CMAS Corrosion Resistance of Al-modified Si-HfO2/YbDS/GYYZO Thermal-environmental Barrier Coating

doi:10.15541/jim20250452

Abstract

Abstract: The rising service temperature of aero-engine hot-section components makes calcium magnesium aluminum silicate (CMAS) corrosion a key failure mechanism for thermal/environmental barrier coatings T/EBCs. The novel Gd₂O₃-Yb₂O₃-Y₂O₃ co-stabilized ZrO₂ (GYYZO) ceramic is promising due to its good thermophysical properties, however, its CMAS corrosion resistance at 1500 ℃ needs improvement. In this work, a PS-PVD-fabricated Si-HfO₂/Yb₂Si₂O₇/GYYZO coating system was enhanced via Al deposition and vacuum heat treatment. Firstly, the as-sprayed coating was annealed at 1300 ℃ to heal microcracks. Subsequently, a 3-4 μm thick aluminum film was deposited on the GYYZO layer surface via direct current pulsed magnetron sputtering. Finally, vacuum heat treatment (400 ℃/2.5 h + 660 ℃/2 h + 808 ℃/1.5 h + 980 °C/1 h) was conducted to promote the formation of a dense Al₂O₃ barrier layer. A comparative study at 1500 ℃ revealed that CMAS rapidly penetrated the unmodified GYYZO coating along grain boundaries, causing blistering and cracking in the Yb₂Si₂O₇ layer and accelerating failure. Conversely, the Al-modified GYYZO coating formed a dense Al₂O₃ barrier in situ, effectively suppressing CMAS penetration and slowing corrosion kinetics, thus maintaining structural integrity after 1 h.

Key words: thermal/environmental barrier coating, CMAS corrosion, aluminum modification, GYYZO

CLC Number:

TQ174

SHANG Sen, JIANG Linwen, DONG Hao, DAI Rui, WU Jian, ZHUO Xueshi, ZHANG Jungui, ZHANG Xiaofeng. CMAS Corrosion Resistance of Al-modified Si-HfO₂/YbDS/GYYZO Thermal-environmental Barrier Coating[J]. Journal of Inorganic Materials, DOI: 10.15541/jim20250452.

References

[1] CHENG H C, WANG Y L, LIU H F,et al. Microstructure evolution and thermochemical interaction of dysprosia stabilized zirconia with CMAS attack. Materials Characterization, 2025, 227: 115331.
[2] GODBOLE E P, HEWAGE N, POERSCHKE D L.Spreading and reaction behavior of CMAS-type silicate melts with multiphase Y and Gd aluminate-zirconate T/EBC materials.Journal of the European Ceramic Society, 2023, 43(14): 6416.
[3] DENG L W, WANG Y, ZHANG X D.Enhancing the anti-CMAS corrosion performance of EBCsvia adding SiC to Yb₂Si₂O₇ top ceramic layer: a novel SiC-Yb₂Si₂O₇/Si EBCs strategy. Journal of the European Ceramic Society, 2026, 46(3): 117847.
[4] FAN D, ZHONG X, WANG Y W,et al. Corrosion behavior and mechanism of aluminum-rich CMAS on rare-earth silicate environmental barrier coatings: . Journal of Inorganic Materials, 2023, 38(5): 544.
[5] YAN S Q, WU J, TAN X,et al. Microstructural evolution and corrosion mechanism of thermal/environmental barrier coatings against molten calcium-magnesium-alumino-silicate. Surface and Coatings Technology, 2024, 478: 130433.
[6] WU Y M, ZHONG X, HONG D,et al. Corrosion behaviors of Lu₄Hf₃O₁₂ thermal/environmental barrier coatings to molten CMAS attack at 1300-1500 ℃. Applied Surface Science, 2024, 676: 161020.
[7] WANG Y Q, WANG F L, MAO J K,et al. Reliability analysis of thermal barrier coatings under CMAS deposition and penetration. Surface and Coatings Technology, 2024, 489: 131139.
[8] ZHANG G H, SHI J Y, SHEN H Y,et al. Synergistic mechanism of Gd³+ and Yb³+ on crystallization behavior of CMAS corrosion products. Journal of Inorganic Materials, 2026, 41(1): 27.
[9] WANG H D, ZHUO X S, ZHANG J G,et al. Strengthening of CMAS corrosion resistance of thermal barrier coatings by surface Al-Ce modification. Surface and Coatings Technology, 2025, 510: 132168.
[10] SONG J B, ZHANG X F, DENG C M,et al. Research of in situ modified PS-PVD thermal barrier coating against CMAS (CaO-MgO-Al₂O₃-SiO₂) corrosion. Ceramics International, 2016, 42(2): 3163.
[11] 玉郅云, 郭凯森, 程一凡, 等. Y₂O₃添加对Al₂O₃陶瓷/CMAS界面致密反应层生长行为的影响研究. 装备制造技术, 2025(8): 60.
[12] LIANG R H, ZHONG X, HONG D,et al. High-temperature water vapor corrosion behaviors of environmental barrier coatings with Yb₂O₃-modified silicon bond layer. Journal of Inorganic Materials, 2025, 40(4): 425.
[13] FAN W K, YANG X, LI H H,et al. Pressureless sintering of (Y_0.2Gd_0.2Er_0.2Yb_0.2Lu_0.2)₂Zr₂O₇ high-entropy ceramic and its high temperature CMAS corrosion resistance. Journal of Inorganic Materials, 2025, 40(2): 159.
[14] LIU Y C, WANG S G, YANG T F,et al. Solid particle erosion of an environmental barrier coating and chemically vapor infiltrated SiC/SiC for aeroengine. Ceramics International, 2024, 50(20): 39993.
[15] LV H Z, GE M, ZHANG H F,et al. Microstructure, thermophysical properties and oxidation resistance of SiC_f/SiC-YSi₂-Si composite fabricated through reactive melt infiltration. Journal of the European Ceramic Society, 2023, 43(14): 5950.
[16] WANG S, ZHENG T, QIN Y,et al. Influence of annealing on the CMAS corrosion behaviour of ytterbium disilicate environmental barrier coatings: a Raman imaging study. Corrosion Science, 2024, 240: 112450.
[17] ZHANG Y H, SUN Y N, TAN X,et al. High temperature stability and sintering resistance of Gd₂O₃-Yb₂O₃-Y₂O₃-ZrO₂(GYYZO) coating. Surface and Coatings Technology, 2023, 459: 129405.
[18] SHI T J, ZHAO T, GUO Y Q,et al. Microstructural optimization of Gd₂O₃-Yb₂O₃-Y₂O₃ co-stabilized ZrO₂/YSZ coatings with enhanced thermal shock resistance. Materials & Design, 2025, 254: 114142.
[19] SHI T J, BAI B T, PENG H R,et al. Improved thermal shock resistance of GYYZO-YSZ double ceramic layer TBCs induced by induction plasma spheroidization. Surface and Coatings Technology, 2024, 477: 130372.
[20] LI J, ZHOU C, WANG J M,et al. Exploration on intrinsic corrosion resistance of β-Lu₂Si₂O₇ against calcium-magnesium-aluminosilicate (CMAS) at 1500 ℃ via grain boundary engineering. Materials & Design, 2025, 253: 113965.
[21] TURCER L R, KRAUSE A R, GARCES H F,et al. Environmental-barrier coating ceramics for resistance against attack by molten calcia-magnesia-aluminosilicate (CMAS) glass: part II, β-Yb₂Si₂O₇ and β-Sc₂Si₂O₇. Journal of the European Ceramic Society, 2018, 38(11): 3914.
[22] WU J, WANG Z F, ZHUO X S,et al. Enhancing CMAS corrosion resistance of PS-PVD Si/Yb₂Si₂O₇ EBCs via Al-modification. Journal of the European Ceramic Society, 2023, 43(8): 3727.
[23] ZHANG X F, ZHOU K S, LIU M,et al. CMAS corrosion and thermal cycle of Al-modified PS-PVD environmental barrier coating. Ceramics International, 2018, 44(13): 15959.
[24] DONG L, WEI X W, LIU M J,et al. Boosting corrosion resistance of environmental barrier coatings through surface aluminum modification against molten salts. Corrosion Science, 2025, 244: 112646.
[25] ZHANG X, ZHANG H F, ZHANG N N,et al. Oxidation behavior of AlCoCrFeNi bond coating in the YSZ-TBCs produced by APS and PS-PVD method. Ceramics International, 2024, 50(10): 17190.
[26] DONG L, LIU M J, ZHANG X F,et al. Infiltration thermodynamics in wrinkle-pores of thermal sprayed coatings. Applied Surface Science, 2021, 543: 148847.
[27] CHENG B, ZHENG G B, HOU D,et al. Formation mechanisms of columnar/dense structure for Gd₂Zr₂O₇ ceramics coatings with superior CMAS corrosion resistance. Corrosion Science, 2025, 257: 113348.
[28] LIU R X, LIANG W P, MIAO Q,et al. Revealing the oxidation growth mechanism and crack evolution law of novel Si-HfO₂/Yb₂Si₂O₇/Yb₂SiO₅ environmental barrier coatings during thermal cycling. Journal of Advanced Ceramics, 2024, 13(10): 1677.
[29] ANTON R, LEISNER V, WATERMEYER P,et al. Hafnia-doped silicon bond Coats manufactured by PVD for SiC/SiC CMCs. Acta Materialia, 2020, 183: 471.

CMAS Corrosion Resistance of Al-modified Si-HfO₂/YbDS/GYYZO Thermal-environmental Barrier Coating

PDF (PC)

Knowledge

Abstract

Cite this article

share this article

References

Related Articles 7

Recommended Articles

Metrics

Comments

[1]	ZHANG Guangheng, SHI Jinyu, SHEN Hongyu, ZHANG Jie, WANG Jingyang. Synergistic Mechanism of Gd³⁺ and Yb³⁺ on Crystallization Behavior of CMAS Corrosion Products [J]. Journal of Inorganic Materials, 2026, 41(1): 27-36.
[2]	FAN Wenkai, YANG Xiao, LI Honghua, LI Yong, LI Jiangtao. Pressureless Sintering of (Y_0.2Gd_0.2Er_0.2Yb_0.2Lu_0.2)₂Zr₂O₇ High-entropy Ceramic and Its High Temperature CMAS Corrosion Resistance [J]. Journal of Inorganic Materials, 2025, 40(2): 159-167.
[3]	LI Liuyuan, HUANG Kaiming, ZHAO Xiuyi, LIU Huichao, WANG Chao. Influence of RE-Si-Al-O Glass Phase on Microstructure and CMAS Corrosion Resistance of High Entropy Rare Earth Disilicates [J]. Journal of Inorganic Materials, 2024, 39(7): 793-802.
[4]	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.
[5]	FAN Dong, ZHONG Xin, WANG Yawen, ZHANG Zhenzhong, NIU Yaran, LI Qilian, ZHANG Le, ZHENG Xuebin. Corrosion Behavior and Mechanism of Aluminum-rich CMAS on Rare-earth Silicate Environmental Barrier Coatings: [J]. Journal of Inorganic Materials, 2023, 38(5): 544-552.
[6]	FAN Jia-Feng,ZHANG Xiao-Feng,ZHOU Ke-Song,LIU Min,DENG Chang-Guang,DENG Chun-Ming,NIU Shao-Peng,DENG Zi-Qian. Influence of Al-modification on CMAS Corrosion Resistance of PS-PVD 7YSZ Thermal Barrier Coatings [J]. Journal of Inorganic Materials, 2019, 34(9): 938-946.
[7]	ZHANG Xiao-Feng, ZHOU Ke-Song, SONG Jin-Bing, DENG Chun-Ming, NIU Shao-Peng, DENG Zi-Qian. Deposition and CMAS Corrosion Mechanism of 7YSZ Thermal Barrier Coatings Prepared by Plasma Spray-Physical Vapor Deposition [J]. Journal of Inorganic Materials, 2015, 30(3): 287-293.