Effects of yttria content on the CMAS infiltration resistance of yttria stabilized thermal barrier coatings system

doi:10.1016/j.jmst.2019.09.039

Abstract

Abstract:

The effects of YO_1.5 doping in yttria-zirconia based thermal barrier coatings (TBCs) against CMAS interaction/infiltration are discussed. The TBCs with an YO_1.5 content ranging from 43-67 mol.% (balance ZrO₂) were produced by electron beam physical vapor deposition (EB-PVD) techniques. The results reveal a trend of higher apatite formation probability with the higher free YO_1.5 available in the yttria-zirconia system. Additionally, the infiltration resistance and amount of consumed coating appears to be strongly dependent on the YO_1.5 content in the coating. The thinnest reaction layer and lowest infiltration was found for the highest produced 67YO_1.5 coating. Complementary XRD experiments with volcanic ash/YO_1.5 powder mixtures with higher yttria contents than in the coatings (80YO_1.5 and pure YO_1.5) also showed higher apatite formation with respect to increasing yttria content. The threshold composition to promote apatite-based reaction products was found to be around 50YO_1.5 in zirconia which was proved in the coatings and XRD powder experiments. An YO_1.5-ZrO₂-FeO-TiO₂ bearing zirconolite-type phase was formed as a reaction product for all the coating compositions which implicates that TiO₂ in the melt acts as a trigger for zirconolite formation. This phase could be detrimental for CMAS/volcanic ash infiltration resistance since it can be formed alongside with apatite which controls or limits the amount of Y³⁺ available for glass crystallization. The Fe rich garnet phase containing all the possible elements exhibited a slower nucleation compared to apatite and its growth was enhanced with slow cooling rates. The implications of phase stability and heat treatment effects on the reaction products are discussed for tests performed at 1250 °C.

Key words: CMAS, Volcanic ash, Infiltration, Electron beam physical vapor deposition, Thermal barrier coating

Chavez Juan J.Gomez, Ravisankar Naraparaju, Peter Mechnich, Klemens Kelm, Uwe Schulz, C.V. Ramana. Effects of yttria content on the CMAS infiltration resistance of yttria stabilized thermal barrier coatings system[J]. J. Mater. Sci. Technol., 2020, 43: 74-83.

Figures/Tables 12

Fig. 1. (A) Schematic representation of the jumping beam evaporation process and (B) schematic representation of the as coated TBCs used for this study.

Fig. 2. SEM cross-section image for the as coated samples from the lowest 43YO1.5 content to the highest 67 YO1.5 content. The dashed red line shows the interface between the underlying previously coated 67 YO1.5 and the new layer. High magnification images are shown on the right side for the area delimited within the dotted yellow rectangles.

Fig. 3. XRD plots for the (A) as coated TBCs with different YO1.5 compositions and (B) as-synthesized YO1.5 powders.

Fig. 4. XRD patterns for the YO1.5/Iceland VA mixtures heat treated for 10 h at 1250 °C.

Table 1 Summary of reaction phases for the Iceland VA/ YO1.5 powders heat treated for 10 h at 1250 °C. RE stands for rare-earth ion.

Phase name	ID	Theoretical formula
Apatite	A	(Ca,Mg,RE)₂(RE,Zr)₈(SiO₄)₆O₂
Garnet	G	(RE,Zr,Ca)₃(Mg,Al,Fe,Ti,Zr)₂(Si,Al,Fe)₃O₁₂
Fluorite	F	(RE,Zr,Ca)O_1._x
Zirconolite	Z	(Ca,RE, Zr)₂(Fe, Ti, Al, Mg)₂O₇

Fig. 5. Cross-section SEM images of the reaction for (A) 43YO1.5, (B) 53YO1.5, (C) 60YO1.5 and (D) 67YO1.5 TBCs for 1 h at 1250 °C with Iceland VA. The area delimited within the dotted lines represent the reaction zone, “g” stands for the unreacted glass.

Fig. 6. Cross-section SEM image of the infiltrated 67YO1.5 TBC sample showing the elemental mapping for the overall infiltration (seen as Ca and Si mappings) and reaction layer zone with the Ti and Fe concentration. The dotted line shows the interface between the new and old deposited coatings.

Fig. 7. Bright field TEM image of the 67YO1.5 column after 1 h heat treatment at 1250 °C from the non-infiltrated zone. The SAED images show the non-mixed alumina phases at the alumina rich zone and the mixture of cubic fluorite and cubic yttria at the core of the TBC column.

Fig. 8. Ratio of g:TBC plot for the produced reaction products, where the g represents the amount (mol.%) of the glass oxides and the TBC represents the YO1.5 and ZrO2 contents for the 67YO1.5 TBC coating infiltrated for 1 h at 1250 °C.

Table 2 Summary of chemical composition of reaction products and residual glass (g) for the 67YO1.5 coating, measured by EDS in SEM. Unless specified in the table, the element composition error was below 1.0 mol.%.

Phase ID	NaO_0.5	MgO	AlO_1.5	SiO₂	KO_0.5	CaO	TiO₂	FeO	YO_1.5	ZrO₂
Z	-	1.5	3.5	3.9 ± 2.5	-	2.0	19.9	19.3	21.2 ± 1.3	28.7 ± 1.9
G	-	6.8 ± 1.1	7.2 ± 2.2	20.7 ± 2.2	-	9.6	0.9	21.9 ± 6.5	29.4 ± 5.1	3.5 ± 2.3
A	-	1.7	0.4	30.7 ± 3.2	-	10.4 ± 1.3	-	0.6	47.8 ± 2.1	8.4 ± 4.7
F	-	-	-	-	-	0.6	4.5	6.7	23.5 ± 2.5	64.8 ± 3.2
G	3.7	5.9	13.2	43.6	0.9	10.3	1.9	10.0	7.8	2.7 ± 0.2

Fig. 9. Adapted phase diagram from [55] of the ZrO2-YO1.5 system showing the possible phases for the tested system at 1250 °C up to 80YO1.5. Single arrows represent the other powder compositions of 65 and 50 YO1.5.

Fig. 10. SEM images of the (A) 43YO1.5 TBC sample after slow cooling, (B) 67YO1.5 TBC sample after slow cooling and (C) 67 YO1.5 TBC sample from the top reaction zone after air quenching showing the small dendrite particle formation. All the samples had the same infiltration time of 1 h at 1250 °C.

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