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The thermal durability of thermal barrier coating systems (TBCs) obtained using feedstock powders with different purity and phase content was investigated by thermal shock testing with different cycle times, including the effects on the sintering and phase transformation behaviors. Four 8 wt.% yttria-stabilized zirconia powders, with regular purity (TC1), high purity (TC2 and TC3), and without monoclinic phase (TC4), were employed to prepare the topcoat of TBC by atmospheric plasma spray on a NiCoCrAlY bondcoat deposited by high velocity oxy-fuel. The microstructure and phase stability of the topcoats affected the TBCs' lifetime in the short-term (1 h) and long-term (24 h) furnace cyclic test (FCT) at 1100 °C and jet engine thermal shock (JETS) test. In the short-term FCT and JETS tests, in which coatings are severely subjected to thermal stress, the TBCs' lifetime is most affected by the microstructure of the topcoat. The coating layer with the lowest monoclinic phase in the as-sprayed state showed the lowest phase-transformation characteristics in the isothermal oxidation test (1400 °C). These properties resulted in the best lifetime in the long-term FCT. Therefore, the coating material and evaluating methods of TBCs' life should be selected depending on the usage environment. [ABSTRACT FROM AUTHOR]

Hot corrosion and CaO–MgO–Al 2 O 3 –SiO 2 (CMAS) resistance of thermal barrier coatings (TBCs) are required in an industrial gas turbine employed with impure fuels and high turbine inlet temperatures. Therefore, various TBC systems with different structural combinations were investigated in thermochemical aspects of hot corrosion and CMAS causing the degradation of TBCs. Four types of 8 wt% yttria-stabilized zirconia (8YSZ), namely dense microstructure (8YSZ), porous microstructure (C–8YSZ), no monoclinic phase (NoM–8YSZ), and low thermal conductivity (low-k), were employed to prepare topcoats using an atmospheric plasma spray on the two bondcoats coated by a vacuum plasma spray with feedstocks of NiCoCrAlY and NiCoCrAlY+Hf + Si. Hot corrosion components penetrated through the whole topcoat layer at 1000 °C however did not infiltrate to the bondcoat layers because of the thermally grown oxide layer formed between the topcoat and the bondcoat. In addition, the elements Hf and Si contained in the bondcoat composition suppressed diffusion of β phase aluminum. In the visual inspection after the hot corrosion at 1000 °C and CMAS test at 1250 °C, the TBC system with the NoM–YSZ topcoat layer showed a sound condition without failure unlike other TBCs, and no monoclinic phase after hot corrosion and the CMAS test, indicating that the phase stability plays a critical role in TBCs' lifetime in the hot corrosion and CMAS environments. • Superiority of Hf and Si elements in MCrAlY bondcoat was observed through hot corrosion test. • Conventional and advanced TBCs failed with a similar trend independent of chemicals and porosity. • low-k TBCs showed a negative dependency on both hot corrosion and CMAS • Phase stability of topcoat layer can also be proposed to have more life time under the environment of hot corrosion and CMAS. [ABSTRACT FROM AUTHOR]