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Journal of Advanced Ceramics https://doi.org/10.26599/JAC.2024.9220867
Research Article | Open Access | Online first | Published: 10 April 2024

Corrosion behavior of Gd2Zr2O7 thermal barrier coatings under Fe-containing environmental sediment attack

Show Author's Information Lei Guo1,2( ),  Yanyan Li1,2,  Kai Yan3
School of Materials Science and Engineering, Tianjin University, Tianjin 300072, China
Tianjin Key Laboratory of Advanced Joining Technology, Key Lab of Advanced Ceramics and Machining Technology of Ministry of Education, Tianjin 300072, China
Key Laboratory of Special Equipment Safety and Energy-saving for State Market Regulation, China Special Equipment Inspection & Research Institute, Beijing 100029, China
Keywords:
thermal barrier coatings (TBCs), corrosion resistance, reaction layer, Gd2Zr2O7, Fe-containing CaO–MgO–Al2O3–SiO2 (CMAS)
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Guo L, Li Y, Yan K. Corrosion behavior of Gd2Zr2O7 thermal barrier coatings under Fe-containing environmental sediment attack. Journal of Advanced Ceramics, 2024, https://doi.org/10.26599/JAC.2024.9220867
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Abstract Full text About this article

Environmental sediments mainly consisting of CaO–MgO–Al2O3–SiO2 (CMAS) corrosion are a serious threat to thermal barrier coatings (TBCs), in which Fe element is usually ignored. Gd2Zr2O7 TBCs are famous for their excellent CMAS resistance. In this study, the characteristics of Fe-containing environmental sediments (CMAS-Fe) and their corrosiveness to Gd2Zr2O7 coatings were investigated. Four types of CMAS-Fe glass with different Fe contents were fabricated. Their melting points were measured to be 1322–1344 ℃, and the high-temperature viscosity showed a decreasing trend with increasing Fe contents. The corrosion behavior of four types of CMAS-Fe to Gd2Zr2O7 coatings at 1350 ℃ was investigated. At the initial corrosion stage (0.1 h), anorthite was precipitated in CMAS-Fe with a high Ca : Si ratio, while Fe-garnet was formed in the melt with the highest Fe content. Prolonging the corrosion time resulted in the formation of a reaction layer, which exhibited an interpenetrating network composed of Gd-oxyapatite, ZrO2, and residual CMAS-Fe. Some spinel was precipitated within the reaction layer. After 1 h or even longer time, the reaction layers tended to be stable and compact, which had comparable hardness and fracture toughness to those of Gd2Zr2O7 coatings. Under the cyclic CMAS-Fe attack, the residual CMAS-Fe in the interpenetrating network provided a pathway for the redeposited CMAS-Fe infiltration, resulting in the continuous growth of the reaction layer. As a result, the Gd2Zr2O7 coatings had a large consumption in the thickness, degrading the coating performance. Therefore, the Gd2Zr2O7 coatings exhibit unsatisfactory corrosion resistance to CMAS-Fe attack.


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About this article

Corrosion behavior of Gd2Zr2O7 thermal barrier coatings under Fe-containing environmental sediment attack

Show Author's information Lei Guo1,2( ), Yanyan Li1,2, Kai Yan3
School of Materials Science and Engineering, Tianjin University, Tianjin 300072, China
Tianjin Key Laboratory of Advanced Joining Technology, Key Lab of Advanced Ceramics and Machining Technology of Ministry of Education, Tianjin 300072, China
Key Laboratory of Special Equipment Safety and Energy-saving for State Market Regulation, China Special Equipment Inspection & Research Institute, Beijing 100029, China

Abstract

Environmental sediments mainly consisting of CaO–MgO–Al2O3–SiO2 (CMAS) corrosion are a serious threat to thermal barrier coatings (TBCs), in which Fe element is usually ignored. Gd2Zr2O7 TBCs are famous for their excellent CMAS resistance. In this study, the characteristics of Fe-containing environmental sediments (CMAS-Fe) and their corrosiveness to Gd2Zr2O7 coatings were investigated. Four types of CMAS-Fe glass with different Fe contents were fabricated. Their melting points were measured to be 1322–1344 ℃, and the high-temperature viscosity showed a decreasing trend with increasing Fe contents. The corrosion behavior of four types of CMAS-Fe to Gd2Zr2O7 coatings at 1350 ℃ was investigated. At the initial corrosion stage (0.1 h), anorthite was precipitated in CMAS-Fe with a high Ca : Si ratio, while Fe-garnet was formed in the melt with the highest Fe content. Prolonging the corrosion time resulted in the formation of a reaction layer, which exhibited an interpenetrating network composed of Gd-oxyapatite, ZrO2, and residual CMAS-Fe. Some spinel was precipitated within the reaction layer. After 1 h or even longer time, the reaction layers tended to be stable and compact, which had comparable hardness and fracture toughness to those of Gd2Zr2O7 coatings. Under the cyclic CMAS-Fe attack, the residual CMAS-Fe in the interpenetrating network provided a pathway for the redeposited CMAS-Fe infiltration, resulting in the continuous growth of the reaction layer. As a result, the Gd2Zr2O7 coatings had a large consumption in the thickness, degrading the coating performance. Therefore, the Gd2Zr2O7 coatings exhibit unsatisfactory corrosion resistance to CMAS-Fe attack.

Keywords: thermal barrier coatings (TBCs), corrosion resistance, reaction layer, Gd2Zr2O7, Fe-containing CaO–MgO–Al2O3–SiO2 (CMAS)

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Received: 08 December 2023
Revised: 20 February 2024
Accepted: 20 February 2024
Published: 10 April 2024

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© The Author(s) 2024.

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This work was supported by the National Natural Science Foundation of China (Grant No. 52272070) and National Science and Technology Major Project (Grant No. J2022-VI-0009-0040).

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