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A Novel Plasma-Sprayed Durable Thermal Barrier Coating with a Well-Bonded YSZ Interlayer Between Porous YSZ and Bond Coat

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Abstract

Atmospheric plasma-sprayed YSZ (yttria-stabilized zirconia) thermal barrier coatings (TBCs) are widely used in industrial gas turbine engines to protect the superalloy blades from failure. The failure of TBCs in service occurs by the spalling of YSZ coating. Crack propagation leading to the failure of plasma-sprayed TBCs usually occurs within the YSZ coating near the YSZ/bond coat interface. In the present study, a novel durable TBC consisting of a YSZ interlayer of well-bonded lamellae between the bond coat and the conventional YSZ porous top coat was introduced. The YSZ interlayer was deposited at different coating surface temperatures, which resulted in the formation of YSZ with significantly improved interlamellar bonding. The result shows that the thermal cyclic lifetime of the novel TBCs with the 20-30-μm-thick YSZ interlayer increased by a factor of 4 compared with that of the conventional one. The improved thermal cyclic lifetime was attributed to the controlled transition of the cracking path from near the YSZ/bond coat interface to the YSZ top layer. The effect of the YSZ interlayer thickness on the lifetime of TBCs was also investigated.

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Acknowledgments

The present study was financially supported by the National Natural Science Funds of China (50725101), and by the National Basic Research Program of China (No. 2007CB707702).

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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, 710049, Shaanxi, China

    Chang-Jiu Li, Yong Li, Guan-Jun Yang & Cheng-Xin Li

  2. Xi’an Thermal Power Research Institute Co. Ltd., Xi’an, Shaanxi, China

    Yong Li

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  1. Chang-Jiu Li
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  2. Yong Li
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  4. 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 2011 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Thermal Spray 2011: Proceedings of the International Thermal Spray Conference, Hamburg, Germany, September 27-29, 2011, Basil R. Marple, Arvind Agarwal, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and André McDonald, Ed., ASM International, Materials Park, OH, 2011.

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Li, CJ., Li, Y., Yang, GJ. et al. A Novel Plasma-Sprayed Durable Thermal Barrier Coating with a Well-Bonded YSZ Interlayer Between Porous YSZ and Bond Coat. J Therm Spray Tech 21, 383–390 (2012). https://doi.org/10.1007/s11666-012-9771-0

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  • DOI: https://doi.org/10.1007/s11666-012-9771-0

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