CMAS Corrosion Resistance of Y3Al5O12/Al2O3 Ceramic Coating Deposited by Atmospheric Plasma Spraying

doi:10.15541/jim20240001

Abstract

Abstract:

The investigation of novel materials exhibiting exceptional resistance to calcium-magnesium-aluminum- silicate (CMAS) corrosion at temperatures of 1300 ℃ and above has emerged as a pivotal objective in the advancement of environmental barrier coatings for aircraft engines in recent years. In this study, atmospheric plasma spraying (APS) technology was employed to fabricate YAG(Y₃Al₅O₁₂)/Al₂O₃ coatings with eutectic composition, which was acknowledged as a promising material possessing outstanding CMAS corrosion resistance, thereby rendering it suitable for application in environmental barrier coatings. The as-deposited coatings were annealed at 1100, 1300, and 1500 ℃ to obtain different microstructures, and the corrosion resistance as well as mechanism of YAG/Al₂O₃ coatings against CMAS were investigated by comparing the corrosion results after exposure to CMAS at 1300 ℃. The reaction products between YAG/Al₂O₃ coatings and CMAS were found to be garnet-structure solid solution, CaAl₂Si₂O₈, and Ca₂MgSi₂O₇. The nearly continuous distribution of the garnet-structure solid solution layer at the reaction interface between YAG/Al₂O₃ coating annealed at 1100 ℃ and CMAS effectively impedes the diffusion of CMAS corrosion elements. For YAG/Al₂O₃coating annealed at 1500 ℃, the increase in grain size and decrease in grain boundaries reduce the dissolution rate of the coating. Both of the above can affect the competitive precipitation of various products by influencing the ion transport rate in the corrosion process, and then improve the CMAS corrosion resistance of the coating. Moreover, heat-treatment temperature can tailor grain size, which influences both dissolution-precipitation rate and competitive precipitation of reaction products during CMAS corrosion. These findings provide guidance for selecting appropriate heat-treatment temperature and offer a novel approach to optimize CMAS corrosion resistance of YAG/Al₂O₃ coatings through microstructure optimization.

Key words: YAG(Y₃Al₅O₁₂)/Al₂O₃, atmospheric plasma spraying, environmental barrier coating, CMAS corrosion resistance, grain boundary corrosion, heat-treatment temperature

CLC Number:

TQ174

LI Jie, LUO Zhixin, CUI Yang, ZHANG Guangheng, SUN Luchao, WANG Jingyang. CMAS Corrosion Resistance of Y₃Al₅O₁₂/Al₂O₃ Ceramic Coating Deposited by Atmospheric Plasma Spraying[J]. Journal of Inorganic Materials, 2024, 39(6): 671-680.

Figures/Tables 15

Table 1 Atmospheric plasma spraying parameters for YAG/Al2O3 coating

Current/A	Ar flow rate/slpm	H₂ flow rate/slpm	Rotation velocity/%	Distance/mm
650	40	12	30	110

Fig. 1 XRD patterns of the surfaces of YAG/Al2O3 coatings after CMAS corrosion at 1300 ℃ for (a) 1, (b) 4, and (c) 25 h Colorful patterns are available on website

Fig. 2 Surface morphologies of YAG/Al2O3 coatings after CMAS corrosion Coatings annealed at 1100, 1300, and 1500 ℃ after CMAS corrosion for (a-c) 1, (d-f) 4, and (g-i) 25 h

Fig. 3 TEM analyses of YAG/Al2O3 coating annealed at 1100 ℃ after CMAS corrosion for 1 h (a) Selected area for TEM sample preparation via FIB; (b) Bright-field TEM image from the region indicated by black dashed box in (a); (c) SAED pattern of area marked with black circle in (b)

Table 2 SEM-EDS analytical results of the phases on the surface of YAG/Al2O3 coating annealed at 1100 ℃ after CMAS corrosion for 1 h (%, in atom)

Region	O	Mg	Al	Si	Ca	Y	Phase
A	50.41±1.59	—	17.47±0.70	22.27±0.71	10.16±0.45	—	CaAl₂Si₂O₈
B	54.10±3.25	—	16.47±0.78	19.42±0.95	10.00±1.84	—	CaAl₂Si₂O₈
C	58.95±0.44	5.60±0.29	3.79±0.49	16.57±0.32	15.09±0.20	—	Ca₂MgSi₂O₇
D	39.07±1.11	3.70±0.34	17.29±0.53	17.48±0.52	12.41±0.50	10.06±0.62	YAG
E	49.54±1.04	3.23±0.40	4.73±0.18	23.34±0.41	13.81±1.60	5.34±0.71	CMAS

Fig. 4 Cross-sectional morphologies of YAG/Al2O3 coatings after CMAS corrosion Coatings annealed at 1100, 1300, and 1500 ℃ after CMAS corrosion for (a-c) 1, (d-f) 4, and (g-i) 25 h

Table 3 SEM-EDS analytical results of phases in the cross-section of YAG/Al2O3 coating annealed at 1300 ℃ after CMAS corrosion for 4 h (%, in atom)

Region	O	Mg	Al	Si	Ca	Y	Phase
A	24.15±0.56	—	24.40±0.29	34.29±0.21	17.16±0.22	—	CaAl₂Si₂O₈
B	23.06±3.46	5.43±0.30	11.72±0.42	28.70±1.50	31.09±1.49	—	CMAS
C	18.45±2.17	3.63±0.42	8.98±0.70	35.71±1.30	20.57±0.38	12.67±0.82	YAG
D	26.70±2.79	2.13±0.61	29.42±0.78	14.12±1.62	10.47±0.54	17.18±0.81	YAG
E	31.18±1.51	1.40±0.17	10.56±0.53	31.3±0.53	21.09±0.73	4.47±0.14	CMAS

Fig. 5 TEM analyses of YAG/Al2O3 coating annealed at 1300 ℃ after CMAS corrosion for 4 h (a-c) Bright-field TEM images from regions indicated by dashed box with numbers 1, 2 and 3 in Fig. 4(e), respectively; (d) SAED pattern of area in (a) marked with letter A; (e-i) SAED patterns of areas in (a) marked with letters C-G, respectively

Fig. 6 EDS mappings of the cross-section of YAG/Al2O3 coating annealed at 1100 ℃ after CMAS corrosion for 1 h

Fig. 7 EDS mappings of the cross-section of YAG/Al2O3 coating annealed at 1500 ℃ after CMAS corrosion for 1 h

Fig. S1 High-magnification cross-section observations of YAG/Al2O3 coatings annealed at 1300 ℃ after CMAS corrosion for (a) 1, (b) 4, and (c) 25 h

Fig. S2 High-magnification cross-section observations of YAG/Al2O3 coatings annealed at 1500 ℃ after CMAS corrosion for (a) 1, (b) 4, and (c) 25 h

Fig. S3 Cross-section observations of (a) as-deposited YAG/Al2O3 coating and coatings annealed at (b) 1100, (c) 1300, and (d) 1500 ℃

Fig. S4 Equivalent thickness statistics of precipitation YAG garnet-structure solid solution of coatings annealed at different temperatures

Table S1 TEM-EDS results of the regions marked with letters E, F, and G in Fig. 5(c)(%, in atom)

Region	O	Mg	Al	Si	Ca	Y	Phase
E	43.12±4.00	6.84±0.22	3.49±0.30	21.96±1.32	24.59±2.26		Ca₂MgSi₂O₇
F	50.79±0.93	5.61±0.19	6.51±0.27	17.50±0.82	11.34±0.49	8.25±0.42	YAG
G	59.33±2.03	0.54±0.14	4.95±0.26	19.53±0.73	13.38±0.89	2.27±0.14	CMAS

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CMAS Corrosion Resistance of Y₃Al₅O₁₂/Al₂O₃ Ceramic Coating Deposited by Atmospheric Plasma Spraying

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