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Hot Corrosion Behavior of YSZ Thermal Barrier Coatings Modified by Laser Remelting and Al Deposition

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Abstract

Thermal barrier coatings that are widely used to protect the turbine blades of gas turbines from failure are subjected to hot corrosion conditions. The present study aims to improve their hot corrosion resistance by modifying the plasma-sprayed yttria-stabilized zirconia topcoat by laser remelting and Al deposition. First, a dense remelted layer with some vertical cracks was obtained by laser remelting. Then, Al film was deposited on the surface of laser-remelted coatings by magnetron sputtering, and the dense α-Al2O3 overlay was in situ synthesized through the reaction of Al and ZrO2 during vacuum heat treatment. Hot corrosion tests of all coatings were conducted in a mixture of 55 wt.% V2O5 and 45 wt.% Na2SO4 corrosive salts at 1000 °C for 30 h. The defects such as pores and microcracks in the as-sprayed coatings provided paths for molten salt penetration, which led to the worst hot corrosion resistance of the as-sprayed coatings. The minimal surface roughness of the dense laser-remelted coatings was the main reason for improving the hot corrosion resistance. However, the resistance of laser-remelted coatings to hot corrosion was significantly improved when they were modified by Al deposition, which is mainly due to the reduced reaction surface between molten salts and yttria stabilizer. The corresponding hot corrosion mechanism was discussed.

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Acknowledgments

This work is supported by GDAS’ Project of Science and Technology Development (2019GDASYL-0502006, 2019GDASYL-0402006, 2019GDASYL-0402004, 2019GDASYL-0501009, 2018GDASCX-0947, 2017GDASCX-0111, and 2017GDASCX-0202), Science and Technology Project of Guangdong Province (2017A070702016, 2017B030314122 and 2017A070701027), Natural Science Foundation of Guangdong Province (2016A030312015), Zhongshan Project of Science and Technology (2017G1FC0008) and innovation capacity building of Guangdong Industrial Technology Research Institute (2014B070705007).

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Authors and Affiliations

  1. The Key Laboratory of Bionic Engineering, Ministry of Education, Jilin University, 5988 Renmin Street, Changchun, 130022, China

    Panpan Zhang, Zhihui Zhang & Luquan Ren

  2. National Engineering Laboratory for Modern Materials Surface Engineering Technology, the Key Lab of Guangdong for Modern Surface Engineering Technology, Guangdong Institute of New Materials, Guangzhou, 510651, China

    Panpan Zhang, Xiaofeng Zhang, Fuhai Li, Yueliang Wang, Hong Li & Min Liu

  3. The State Key Laboratory of Automotive Simulation and Control, Jilin University, 5988 Renmin Street, Changchun, 130022, China

    Zhihui Zhang

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  1. Panpan Zhang
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Zhang, P., Zhang, X., Li, F. et al. Hot Corrosion Behavior of YSZ Thermal Barrier Coatings Modified by Laser Remelting and Al Deposition. J Therm Spray Tech 28, 1225–1238 (2019). https://doi.org/10.1007/s11666-019-00880-2

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