Abstract
In the present study, laser cladding of alumina on the top surface of YSZ thermal barrier coatings (TBC) was conducted via Nd:YAG pulsed laser. The thermal shock behavior of the TBC before and after laser cladding was modified by heating at 1000 °C for 15 min and quenching in cold water. Phase analysis, microstructural evaluation and elemental analysis were performed using x-ray diffractometry, scanning electron microscopy (SEM), and energy-dispersive spectroscopy. The results of thermal shock tests indicated that the failure in the conventional YSZ (not laser clad) and the laser clad coatings happened after 200 and 270 cycles, respectively. The SEM images of the samples showed that delamination and spallation occurred in both coatings as the main mechanism of failure. Formation of TGO was also observed in the fractured cross section of the samples, which is also a main reason for degradation. Thermal shock resistance in the laser clad coatings improved about 35% after cladding. The improvement is due to the presence of continuous network cracks perpendicular to the surface in the clad layer and also the thermal stability and high melting point of alumina in Al2O3/ZrO2 composite.
Similar content being viewed by others
References
N.V. Patel, E.H. Jordan, S. Sridharan, and M. Gell, Cyclic Furnace Testing and Life Predictions of Thermal Barrier Coating Spallation Subject to a Step Change in Temperature or in Cycle Duration, Surf. Coat. Technol., 2015, 275, p 384–391
M. Zhaia, D. Lia, Y. Zhao, X. Zhong, F. Shao, H. Zhao, C. Liu, and S. Tao, Comparative Study on Thermal Shock Behavior of Thick Thermal Barrier Coatings Fabricated with Nano-Based YSZ Suspension and Agglomerated Particles, Ceram. Int., 2016, 42, p 12172–12179
J. Wu, H.B. Guo, L. Zhou, L. Wang, and S.K. Gong, Microstructure and Thermal Properties of Plasma Sprayed Thermal Barrier Coatings from Nanostructured YSZ, J. Therm. Spray Technol., 2010, 19, p 1186–1194
R. Liu, S. Yuan, Z. Wang, Y. Zhao, M. Zhang, and L. Shi, Graded YSZ/Al2O3 Hot Corrosion Resistant Coating with Enhanced Thermal Shock Resistance, RSC Adv., 2013, 3, p 17034–17038
X. Song, Z. Liu, T. Suhonen, T. Varis, L. Huang, X. Zheng, and Y. Zeng, Effect of Melting State on the Thermal Shock Resistance and Thermal Conductivity of APS ZrO2-7.5 wt.% Y2O3 Coatings, Surf. Coat. Technol., 2015, 270, p 132–138
H. Jamali, R. Mozafarinia, R. Shoja Razavi, and R. Ahmadi-Pidani, Comparison of Thermal Shock Resistances of Plasma-Sprayed Nanostructured and Conventional Yttria Stabilized Zirconia Thermal Barrier Coatings, Ceram. Int., 2012, 38, p 6705–6712
R. Ghasemin, R. Shoja-Razavi, R. Mozafarinia, and H. Jamali, The Influence of Laser Treatment on Thermal Shock Resistance of Plasma-Sprayed Nanostructured Yttria Stabilized Zirconia Thermal Barrier Coatings, Ceram. Int., 2014, 40, p 347–355
C. Giolli, A. Scrivani, G. Rizzi, F. Borgioli, G. Bolelli, and L. Lusvarghi, Failure Mechanism for Thermal Fatigue of Thermal Barrier Coating Systems, J. Therm. Spray Technol., 2009, 18, p 223–230
R. Eriksson, H. Brodin, S. Johansson, L. Östergren, and X.H. Li, Fractographic and Microstructural Study of Isothermally and Cyclically Heat Treated Thermal Barrier Coatings, Surf. Coat. Technol., 2014, 243, p 82–90
N.M. Yanar, G.H. Meier, and F.S. Pettit, The Influence of Platinum on the Failure of EBPVD YSZ TBCs on NiCoCrAlY Bond Coats, Scr. Mater., 2002, 46, p 325–330
S. Guo and Y. Kagawa, Isothermal and Cycle Properties of EB-PVD Yttria-Partially-Stabilized Zirconia Thermal Barrier Coatings at 1150 and 1300 °C, Ceram. Int., 2007, 33, p 373–378
T.A. Dobbins, R. Knight, and M.J. Mayo, HVOF Thermal Spray Deposited Y2O3-Stabilized ZrO2 Coatings for Thermal Barrier Applications, J. Therm. Spray Technol., 2003, 12, p 214–225
J.R.V. Garcial and T. Goto, Thermal Barrier Coatings Produced by Chemical Vapor Deposition, Sci. Technol. Adv. Mater., 2003, 4, p 397–402
X. Chen, Y. Zhao, X. Fan, Y. Liu, B. Zou, Y. Wang, H. Ma, and X. Cao, Thermal Cycling Failure of New LaMgAl11O19/YSZ Double Ceramic Top Coat Thermal Barrier Coating Systems, Surf. Coat. Technol., 2011, 205, p 3293–3300
Y. Bai, Z.H. Han, H.Q. Li, C. Xu, Y.L. Xu, Z. Wang, C.H. Ding, and J.F. Yan, High Performance Nanostructured ZrO2 Based Thermal Barrier Coatings Deposited by High Efficiency Supersonic Plasma Spraying, Appl. Surf. Sci., 2011, 257, p 7210–7216
E. Sanchez, E. Bannier, V. Cantavella, M.D. Salvador, E. Klyatskina, J.Grzonka Morgiel, and A.R. Boccaccini, Deposition of Al2O3-TiO2 Nanostructured Powders by Atmospheric Plasma Spraying, J. Therm. Spray Technol., 2008, 17, p 329–337
R. Ahmadi-Pidani, R. Shoja-Razavi, R. Mozafarinia, and H. Jamali, Improving the Thermal Shock Resistance of Plasma Sprayed CYSZ Thermal Barrier Coatings by Laser Surface Modification, Opt. Lasers Eng., 2012, 50, p 780–786
Q. Cui, S.M. Seo, Y.S. Yoo, Z. Lu, and S.W. Myoung, Thermal Durability of Thermal Barrier Coatings with Bond Coat Composition in Cyclic Thermal Exposure, Surf. Coat. Technol., 2015, 284, p 69–74
H. Dong, G.J. Yang, H.N. Cai, H. Ding, C.X. Li, and C.J. Li, The Influence of Temperature Gradient Across YSZ on Thermal Cyclic Lifetime of Plasma-Sprayed Thermal Barrier Coatings, Ceram. Int., 2015, 41, p 11046–11056
M.R. Begley and H.N.G. Wadley, Delamination Resistance of Thermal Barrier Coatings Containing Embedded Ductile Layers, Acta Mater., 2012, 60, p 2497–2508
X. Zhong, H. Zhao, C. Liu, L. Wang, and F. Shao, Improvement in Thermal Shock Resistance of Gadolinium Zirconate Coating by Addition of Nanostructured Yttria Partially-Stabilized Zirconia, Ceram. Int., 2015, 41, p 7318–7324
J.H. Lee, P.C. Tsai, and C.L. Chang, Microstructure and Thermal Cyclic Performance of Laser Glazed Plasma-Sprayed Ceria-Yttria-Stabilized Zirconia Thermal Barrier Coatings, Surf. Coat. Technol., 2008, 202, p 5607–5612
C. Ren, Y.D. He, and D.R. Wang, Cyclic Oxidation Behavior and Thermal Barrier Effect of YSZ-(Al2O3/YAG) Double-Layer TBCs Prepared by the Composite Sol-Gel Method, Surf. Coat. Technol., 2011, 206, p 1461–1468
J.D. Kim and Y. Peng, Melt pool Shape and Dilution of Laser Cladding with Wire Feeding, J. Mater. Process. Technol., 2000, 104, p 284–293
A. Afrasiabi, M. Saremi, and A. Kobayashi, A Comparative Study on Hot Corrosion Resistance of Three Types of Thermal Barrier Coatings: YSZ, YSZ + Al2O3 and YSZ/Al2O3, Mater. Sci. Eng. A, 2008, 478, p 264–269
C. Batista, A. Portinha, R.M. Ribeiro, V. Teixeira, M.F. Costa, and C.R. Oliveira, Surface Laser-Glazing of Plasma-Sprayed Thermal Barrier Coatings, Appl. Surf. Sci., 2005, 9, p 247–313
C. Ren, Y.D. He, and D.R. Wang, Preparation and Characteristics of Three Layer YSZ-(YSZ/Al2O3)-YSZ TBCs, Appl. Surf. Sci., 2011, 257, p 6837–6842
X.Q. Cao, R. Vassen, and D. Stoever, Ceramic Materials for Thermal Barrier Coatings, J. Eur. Ceram. Soc., 2004, 24, p 1–10
G.M. Pharr, Measurement of Mechanical Properties by Ultra-Low Load Indentation, Mater. Sci. Eng., 1998, A253, p 151–159
G. Di Girolamo, F. Marra, C. Blasi, E. Serra, and T. Valente, Microstructure, Mechanical Properties and Thermal Shock Resistance of Plasma Sprayed Nanostructured Zirconia Coatings, Ceram. Int., 2011, 37, p 2711–2717
L. Wang, Y. Wang, X.G. Sun, J.Q. He, Z.Y. Pan, and C.H. Wang, Thermal Shock Behavior of 8YSZ and Double-Ceramic-Layer La2Zr2O7/8YSZ Thermal Barrier Coatings Fabricated by Atmospheric Plasma Spraying, Ceram. Int., 2012, 38, p 3595–3606
X. Chen, Y. Zhang, X. Zhong, Z. Xu, J. Zhang, Y. Cheng, Y. Zhao, Y. Liu, X. Fan, Y. Wang, H. Ma, and X. Cao, Thermal Cycling Behaviors of the Plasma Sprayed Thermal Barrier Coatings of Hexaluminates with Magnetoplumbite Structure, J. Eur. Ceram. Soc., 2010, 30, p 1649–1657
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Soleimanipour, Z., Baghshahi, S. & Shoja-razavi, R. Improving the Thermal Shock Resistance of Thermal Barrier Coatings Through Formation of an In Situ YSZ/Al2O3 Composite via Laser Cladding. J. of Materi Eng and Perform 26, 1890–1899 (2017). https://doi.org/10.1007/s11665-017-2591-0
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11665-017-2591-0