Formation mechanisms of columnar/dense structure for Gd2Zr2O7 ceramics coatings with superior CMAS corrosion resistance

IF 7.4 1区 材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY
Bo Cheng , Guangbin Zheng , Dong Hou , Chengyun Ding , Qianqian Chu , Li Feng , Guosheng An , Xinjian Zhang , Lan Sun , Haoteng Sun , Wensheng Li
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Abstract

Corrosion failure induced by calcium-magnesium-alumina-silicate (CMAS) deposits represents a predominant degradation mechanism in advanced thermal barrier coatings (TBCs) systems. In this study, a laser-based surface modification strategy was systematically investigated to reconfigure the microstructure of air plasma spray (APS) Gd₂Zr₂O₇ (GZO) coatings, with the aim of enhancing their resistance to CMAS corrosion. Numerical simulations revealed that laser power dictates microstructural transformations: a fully dense layer forms near the surface at 8 W; in contrast, at 12 W, honeycomb-like crystals are first nucleate at the bottom of the melt pool and grow upward, exhibiting a slight orientation bias in the laser scanning direction. Subsequently, a micro-columnar structure develops in the middle and upper regions of the melt pool. A parameter combination (laser power: 14 W, scan speed: 100 mm/s, line spacing: 0.02 mm, spot diameter: 0.5 mm) was selected to fabricate a hybrid surface texture, which consists of vertically aligned micro-columns (∼10 μm) atop a dense subsurface layer (∼15 μm). The resulting micro columnar and micro-nanocomposite structure conferred superior CMAS corrosion resistance, which is attributable to reduced CMAS wettability on the coating surface and limited CMAS infiltration into the coating interior. The synergistic effects of surface texturing and subsurface structural engineering provide new insights into the design of the corrosion-resistant TBCs via laser-induced phase-selective recrystallization.
具有优异CMAS耐蚀性的Gd2Zr2O7陶瓷涂层柱状/致密结构的形成机理
钙镁铝硅酸盐(CMAS)沉积引起的腐蚀失效是先进热障涂层(tbc)体系中主要的降解机制。本研究系统地研究了激光表面改性策略,以重新配置空气等离子喷涂(APS) Gd₂Zr₂O₇(GZO)涂层的微观结构,以提高其抗CMAS腐蚀的能力。数值模拟表明,激光功率决定了微观结构的转变:在8 W时,在表面附近形成一个完全致密的层;相反,在12 W时,蜂窝状晶体首先在熔池底部成核并向上生长,在激光扫描方向上表现出轻微的取向偏置。随后,在熔池中部和上部区域形成微柱状结构。选择一个参数组合(激光功率:14 W,扫描速度:100 mm/s,线间距:0.02 mm,光斑直径:0.5 mm)来制造混合表面纹理,该纹理由密集的亚表层(~ 15 μm)上垂直排列的微柱(~ 10 μm)组成。所得到的微柱状和微纳复合结构赋予了优异的CMAS耐腐蚀性,这是由于涂层表面的CMAS润湿性降低,限制了CMAS向涂层内部的渗透。表面织构和地下结构工程的协同作用为激光诱导相选择再结晶设计耐腐蚀tbc提供了新的思路。
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来源期刊
Corrosion Science
Corrosion Science 工程技术-材料科学:综合
CiteScore
13.60
自引率
18.10%
发文量
763
审稿时长
46 days
期刊介绍: Corrosion occurrence and its practical control encompass a vast array of scientific knowledge. Corrosion Science endeavors to serve as the conduit for the exchange of ideas, developments, and research across all facets of this field, encompassing both metallic and non-metallic corrosion. The scope of this international journal is broad and inclusive. Published papers span from highly theoretical inquiries to essentially practical applications, covering diverse areas such as high-temperature oxidation, passivity, anodic oxidation, biochemical corrosion, stress corrosion cracking, and corrosion control mechanisms and methodologies. This journal publishes original papers and critical reviews across the spectrum of pure and applied corrosion, material degradation, and surface science and engineering. It serves as a crucial link connecting metallurgists, materials scientists, and researchers investigating corrosion and degradation phenomena. Join us in advancing knowledge and understanding in the vital field of corrosion science.
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