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Failure analysis of Gd2Zr2O7/YSZ multi-layered thermal barrier coatings subjected to thermal cyclic fatigue
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0003-2475-9284 
Treibacher Industrie AG, Austria.ORCID iD: 0000-0003-0209-1332
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0003-1181-0415
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0002-9578-4076
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2016 (English)In: Journal of Alloys and Compounds, ISSN 0925-8388, E-ISSN 1873-4669, Vol. 689, 1011-1019 p.Article in journal (Refereed) Published
Abstract [en]

8 wt.% yttria stabilized zirconia (8YSZ) is the standard ceramic top coat material used in thermal barrier coatings (TBCs) due to its excellent thermo-physical and thermo-mechanical properties. However, above 1200 °C, YSZ has issues such as susceptibility to CMAS (Calcium Magnesium Alumino Silicates) attack and enhanced sintering which could lead to catastrophic failure of the TBC. Pyrochlores of rare earth zirconate composition such as gadolinium zirconate have shown to be resistant to CMAS attack and at the same time possess several other attractive properties. However, poor thermal cycling life of single layer gadolinium zirconate (GZ) TBC compared to single layer YSZ has been reported. Therefore, a double layered GZ/YSZ TBC with YSZ as the intermediate coating and GZ as the top coat and a single layer 8YSZ were deposited by the axial suspension plasma spray process. Additionally, a triple layer TBC (GZdense/GZ/YSZ) comprising of denser GZ coating on top of GZ/YSZ TBC was deposited. SEM analysis revealed a columnar microstructure in the single, double and triple layer TBCs. XRD analysis confirmed the presence of tetragonal prime and defect fluorite phases in the top surface of YSZ and GZ based as sprayed TBCs respectively. The single layer YSZ and GZ/YSZ multi-layered TBCs were subjected to thermal cyclic fatigue (TCF) testing at 1100 °C and 1200 °C. The triple layer TBC showed a higher thermal cyclic life at both the temperatures compared to the single and double layer TBCs. The failed TBCs at 1100 °C were analyzed by SEM/EDS and image analysis. It was found that the failure modes in single layer YSZ and GZ based TBCs were different.

Place, publisher, year, edition, pages
2016. Vol. 689, 1011-1019 p.
Keyword [en]
Gadolinium zirconate, yttria stabilized zirconia, axial suspension plasma spray, multi-layered thermal barrier coating, columnar microstructure, thermal cyclic fatigue
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering; Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-9811DOI: 10.1016/j.jallcom.2016.07.333ISI: 000384427200129Scopus ID: 2-s2.0-84982239051OAI: oai:DiVA.org:hv-9811DiVA: diva2:955783
Available from: 2016-08-26 Created: 2016-08-26 Last updated: 2016-12-20Bibliographically approved

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Mahade, SatyapalCurry, NicholasBjörklund, StefanMarkocsan, NicolaieNylén, Per
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