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Investigation of CMAS Resistance of Sacrificial Suspension Sprayed Alumina Topcoats on EB-PVD 7YSZ Layers

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Abstract

Molten calcium–magnesium–aluminum–silicate (CMAS) mineral particles cause significant degradation of thermal barrier coatings (TBCs) in aero-engines. One approach to protect the TBC coating against the CMAS attack is the application of a sacrificial coating on top of the TBC coating. In this work, Al2O3 coatings were deposited on EB-PVD 7YSZ layers using suspension plasma spraying (SPS) and suspension high velocity oxy-fuel spraying (SHVOF), in order to produce sacrificial topcoats with two different microstructures and porosity levels. The coating systems were tested under CMAS attack with one natural volcanic ash and two artificial CMAS powders by conducting infiltration tests at 1250 °C in the time intervals between 5 min and 10 h. It was found that the porosity and morphology of suspension sprayed alumina topcoats, the chemical composition of the deposits and the infiltration conditions strongly influence the CMAS infiltration, reaction kinetics and formation of the reaction products. While the porous SPS coatings offer limited resistance against CMAS infiltration, the dense SHVOF coatings show promising CMAS sealing behavior. Among the formed reaction products, only (Fe, Mg) Al spinel acted as an efficient barrier against CMAS infiltration. However, the formation of uniform spinel layers strongly depends on the pore morphology of the sacrificial coating and the CMAS chemistry.

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Acknowledgments

The authors express their gratitude to J. Brien, A. Handwerk and D. Peters from DLR Cologne for producing of the EB-PVD 7YSZ layers, as well as for technical support and advisory. The work was performed in the Framework of the Research Project DFG No. SCHU 1372/5 1, LE1373/34-1 funded by DFG-Deutsche Forschungsgemeinschaft (German Research Foundation). The authors acknowledge the financial support.

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Authors and Affiliations

  1. Institute of Materials Research, German Aerospace Center (DLR), Linder Hoehe, 51147, Cologne, Germany

    Christoph Mikulla, Ravisankar Naraparaju & Uwe Schulz

  2. Fraunhofer Institute for Material and Beam Technology (IWS), Winterbergstrasse 28, 01277, Dresden, Germany

    Filofteia-Laura Toma, Maria Barbosa & Christoph Leyens

  3. Institute of Materials Science, Technische Universität Dresden (TUD), Helmholtzstrasse 7, 01069, Dresden, Germany

    Lars Steinberg & Christoph Leyens

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  1. Christoph Mikulla
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  2. Ravisankar Naraparaju
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  3. Uwe Schulz
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  4. Filofteia-Laura Toma
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Correspondence to Filofteia-Laura Toma.

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Production Notes: Credit Line: This article is an invited paper selected from presentations at the 2019 International Thermal Spray Conference, held May 26-29, 2019 in Yokohama, Japan, and has been expanded from the original presentation.

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Mikulla, C., Naraparaju, R., Schulz, U. et al. Investigation of CMAS Resistance of Sacrificial Suspension Sprayed Alumina Topcoats on EB-PVD 7YSZ Layers. J Therm Spray Tech 29, 90–104 (2020). https://doi.org/10.1007/s11666-019-00951-4

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