Structural design and plasma ablation mechanism of multilayered and gradient YSZ-MoSi2-Mo composite coating on Ta-10W alloy beyond 2100 °C

IF 5.1 2区材料科学 Q1 MATERIALS SCIENCE, CERAMICS

Ceramics International Pub Date : 2025-06-01 DOI:10.1016/j.ceramint.2025.02.154

Xiangjun Bu , Pengfei He , Ping Zhang , Chuan Sun , Ximing Duan , Yue Xing , Shujun Hu , Zhenfeng Hu , Xiubing Liang

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Abstract

To improve the high-temperature ablation resistance of Ta-10W alloy as a hot-end component of high-speed craft, a novel multilayered YSZ-MoSi₂-Mo (YMM) gradient coating was designed and prepared using plasma spraying. The coating consisted of a YSZ surface layer (∼250 μm), a MoSi₂-YSZ gradient middle layer (∼150 μm), and a Mo-MoSi₂ bottom layer (∼100 μm). The ablation behavior of the coating was investigated using a plasma flame at 2100 °C, 2200 °C, 2300 °C, and 2400 °C for 300 s, respectively. Results showed that the coating remains intact during plasma ablation at 2100 °C. However, bulging (∼199.2 μm) at the ablation center occurred at 2200 °C, while the depth of the oxygen erosion was about 370 μm. Besides, the Mo-MoSi₂ bottom layers were incompletely oxidized and damaged under all the ablation conditions. This indicates that the YMM coating could effectively protect the Ta-10W alloy at ablation temperatures ranging from 2100 to 2400 °C for 300 s. This excellent ablation resistance of the YMM coating was mainly attributed to the damage resistance from the plasma flame of the YSZ layer as well as the oxygen barrier effect and self-healing effect to cracks of SiO₂ formed from MoSi₂. Besides, the multilayered gradient structure of the coating effectively reduced the mismatch between the coefficient of thermal expansion of the YSZ layer and the Ta-10W alloy.

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Ta-10W合金多层梯度YSZ-MoSi2-Mo复合涂层的结构设计及2100℃高温等离子体烧蚀机理

为了提高高速飞行器热端部件Ta-10W合金的耐高温烧蚀性能，采用等离子喷涂技术制备了一种新型多层YSZ-MoSi2-Mo （YMM）梯度涂层。该涂层由YSZ表层（~ 250 μm）、MoSi2-YSZ梯度中间层（~ 150 μm）和Mo-MoSi2底层（~ 100 μm）组成。采用等离子体火焰分别在2100℃、2200℃、2300℃和2400℃下烧蚀300 s，研究了涂层的烧蚀行为。结果表明，在2100℃等离子体烧蚀过程中，涂层保持完整。在2200℃时，烧蚀中心出现胀形（~ 199.2 μm），而氧蚀深度约为370 μm。此外，在所有烧蚀条件下，Mo-MoSi2的底层均未完全氧化并出现损伤。这表明YMM涂层可以在2100 ~ 2400℃烧蚀温度下有效保护Ta-10W合金300 s。YMM涂层之所以具有优异的抗烧蚀性能，主要是由于YSZ层具有抗等离子体火焰损伤的能力，以及MoSi2对SiO2形成的裂纹具有氧障作用和自愈作用。此外，涂层的多层梯度结构有效地减少了YSZ层与Ta-10W合金热膨胀系数的不匹配。

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来源期刊

Ceramics International 工程技术-材料科学：硅酸盐

CiteScore

9.40

自引率

15.40%

发文量

4558

审稿时长

25 days

期刊介绍： Ceramics International covers the science of advanced ceramic materials. The journal encourages contributions that demonstrate how an understanding of the basic chemical and physical phenomena may direct materials design and stimulate ideas for new or improved processing techniques, in order to obtain materials with desired structural features and properties. Ceramics International covers oxide and non-oxide ceramics, functional glasses, glass ceramics, amorphous inorganic non-metallic materials (and their combinations with metal and organic materials), in the form of particulates, dense or porous bodies, thin/thick films and laminated, graded and composite structures. Process related topics such as ceramic-ceramic joints or joining ceramics with dissimilar materials, as well as surface finishing and conditioning are also covered. Besides traditional processing techniques, manufacturing routes of interest include innovative procedures benefiting from externally applied stresses, electromagnetic fields and energetic beams, as well as top-down and self-assembly nanotechnology approaches. In addition, the journal welcomes submissions on bio-inspired and bio-enabled materials designs, experimentally validated multi scale modelling and simulation for materials design, and the use of the most advanced chemical and physical characterization techniques of structure, properties and behaviour. Technologically relevant low-dimensional systems are a particular focus of Ceramics International. These include 0, 1 and 2-D nanomaterials (also covering CNTs, graphene and related materials, and diamond-like carbons), their nanocomposites, as well as nano-hybrids and hierarchical multifunctional nanostructures that might integrate molecular, biological and electronic components.