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Thermal Failure of Nanostructured Thermal Barrier Coatings with Cold-Sprayed Nanostructured NiCrAlY Bond Coat

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Abstract

Nanostructured thermal barrier coatings (TBCs) were deposited by plasma spraying using agglomerated nanostructured YSZ powder on Inconel 738 substrate with cold-sprayed nanostructured NiCrAlY powder as bond coat. The isothermal oxidation and thermal cycling tests were applied to examine failure modes of plasma-sprayed nanostructured TBCs. For comparison, the TBC consisting of conventional microstructure YSZ and conventional NiCrAlY bond coat was also deposited and subjected to the thermal shock test. The results showed that nanostructured YSZ coating contained two kinds of microstructures; nanosized zirconia particles embedded in the matrix and microcolumnar grain structures of zirconia similar to those of conventional YSZ. Although, after thermal cyclic test, a continuous, uniform thermally grown oxide (TGO) was formed, cracks were observed at the interface between TGO/BC or TGO/YSZ after thermal cyclic test. However, the failure of nanostructured and conventional TBCs mainly occurred through spalling of YSZ. Compared with conventional TBCs, nanostructured TBCs exhibited better thermal shock resistance.

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Acknowledgments

The present work is supported by National Basic Research Program (Grant No. 2007CB707702), National Science Fund for Distinguished Young Scholars (Grant No. 50725101), and Research Foundation of National Key Laboratory for High Energy Density Beam Processing Technology (Grant No. 51461070705JW0805).

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Authors and Affiliations

  1. State Key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, Xi’an Jiaotong University, Xi’an, Shaanxi, 710049, P.R. China

    Qiang Zhang, Chang-Jiu Li, Yong Li, Shao-Ling Zhang, Xiu-Ru Wang, Guan-Jun Yang & Cheng-Xin Li

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  1. Qiang Zhang
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  2. Chang-Jiu Li
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  3. Yong Li
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  4. Shao-Ling Zhang
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  7. Cheng-Xin Li
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Correspondence to Chang-Jiu Li.

Additional information

This article is an invited paper selected from presentations at the 2008 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Thermal Spray Crossing Borders, Proceedings of the 2008 International Thermal Spray Conference, Maastricht, The Netherlands, June 2-4, 2008, Basil R. Marple, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Ghislain Montavon, Ed., ASM International, Materials Park, OH, 2008.

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Zhang, Q., Li, CJ., Li, Y. et al. Thermal Failure of Nanostructured Thermal Barrier Coatings with Cold-Sprayed Nanostructured NiCrAlY Bond Coat. J Therm Spray Tech 17, 838–845 (2008). https://doi.org/10.1007/s11666-008-9223-z

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  • DOI: https://doi.org/10.1007/s11666-008-9223-z

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