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Comparison of Hot Corrosion Behavior of YSZ, YSZ/Mullite and YSZ/Mullite Gradient Coatings on Nickel Base Superalloy Prepared by Plasma Spray Method

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Abstract

Three types of thermal barrier coatings, namely NiCrAlY/YSZ double-layer, NiCrAlY/YSZ/mullite three-layer and NiCrAlY/YSZ/gradient of YSZ and mullite coatings, were deposited on a nickel-base superalloy using a plasma spray method. Hot corrosion studies of the plasma-sprayed thermal barrier coatings were conducted in 45wt% Na2SO4 + 55 wt% V2O5 molten salt at 1050 °C. Microstructure and morphology of the coatings were examined and compared by scanning electron microscopy and X-ray diffraction. The addition of mullite in thermal barrier coating results in the mullite phase reacting with corrosive salt and oxygen to form NaAlSiO4 phase. In addition to this phase, alumina (Al2O3) and Na2O phases are also formed. The presence of alumina phase (Al2O3) along with Na2O leads to formation of NaAlO2. A dense layer of NaAlO2 can increase the resistance to hot corrosion of the coating compared to YSZ coating.

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Acknowledgements

The authors of the manuscript are grateful to the experts of the Central Laboratory of Materials and Energy Research Center.

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Authors and Affiliations

  1. Ceramics Department, Materials and Energy Research Center, P.O. Box 31787-316, Karaj, Alborz, Iran

    Nader Soltani, Iman Mobasherpour, Esmail Salahi & Ali Sedaghat Ahangari Hossein Zadeh

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  1. Nader Soltani
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  2. Iman Mobasherpour
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  3. Esmail Salahi
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  4. Ali Sedaghat Ahangari Hossein Zadeh
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NS and IM wrote the main manuscript text. ES and AS prepared raw material and experimental design. All authors reviewed the manuscript.

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Correspondence to Iman Mobasherpour.

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Soltani, N., Mobasherpour, I., Salahi, E. et al. Comparison of Hot Corrosion Behavior of YSZ, YSZ/Mullite and YSZ/Mullite Gradient Coatings on Nickel Base Superalloy Prepared by Plasma Spray Method. High Temperature Corrosion of mater. 99, 163–181 (2023). https://doi.org/10.1007/s11085-023-10147-5

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  • DOI: https://doi.org/10.1007/s11085-023-10147-5

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