To address the challenges of insufficient thermal resistance and high-temperature stability in current environmental barrier coating (EBC) bond coats above 1500 °C, this study successfully synthesized HfO2–Al2O3–SiO2 powders with a dispersion-strengthened structure for EBC bond coat raw material for spraying through a solid-phase synthesis method using HfO2, Al2O3, and SiO2 sol. The dispersion-strengthened structure with a microstructure of oxides (HfO2 and Al2O3) dispersed in silicates (mullite and HfSiO4) can be achieved by systematically adjusting the component molar ratios, synthesis temperature, and time. The synthesized raw powders underwent subsequent high-temperature hot-pressing sintering to form ceramic bulks, allowing for a comprehensive characterization of the intrinsic material properties, including thermal conductivity, coefficient of thermal expansion, mechanical performance, oxidation resistance at 1600 °C, and water‒oxygen corrosion resistance at 1300 °C. The investigation elucidates the property evolution and related mechanisms, conclusively demonstrating the viability of the HfO2–Al2O3–SiO2 system as an EBC bond coating material. Additional chemical compatibility tests with SiO2 at 1500 °C further validated the dispersion-strengthened structure. Notably, oxidation resistance testing at 1600 °C revealed that Al2O3 could better capture SiO2 generated by the decomposition of HfSiO4 to form mullite, thus enhancing the high-temperature stability of the HfO2–Al2O3–SiO2 material, benefiting from its dispersion-strengthened structure. The present study establishes a robust theoretical foundation for the development of EBC bond coatings with exceptional high-temperature endurance exceeding 1500 °C.
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Journal of Advanced Ceramics 2025, 14(5): 9221066
Published: 29 May 2025
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