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 ℃/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, 2026, 41(7): 923-929.

Figures/Tables 11

Table 1 PS-PVD spraying parameters

Parameter	Si-HfO₂	YbDS	GYYZO
Spray distance/mm	300	350	280
Current/A	650	700	630
Ar/(L•min^-1)	40	40	50
H₂/(L•min^-1)	5	12	8
Feeding rate/(r•min^-1)	2.5	2.8	3
Chamber pressure/mbar	40	50	60
Carrier gas/(L•min^-1)	3	2.5	2.5

Table 2 Compositions of CMAS

Oxide	CaO	MgO	Al₂O₃	SiO₂	Fe₂O₃+Na₂O+K₂O+ZrO₂
Mole/%	34.91	4.44	10.58	46.20	3.87

Fig. 1 Cross-sectional morphologies of GYYZO coating (a) Cross-sectional view of Si-HfO2/Yb2Si2O7/GYYZO coating system; (b) Interface between Si-HfO2 and Yb2Si2O7 layers; (c) Interface between Yb2Si2O7 and GYYZO layers; (d) High-magnification view of GYYZO layer

Fig. 2 XRD patterns of GYYZO and Al-GYYZO coatings

Fig. 3 Cross-sectional morphologies of GYYZO coating after CMAS corrosion at 1500 ℃ for different time (a) 1 min; (b) 10 min; (c) 30 min; (d) 1 h

Fig. 4 Cross-sectional morphologies of GYYZO coating after CMAS corrosion at 1500 ℃ for 10 min (a) Cross-sectional morphology; (b) Reaction layer; (c) EDS elemental mappings of Fig. (b); (d) Transverse cracks in the intermediate layer

Fig. 5 Cross-sectional morphologies of Al-GYYZO coating (a) As-sprayed cross-section; (b) Interface between bond coat and interlayer; (c) Al-modified layer; (d) Interface between GYYZO and interlayer; (e) EDS elemental mappings of Fig. (a)

Fig. 6 Cross-sectional morphologies of Al-GYYZO coating after CMAS corrosion at 1500 ℃ for different time (a) 1 min; (b) 10 min; (c) 30 min; (d) 1 h

Table 3 EDS elemental compositions of the marked spots in Fig. 6(d)

Element	Content/% (in atom)
Element	Spot 1	Spot 2	Spot 3
Si	20.85	99.04	27.10
Hf	17.58	0.91	18.84
O	61.58	0.05	52.28
Ca	0	0	0.20
Mg	0	0	0.17
Al	0	0	1.41

Fig. 7 Cross-sectional morphologies of Al-GYYZO coating after CMAS corrosion at 1500 ℃ for 10 min (a) Cross-sectional morphology; (b) Reaction layer; (c) EDS elemental mappings of Fig. (b)

Fig. 8 Cross-sectional morphologies of Al-GYYZO coating after CMAS corrosion at 1500 ℃ for 30 min (a) Cross-sectional morphology; (b) Reaction layer; (c) EDS elemental mappings of Fig. (a)

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

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