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Evaluation of stress concentrations during high-temperature exposure on the lifetime of single and dual-layer ZrO2-8Y2O3/ZrO2-9.5Y2O3-5.6Yb2O3-5.2Gd2O3 TBCs

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Abstract

In this study, the effective stresses in determining the lifetime of new-generation single-layer ZrO2-9.5Y2O3-5.6Yb2O3-5.2Gd2O3 (ZGdYbYO) and dual-layer ZrO2-8Y2O3 (YSZ)/ZGdYbYO thermal barrier coatings (TBCs) were investigated. For this purpose, single-layer ZGdYbYO and dual-layer YSZ/ZGdYbYO TBCs were applied on IN738LC/CoNiCrAlY by atmospheric plasma spraying technique. Then, their cyclic oxidation behavior was studied at 1100 °C with 4-h cycles. The morphologies of the TBCs (before and after oxidation) were investigated by field emission scanning electron microscopy (FESEM). In addition, the mechanical behavior of the TBCs was examined by the nano-indentation test. Thermal stress was measured in single-layer ZGdYbYO and dual-layer YSZ/ZGdYbYO TBCs to be 1.2 and 1.1 GPa, respectively, with thermal growth oxide (TGO) layer growth causing stresses of 0.8 GPa and 0.3 GPa, respectively. The variation in the energy release rate of the TBCs during oxidation cycles was calculated. The results showed that the changes in the energy release rate of dual-layer YSZ/ZGdYbYO TBC compared to single-layer ZGdYbYO TBC are less, and, therefore, have a better high-temperature performance. Applying an intermediate YSZ layer with higher fracture toughness than that of ZGdYbYO between the bond and top coats enhances the mechanical properties of new TBCs and extends their lifetime by improving their resistance to high-temperature oxidation.

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Authors and Affiliations

  1. Department of Mining and Metallurgical Engineering, Yazd University, Yazd, 89195-741, Iran

    Zahra Nasr-Esfahani, Milad Bahamirian & Mohsen Nouri-Khezrabad

  2. Department of Ceramic, Materials and Energy Research Center, Karaj, 31787-316, Iran

    Mohammad Farvizi

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  1. Zahra Nasr-Esfahani
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  2. Milad Bahamirian
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  3. Mohammad Farvizi
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  4. Mohsen Nouri-Khezrabad
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Contributions

Milad Bahamirian: conceptualization, supervision, and writing original draft. Zahra Nasr-Esfahani: investigation. Mohammad Farvizi and Mohsen Nouri-Khezrabad: writing, review, and editing.

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Correspondence to Milad Bahamirian.

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Nasr-Esfahani, Z., Bahamirian, M., Farvizi, M. et al. Evaluation of stress concentrations during high-temperature exposure on the lifetime of single and dual-layer ZrO2-8Y2O3/ZrO2-9.5Y2O3-5.6Yb2O3-5.2Gd2O3 TBCs. emergent mater. 6, 1611–1621 (2023). https://doi.org/10.1007/s42247-023-00556-2

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