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Journal of Advanced Ceramics 2023, 12(9): 1805-1820 https://doi.org/10.26599/JAC.2023.9220789
Research Article | Open Access | Issue | Published: 18 September 2023

Comparative study on microstructure evolution and failure mechanisms of ordinary and refurbished EB-PVD TBC under cyclic oxidation

Show Author's Information Pan Lia,  Xiaochao Jina( ),  Pin Lua,  Delin Liub,  Rende Moub,  Xueling Fana
Xi’an Key Laboratory of Extreme Environmental Serviceability and Protection Technologies, School of Aerospace Engineering, Xi’an Jiaotong University, Xi’an 710049, China
AECC Beijing Institute of Aeronautical Materials, Beijing 100095, China
Keywords:
microstructure evolution, failure mechanism, coating removal, refurbishment, cyclic oxidation, thermal barrier coating (TBC) systems
Cite this article:
Li P, Jin X, Lu P, et al. Comparative study on microstructure evolution and failure mechanisms of ordinary and refurbished EB-PVD TBC under cyclic oxidation. Journal of Advanced Ceramics, 2023, 12(9): 1805-1820. https://doi.org/10.26599/JAC.2023.9220789
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Abstract Full text Electronic supplementary material About this article

Refurbishment of thermal barrier coating (TBC) has become a valuable technique to prolong the service life of high-temperature components. This study investigates the effect of the refurbishment process (coating removal and recoating) on the microstructure evolution and physical properties of TBC, including oxidation characteristics, element diffusion behavior, and crack failure mechanisms. The results showed that a certain amount of interdiffusion zone (IDZ) with Cr-rich would be retained in DD6 superalloy substrate after coating removal. The microstructure of the refurbished specimens showed equiaxed β-NiAl phases, while the ordinary specimens have elongated grain shapes with a high aspect ratio. Moreover, mixed oxides in the refurbished TBC specimens were earlier observed during cyclic oxidation, with a greater thickness compared to ordinary TBC, due to the influence of BC layer phase sizes. The growth mechanism of thermally grown oxide (TGO-Al2O3 layer) in the refurbished TBC specimens was also different, resulting from the different mechanisms of mixed oxides growth. Furthermore, under cyclic oxidation with water quenching at 1100 ℃, the cracks in the refurbished specimen tend to occur in the mixed oxides layer, while the cracks in the ordinary specimen occur in the top coat (TC) layer, attributing to the earlier and thicker mixed oxides layer formed in refurbished specimens.


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About this article

Comparative study on microstructure evolution and failure mechanisms of ordinary and refurbished EB-PVD TBC under cyclic oxidation

Show Author's information Pan Lia, Xiaochao Jina( ), Pin Lua, Delin Liub, Rende Moub, Xueling Fana
Xi’an Key Laboratory of Extreme Environmental Serviceability and Protection Technologies, School of Aerospace Engineering, Xi’an Jiaotong University, Xi’an 710049, China
AECC Beijing Institute of Aeronautical Materials, Beijing 100095, China

Abstract

Refurbishment of thermal barrier coating (TBC) has become a valuable technique to prolong the service life of high-temperature components. This study investigates the effect of the refurbishment process (coating removal and recoating) on the microstructure evolution and physical properties of TBC, including oxidation characteristics, element diffusion behavior, and crack failure mechanisms. The results showed that a certain amount of interdiffusion zone (IDZ) with Cr-rich would be retained in DD6 superalloy substrate after coating removal. The microstructure of the refurbished specimens showed equiaxed β-NiAl phases, while the ordinary specimens have elongated grain shapes with a high aspect ratio. Moreover, mixed oxides in the refurbished TBC specimens were earlier observed during cyclic oxidation, with a greater thickness compared to ordinary TBC, due to the influence of BC layer phase sizes. The growth mechanism of thermally grown oxide (TGO-Al2O3 layer) in the refurbished TBC specimens was also different, resulting from the different mechanisms of mixed oxides growth. Furthermore, under cyclic oxidation with water quenching at 1100 ℃, the cracks in the refurbished specimen tend to occur in the mixed oxides layer, while the cracks in the ordinary specimen occur in the top coat (TC) layer, attributing to the earlier and thicker mixed oxides layer formed in refurbished specimens.

Keywords: microstructure evolution, failure mechanism, coating removal, refurbishment, cyclic oxidation, thermal barrier coating (TBC) systems

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Publication history

Received: 25 May 2023
Revised: 19 July 2023
Accepted: 19 July 2023
Published: 18 September 2023
Issue date: September 2023

Copyright

© The Author(s) 2023.

Acknowledgements

This work is supported by the National Science and Technology Major Project (J2019-IV-0003-0070), National Natural Science Foundation of China (12102320), and China Postdoctoral Science Foundation (2021M692571). Moreover, we thank Dr. Yanan Chen at Instrument Analysis Center of Xi’an Jiaotong University for his assistance with microstructure analysis.

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