
[53]
Huang JB, Wang WZ, Li YJ, et al. Improve durability of plasma-splayed thermal barrier coatings by decreasing sintering-induced stiffening in ceramic coatings. J Eur Ceram Soc 2020, 40: 1433–1442.
DOI Google Scholar
[54]
Xiao BJ, Huang X, Robertson T, et al. Sintering resistance of suspension plasma sprayed 7YSZ TBC under isothermal and cyclic oxidation. J Eur Ceram Soc 2020, 40: 2030–2041.
DOI Google Scholar
[55]
Moon J, Choi H, Kim H, et al. The effects of heat treatment on the phase transformation behavior of plasma-sprayed stabilized ZrO2 coatings. Surf Coat Tech 2002, 155: 1–10.
DOI Google Scholar
Publication history
Copyright
Acknowledgements
Rights and permissions

Publication history

Received: 16 February 2023
Revised: 30 March 2023
Accepted: 07 April 2023
Published: 25 May 2023
Issue date: July 2023

Copyright

© The Author(s) 2023.

Acknowledgements

This work was supported by the National Science and Technology Major Project (Grant No. 2019-VII-0007-0147), the Young Elite Scientists Sponsorship Program by China Association for Science and Technology (CAST) (Grant No. YESS20200083), and the Fundamental Research Funds for the Central Universities (Grant No. xzy012022057).

Rights and permissions

Open Access This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made.

The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder.

To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/.

Return