Search

This study investigated the microstructure and tribological performance of TiO 2 coating prepared through the plasma-spraying of TiO 2 on an aluminum alloy (ZL109) surface. Box–Behnken design was employed to calculate the optimal spraying parameters (spraying current: 439 A, spraying voltage: 129 V, and Ar flow rate: 117 m3/h). High-temperature tribological characteristics (T = 120 °C) were examined under varying loads (F = 100 N, 120 N, and 140 N). The scanning electron microscopy and energy-dispersive X-ray spectroscopy analysis results revealed that the coating porosity decreased from 3.31 % to 0.31 % with the increase in the spraying voltage from 120 V to 130 V. Both powder and coating exhibited consistent elemental composition (Ti, O) and phase composition (TiO 2 , TiO, Ti 2 O 3). During the spraying process, part of the powder was oxidized. The average coefficient of friction of the coatings varied from 0.05 to 0.08, and as the load increased, the wear mechanism of the coating changed from abrasion to adhesive wear and oxidation. [ABSTRACT FROM AUTHOR]

The addition of Al 2 O 3 inside thermal barrier coatings (TBCs) is highlighted effective on mitigating TBCs degradation induced by CMAS corrosion. In this study, the cost-effective 20 wt.%Al 2 O 3 -7YSZ/7YSZ double ceramic layer (DCL) TBCs were fabricated and their long-term performance resisting CMAS corrosion was investigated. Significant bending and CMAS infiltration occurred readily for the single layer 7YSZ coatings just after 5 h duration. The top sacrificial Al 2 O 3 -7YSZ layer of DCL coatings greatly constrained coating deflection and CMAS infiltration. This is due to the chemical reaction between alumina splats and CMAS, generating interconnected anorthites for effectively blocking CMAS infiltration and improving resistance to CMAS attack. However, it is highlighted that the role of alumina splats on mitigating CMAS degradation was found different between the short-term corrosion and long-term corrosion. In addition, interfacial delamination/cracking was not observed between the top Al 2 O 3 -7YSZ layer and bottom 7YSZ layer after 100 h CMAS corrosion, demonstrating superior interface integrity and durability. [ABSTRACT FROM AUTHOR]

Boron doped MoSi 2 particles have been envisioned as sacrificial particles for self-healing thermal barrier coatings (TBCs) but their oxidation behaviour is yet not well understood. In this work, oxidation of MoSi 2 based particle is studied in the temperature range of 1050–1200 °C. The oxidation proceeds from a transient to a steady-state oxidation stage. The kinetics during steady-state oxidation is captured with a thermal diffusion-based model. As compared to the oxidation of pure MoSi 2 particles, the addition of boron strongly enhances the silica formation. Also, a finer dispersion of MoB x in the MoSi 2 matrix accelerates the formation of silica. The oxide growth rate constant increases proportional with the boron content of the MoSi 2 particles. This enhanced oxidation is related to the microstructure of the oxide scale. Upon oxidation, boron yields B 2 O 3 , which promptly merge with SiO 2 to form amorphous borosilicate, hindering the formation of crystalline SiO 2. Consequently, the migration of oxygen in the borosilicate oxide scale is faster than in the silica oxide scale on pure MoSi 2 particles. [ABSTRACT FROM AUTHOR]

M-YTaO 4 is one of the most promising candidates for the next-generation thermal barrier coatings. However, the CMAS-induced degradation of M-YTaO 4 is still in dispute. This work comprehensively investigates the CMAS corrosion of M-YTaO 4 at 1300 °C which provides new insights into the corrosion mechanism. CMAS attacks M-YTaO 4 forming a thick recession layer and the main corrosion product is accurately confirmed to be (Ca 2-x Y x)(Ta 2-y-z Mg y Al z)O 7 solid solution. The recession layer presented a small difference in Young's modulus with M-YTaO 4. No delamination cracking occurred during the thermal cycling process indicating good reliability. In addition, grain boundary infiltration of CMAS is first revealed in M-YTaO 4. The results have corrected the misjudgment of the corrosion mechanism and CMAS infiltration process in previous studies which provides guidelines for the design of M-YTaO 4 thermal barrier coatings. [ABSTRACT FROM AUTHOR]

Thermal barrier coatings (TBCs) provide thermal protection for high-temperature components of aero-engines and steam turbines, but are susceptible to failure under thermal cyclic loads. The effective design of interfacial texture is one of the approaches to enhance the lifetime of ceramic TBCs. In this study, four types of interfacial textures were designed on the surface of substrates, and 8YSZ coatings of equal thickness were prepared using atmospheric plasma spraying, and thermal cycling tests were carried out. Meanwhile, the thermal cycle lifetime, microstructure evolution, residual stress, and energy release rate criterion were also studied. The optimal morphology and parameters of the texture are determined. It is found that the lifetime of the concave trapezoidal texture is the longest, with a deflection angle of 67°, diameter of 700 μm, depth of 500 μm, and spacing of 5 mm. This study can provide theoretical guidance for the interfacial texture design of ceramic TBCs. [ABSTRACT FROM AUTHOR]

Thermal barrier coatings, including Al 2 O 3 -doped tetragonal yttria-stabilized zirconia (t-YSZ) coatings are vital in diverse applications. Thermal conductivity is a key property, but prediction often requires some complex experiments. In this study, a novel dual-structure feature extraction coupled with a multi-scale attention fusion network (RCFNet) is introduced for accurate thermal conductivity prediction using electron backscattered diffraction (EBSD) microstructure images. The method requires minimal data, and the result shows high accuracy with a Mean Square Error (MSE) of 0.003 W(m ⋅ k)−1 and an R-squared (R 2) value of 0.81. Furthermore, the model reveals specific correlations between microstructural characteristics and thermal conductivity, facilitating rapid structure selection for specific thermal conductivity. [Display omitted] • New dual-structure, multi-scale fusion for precise thermal conductivity prediction. • Proposed multi-scale attention fusion optimizes data utilization effectively. • Reveals microstructure-performance link in material images. [ABSTRACT FROM AUTHOR]

Gd 2 Zr 2 O 7 thermal barrier coatings (TBCs) were reported to be resistant to calcium-magnesium-aluminum-silicon (CMAS) corrosion, but is still unsatisfactory. In this study, laser surface modification is employed to further improve CMAS resistance of Gd 2 Zr 2 O 7 coatings. The modification layer consists of a columnar microstructure, which is affected by the modification parameters such as pulse width and beam length. CMAS corrosion resistance of the as-fabricated and laser modified Gd 2 Zr 2 O 7 coatings is compared. At 1250 °C for 1 h, a reaction layer forms between the Gd 2 Zr 2 O 7 coating and CMAS which has some ability to suppress molten CMAS penetration. After prolonged corrosion (4 and 10 h), however, the reaction layer continues to thicken until no CMAS remains, which largely consumes the coating thickness and degrades the coating performance. Laser surface modification has solved this problem effectively due to its ability to reduce the melt penetration channels. Hence, laser-modified Gd 2 Zr 2 O 7 coatings have enhanced CMAS resistance. [ABSTRACT FROM AUTHOR]

A novel (Nd 0.2 Sm 0.2 Eu 0.2 La 0.2 Dy 0.2) 2 Gd 0.5 Yb 0.5 TaO 7 high-entropy oxide was successfully prepared through the sol–gel and high-sintering technique. The synthesized powder has a single-lattice structure, and the bulk sample has sole pyrochlore-type lattice. Given the particularity structure and the high concentration of oxygen vacancies caused by ion doping, the (Nd 0.2 Sm 0.2 Eu 0.2 La 0.2 Dy 0.2) 2 Gd 0.5 Yb 0.5 TaO 7 's thermal conductivity (1.385–1.187W·m−1·K−1) is lower than those of (La 1/6 Nd 1/6 Yb 1/6 Y 1/6 Sm 1/6 Lu 1/6) 2 Ce 2 O 7 , Sm 2 Zr 2 O 7 , and Sm 2 Ce 2 O 7. Its excellent phase stability and suitable coefficient of thermal expansion (～10.80 × 10−6 K−1, ～1200 °C) also indicate its potential as candidate oxide for thermal barrier coatings. [ABSTRACT FROM AUTHOR]

Although Hf x Ta 2 O 2 x+ 5 shows great potential as a next-generation thermal barrier coating (TBC) material, the diversity of its potential modulated structures presents challenges in determining their mechanical properties. Hf x Ta 2 O 2 x+ 5 (x = 4, 6, 8) ceramics were successfully fabricated using the sol–gel method. Research on growth kinetics has indicated that grain boundary diffusion is the speed-controlling step. The activation energy increased with a larger modulated structure. In addition, the fracture toughness also increased from 1.98 MPa m1/2 for Hf 4 Ta 2 O 13 to 3.30 MPa m1/2 for Hf 8 Ta 2 O 21. Density functional theory calculations revealed that Hf x Ta 2 O 2 x+ 5 exhibited intrinsic ductility owing to the denser packing of atoms in its larger modulated structure. Thus, the tight-knit chemical bond net may contribute to a large surface energy. The results of this study provide deep insights into the toughening mechanism of modulated structures and pave the way for the design of next-generation TBCs. [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this study is to investigate the effects of high-temperature oxidation tests and gas thermal shock tests on IC10 simulated components with thermal barrier coatings under different temperatures and oxidation times. Design/methodology/approach: In the high-temperature oxidation test, specimens were oxidized at three different temperatures of 850, 980, and 1,100 °C for durations of 10, 20, 50, 100, 200, and 300 h, respectively. In the gas thermal shock test, specimens were pre-oxidized for 10, 20, 50, and 100 h, followed by a high-temperature gas thermal shock test at 1,100 °C. Findings: In the high-temperature oxidation tests, with increasing oxidation time, the oxidation layer thickened, and the air-film holes diameter decreased. The microstructure of the bond coat transitioned from strip-like to block-like, and internal cracks transformed from numerous and short to larger and deeper. Below the bond coat, a noticeable disappearance layer of strengthening phase appeared, with increasing thickness. The strengthening phase in the substrate transitioned from regular square shapes to circles as temperature increased. In gas thermal shock tests at 1,100 °C, the oxidation weight gain ratio increased with longer pre-oxidation times, whereas the erosion weight loss ratio gradually decreased. Originality/value: The originality and significance of this study lie in its departure from the typical subjects of high-temperature oxidation and thermal shock tests. Unlike common research targets, this study focuses on IC10 simulative specimens with thermal barrier coatings and air-film holes. Furthermore, it investigates the effects of varying temperatures and oxidation durations. [ABSTRACT FROM AUTHOR]

For the temperature monitoring requirements of gas turbine blades, a new infrared temperature measurement probe structure is designed in this paper. Cooling air is used to cool the probe and prevent flue gas flowing into the probe. The computational fluid dynamics method is used to analyze the working process of the temperature probe. Two cases that the optical opening of probe is facing to and on the back of flue gas are considered. The influences of the air inlet total pressure on the pollution protective performance and thermal protective performance of the probe are analyzed. The results show that when the optical opening of probe is facing to flue gas, the pollution protective performance is poorer while the thermal protective performance is better than that when facing to gas. According to the temperature distribution of the probe, three optimization schemes of the probe are proposed: spraying thermal barrier coating on the wall of the probe, drilling film holes at the bottom of the probe, and combining film holes with thermal protective performance. The results show that the probe maximum temperature is reduced by 97, 187 and 328 K by using these three methods, respectively. [ABSTRACT FROM AUTHOR]

LaMgAl 11 O 19 (LMA) with magnetoplumbite structure has emerged as a promising candidate for thermal barrier coating (TBC). However, the inherent high thermal conductivity and relatively low thermal expansion coefficient (TEC) of LMA impose limitations on its further application. In this work, a novel high-entropy hexaluminate (La 0.2 Nd 0.2 Sm 0.2 Eu 0.2 Gd 0.2)MgAl 11 O 19 (HE-LMA) has been designed and prepared to overcome these obstacles. HE-LMA with homogeneous chemical composition distribution possesses excellent phase stability up to 1600°C. Moreover, the TEC of HE-LMA (9.22 × 10−6 K−1 at 1300°C) is larger than that of LMA. The high-entropy strategy effectively decreases the thermal conductivity of HE-LMA (from 3.27 W/(m⋅K) at room temperature to 2.19 W/(m∙K) at 1000°C) in comparison to that of LMA (3.63–2.62 W/(m∙K)). Furthermore, HE-LMA demonstrates higher microhardness and fracture toughness due to the lattice distortion. These results indicate that (La 0.2 Nd 0.2 Sm 0.2 Eu 0.2 Gd 0.2)MgAl 11 O 19 has the potential to be applied as a TBC. [ABSTRACT FROM AUTHOR]

Rare earth niobate Re 3 NbO 7 (Re=Rare earth element) possesses ultra-low thermal conductivity for application as thermal barrier coatings (TBCs). However, Re 3 NbO 7 with large rare earth ion radius (Re La, Nd, Sm) exhibits both low temperature phase transition and poor facture toughness which is detrimental to the durability of the coatings. In this work, an effective method was proposed to solve those problems by doping. Considering the low-temperature phase transition at about 340K, La 3 NbO 7 is selected as representative material. In order to suppress phase transition, Y3+ with relatively smaller ionic radius is used as a doped ion, and (La 1- x Y x) 3 NbO 7 (x = 0.0,0.1,0.3,0.5) were prepared and investigated. It is shown that, low temperature phase transition of La 3 NbO 7 is effectively suppressed due to Y3+ doped. Facture toughness is increased significantly from 0.5 to 2.3 MPa m1/2 with the increase of doping concentration. Furthermore, the Vickers hardness is also improved by doping. Considering the phase stability and ultra-low thermal conductivity, (La 1- x Y x) 3 NbO 7 solid solution (x = 0.5) maybe promising candidates for high temperature thermal insulation materials such as TBCs, thermoelectric materials, etc. [ABSTRACT FROM AUTHOR]

As a thermal barrier coating (TBC) material, 8 wt% yttria-stabilized zirconia (8YSZ) exhibits poor resistance against calcium–magnesium–aluminosilicate (CMAS) corrosion. This is caused by the penetration of molten CMAS glass and the depletion of Y3+, which limits the lifetime of 8YSZ. In this study, a multi-rare-earth-oxide-doped zirconia (15 wt% (Lu 0.2 Yb 0.2 Dy 0.2 Gd 0.2 Y 0.2)–ZrO 2 , denoted as 15LYDGY–SZ) ceramic was prepared to examine its interaction with CMAS. The sluggish diffusion effect and the competition between various dopant elements toward reaction with CMAS effectively slow down the atomic diffusion and limit the transformation of tetragonal phase into monoclinic phase in 15LYDGY–SZ ceramic. Compared with the currently used 8YSZ ceramic, the corrosion resistance of 15LYDGY–SZ to CMAS and its retention rate of fracture toughness after CMAS corrosion are improved. The results show that the multi-rare-earth-oxide-doped zirconia ceramic prepared in this study is a promising candidate material for the development of future TBCs. [ABSTRACT FROM AUTHOR]

The thermal barrier coatings (TBCs) consisting of Srx(Zr0.9Y0.05Yb0.05)O1.95+x were prepared using the suspension plasma spraying (SPS) method. Precursor suspensions were prepared via co‐precipitation for this purpose. Detailed microstructural, phase composition, and phase content analyses were conducted on these coatings, designated as SZYY‐1 (x = 1.0), SZYY‐2 (x = 0.9), and SZYY‐3 (x = 0.8). Additionally, the coatings underwent a thermal cycling test at 1121°C for 1 h. To assess the morphology of thermally grown oxide (TGO) in a real coating, a finite element model was employed. SPS‐SZYY‐2 with columnar crystal structure was found to have the highest number of thermal cycling, up to 345 times. The thermophysical high‐temperature properties of the coating can be effectively improved through suitable second‐phase content. Microstructural and finite element analyses revealed that stress, primarily caused by the continuous growth of the Co3O4, NiO and Spinel (CNS) layer within TGO, was the predominant factor leading to coating failure. At elevated temperatures, transverse cracks formed at the interface between the bond coating and ceramic top coating due to mismatched thermal expansion and sintering effects, ultimately leading to coating degradation. Therefore, reducing the generation rate of large stresses in the coating, especially shear stresses, can effectively prevent the generation and propagation of transverse cracks and increase the thermal cycling life of TBCs. [ABSTRACT FROM AUTHOR]

Thermal barrier coatings (TBCs) require both a porous structure to effectively prevent heat flux and a considerably dense structure to resist cracking for long‐term protection. These opposite requirements are difficult to achieve in conventional TBCs, which often exhibit uniform structures across their thickness. In fact, the main requirements of a coating vary with thickness owing to differential service conditions. In this study, the structure of a TBC is locally tailored to meet regional performance requirements. First, the load‐bearing conditions across the thickness are investigated in a simulation study. Resulting from multiple causes, the bottom region must bear a larger stress than the top region, which is directly exposed to heat flux. Therefore, the structure should be crack‐resistant in its bottom region and thermally insulating in its top region. Second, region‐function‐matching TBCs were prepared, and their performances were evaluated through isothermal cycling and thermal exposure tests. Results show that the TBCs with matching design exhibited double the lifespan of the conventional samples, whereas the thermal insulation was comparable. Finally, the structural evolutions were examined in different regions to analyze the failure behaviors of the TBCs. Healing of the intrinsic two‐dimensional pores and formation of the new large pores mainly account for the changes in thermal and mechanical properties of the TBCs. Overall, this region‐function‐matching design is expected to balance the tradeoff between high thermal insulation and long lifespan. [ABSTRACT FROM AUTHOR]

Plasma spray-physical vapor deposition (PS-PVD) is a promising third-generation thermal barrier coatings (TBCs) technique. Feather-like columnar TBCs with excellent strain tolerance and low thermal conductivity can be achieved using PS-PVD. However, molten CMAS (CaO–MgO–Al2O3–SiO2) can penetrate coatings and accelerate PS-PVD TBCs failure due to the feather-like columnar structure. Hence, a strategy is proposed to alleviate molten CMAS corrosion. The super-hydrophobicity structure is fabricated via laser texturing on the surface of PS-PVD TBCs to repel molten CMAS wetting and spreading. Then, a thin layer of the Al-film is deposited on the laser-textured surface. Next, the Al-modified layer is in situ synthesized after vacuum heat treatment, preventing the infiltration of molten CMAS into the TBCs and reducing the coating damage. The results show that the contact angle of laser textured and Al-modified PS-PVD TBCs (LT-Al) at room temperature increased from 12.3° to 168.8°. The wetting and spreading behavior of molten CMAS of as-sprayed (AS), laser textured (LT), and LT-Al coatings is observed in situ at 1230 °C for 1800 s. The LT-Al coatings exhibited excellent CMAS corrosion resistance, attributed to the laser-textured micro-nano structures and Al-modified layer protection. The findings may be an effective approach for solving the disadvantage of PS-PVD feather-like columnar structure TBCs. [ABSTRACT FROM AUTHOR]

Liner materials have extensive applications in automobile industry, packaging, and aeronautics. One of the specific uses of such materials is in thermal barrier, coating rockets, missile, and other systems used in space and defense. Each liner material exhibits different properties according to their chemical structure and composition. In this study, accelerated thermal aging of the liner material, silicone‐hollow glass microsphere composite (SHGC) has been studied along with the determination of its life span. The effect of such aging on the thermal properties of SHGC has been studied using thermogravimetry. Activation energy of the process has been determined to be in the range of 45–55 KJmol−1. The results have been compared with already reported silicon polymers. Shelf‐life of SHGC composite has also been determined using Arrhenius model. Stochastic model has been applied to determine the lower and upper limits of shelf‐life. Shelf‐life of SHGC is found to be 24 years with 28 and 18 years of upper and lower error limits. [ABSTRACT FROM AUTHOR]

The thermal barrier coatings (TBCs) system, a pivotal technology for advanced aviation engines and ground gas turbines, mitigates direct interaction between high-temperature gas and high-temperature alloy substrates. In this investigation, a series of high-entropy Eu 2 B 2 O 7 (where B = Y, Yb, Ce, Zr, Hf, Ta, and Nb) oxides were synthesized through solid-state reactions. By manipulating B-site cations and introducing substantial atomic size disparities, as well as mass and charge disorder, we synthesized a highly disordered high-entropy Eu 2 B 2 O 7 oxide. This oxide exhibits a disordered fluorite structure and commendable thermal insulation attributes. The observed thermal conductivity of Eu 2 (Y 0.2 Yb 0.2 Zr 0.2 Nb 0.2 Ta 0.2) 2 O 7 ranges from 0.94 to 1.13 W·m–1·K–1, which can be ascribed to amplified lattice anharmonicity and disorder causing supplementary phonon scattering. In addition, It also shows the thermal expansion coefficient of 10.52 × 10−6 K−1 and high-temperature stability. These results denote that the high-entropy Eu 2 B 2 O 7 oxide may become a prospective contender for thermal barrier coatings and thermal insulators. [ABSTRACT FROM AUTHOR]

In this study, Gd 2 O 3 –Yb 2 O 3 co-doped YSZ thermal barrier coatings with a top coat thickness of 400 μm were prepared on a nickel-based superalloy by atmospheric plasma spraying. The samples underwent multiple short-term and single long-term thermal exposures through burner rig tests under high-temperature gradients. The short-term thermal exposure duration of the coating was 25 s and the long-term thermal exposure duration was 1200 s. The microstructures and phase compositions of the samples were characterized, and their failure mechanism was discussed. The results demonstrate that during the burner rig tests, the coating surface temperature reached 2600K, resulting in coating sintering and sintered zone formation comprising coarse equiaxed grains. The short-term thermal exposure life of the coating is 3 cycles, and the long-term life is more than 1200s. After the single 1200s thermal exposure, the coating exhibited a stable cubic phase. However, under multiple 25s thermal exposures, the depth of the sintered zone increased with increasing number of cycles, leading to the formation of various vertical and transverse cracks within the coating. Coating failure was due to a combination of sintering and thermal-mismatch-induced stress.The early-stage coating delamination was attributed to sintering-induced transverse cracks, while the overall spallation was primarily ascribed to thermal-mismatch-induced transverse cracks. [ABSTRACT FROM AUTHOR]

Thermal barrier coatings (TBCs) are effective protective and insulative coatings on hot section components of turbine engines. The quality and subsequent performance of the TBCs are strongly dependent on the adhesion between the coating and the metal substrate. The adhesion strength of TBCs varies depending on the substrate materials and coating, the coating technique used, the coating application parameters, the substrate surface treatments, and environmental conditions. Therefore, the roughness of the substrate surface has a significant effect on the performance of the TBC system. In this work, the roughness and microstructure of the 7YSZ (7 wt.% yttria-stabilised zirconia) top coat under different bond coat roughness treatments were studied. The purpose of this paper was to investigate the influence of the roughness of the bond coat on the adhesion of 7YSZ TBCs prepared by the electron beam–physical vapour deposition (EB-PVD) process. The VPA (vapour phase aluminium) bond coat was deposited on Inconel 718 nickel superalloy substrate using the above-the-pack technique. The ceramic top coat was applied to the bond coat using the EB-PVD process. The dependence between the TBC coating roughness and the bond coat roughness was determined. Adhesion strength measurements were performed according to the ASTM C 633 standard test method. The highest adhesion value observed in the tensile adhesion tests was 105 MPa. However, it was not determined whether the surface roughness of the bond coat affects the adhesion of the 7YSZ top coat. [ABSTRACT FROM AUTHOR]

A multiyear power system R&D program was completed with the objective of developing an off-road hybrid heavy duty diesel engine with front end accessory drive-integrated energy storage. This system was validated to deliver 10.5-25.6% reduction in fuel consumption over current Tier 4 Final-based 18L diesel engines, over various off-road machine application cycles. The power system consisted of a downsized heavy-duty diesel 13L engine containing advanced combustion technologies, capable of elevated peak cylinder pressures and thermal efficiencies, thermal barrier coatings, exhaust waste heat recovery via SuperTurbo™ turbocompounding, and hybrid energy assisting and recovery through both mechanical and electrical systems. Following the concept definition, design, and analysis phases of the program, the final phase focused on building and validating the performance and efficiency in laboratory tests. While aspects of the system such as start/stop and reduced off-road cooling package energy losses were only analytically evaluated, the main 13L concept engine with full hybrid system was successfully built and tested in steady-state and in transient certification and real-world application cycles. Extensive simulations in Caterpillar's DYNASTY™ software environment utilized the validation test data to assess performance more fully and confidently over varied cycles and strategies. An average fuel consumption reduction of 17.9% was realized, and the majority (~13%) of the benefit stemmed from the core concept 13L engine. To conclude, a total cost of ownership analysis provides context to commercial viability and where adoption focus should be placed. [ABSTRACT FROM AUTHOR]

La2Ce2O7 (LC) has been identified as a promising thermal barrier coating (TBC) for use up to 1250 °C. In this study, a TBC system was deposited on grit-blasted Inconel 738 using atmospheric plasma spraying (APS) with NiCrAlY as the bond coat, followed by YSZ, and then LC as the top layer. The coatings were exposed to a mixture of molten Na2SO4 (45 wt.%) and V2O5 (55 wt.%) at 950 °C for hot corrosion. On the top LC layer, LaVO4, CeVO4 and CeO(1.66–2.00) formed as hot corrosion products after 4 h exposure. A reaction between YSZ and the corrosion products could not be observed due to the absence of YVO4. The hot corrosion mechanism of the LC-based TBC is also discussed in this study. [ABSTRACT FROM AUTHOR]

Rare‐earth tantalates present promise as thermal barrier coatings due to their favorable thermodynamic characteristics. To further diminish thermal conductivity, three high‐entropy tantalate samples, namely (Ce0.2Nd0.2Sm0.2Eu0.2Lu0.2)3TaO7, (Nd0.2Sm0.2Eu0.2Gd0.2Tm0.2)3TaO7, and (Ce0.2Nd0.2Sm0.2Eu0.2Dy0.2)3TaO7, denoted as HE‐1, HE‐2, and HE‐3, respectively, were synthesized in this investigation. HE‐1 exhibits a low thermal conductivity of 1.46 W/(m·K)–1 at 1000°C. The rationale behind this reduced thermal conductivity is expounded via the phonon scattering mechanism. The introduction of atomic disparities and grain size inhomogeneity, attributable to high‐entropy doping, collaborates to enhance phonon scattering, culminating in the lowest thermal conductivity. HE‐3, on the other hand, possesses a notable thermal expansion coefficient of 11.6 × 10−6 K−1 at 1200°C and manifests pronounced anisotropy in CTEs. All three high‐entropy samples demonstrate commendable mechanical properties, with Young's modulus lower than that of single‐component rare‐earth tantalates, while simultaneously exhibiting high hardness values (>8.4 GPa). This work furnishes a valuable reference for the utilization of high entropy rare‐earth tantalates in the realm of thermal barrier coatings. [ABSTRACT FROM AUTHOR]

Rare earth silicates are promising environmental/thermal barrier coating (E/TBC) materials facing severe CMAS (CaO‐MgO‐Al2O3‐SiO2) corrosion. Previous studies mainly focused on the intrinsic properties of precorrosion coatings, but there were few studies on their CMAS corrosion products that play a crucial role in the performance of coatings in postservice stage. In this work, the mechanical and thermal properties of nine corrosion products between lutetium silicates and CMAS are studied using first‐principles calculations. Their differences of elastic stiffness are attributed to the different crystal structures and bonding strength. The T:O ratio is identified as a factor of the crystal structure for silicate products, and it has a good correlation with their elastic stiffness. Moreover, the divergences of thermal conductivity are dominated by three essential factors, that is, atomic vibration intensity, lattice vibrational anharmonicity, and complexity of crystal structure. Compared with rare earth silicates, six products, that is, the α‐CaSiO3, β‐CaSiO3, Ca2MgSi2O7, Ca2Al2SiO7, CaAl2Si2O8, and Ca2Lu8(SiO4)6O2, showing good damage tolerance and low thermal conductivities, are predicted to be advantageous to E/TBCs. These discoveries reveal the mechanical/thermal properties of corrosion products between lutetium silicates and CMAS and are expected to support the future researches on the performance of E/TBC in the postservice stage. [ABSTRACT FROM AUTHOR]

Yttria-stabilized zirconia (YSZ) oxide ceramic powder is a thermal-barrier material used to fabricate thermal barrier coatings (TBC). In this study, to improve the electromagnetic wave (EMW) absorbing properties of TBCs, microwave-absorbing samarium iron nitrogen (SmFeN) particles were used to prepare SmFeN/yttria-stabilized zirconia (YSZ) composites. To study the effect of the SmFeN/YSZ interfaces on the EMW-absorbing properties of the SmFeN/YSZ composite, SmFeN/YSZ interfaces were built in different ways in composite materials having the same mass ratio of 1:1, for example, SmFeN and YSZ particles homogeneously mixed together, SmFeN/YSZ interfaces perpendicular and parallel to the EMW incident direction, and different interfaces between YSZ and SmFeN. Thus, the microwave absorbing performance of the samples, including the electromagnetic parameters, attenuation coefficient, eddy-loss current (C 0), impedance matching, and minimum reflection loss (RL min) values were examined and analyzed. The results demonstrate that interfaces perpendicular to the direction of the EMWs can increase the contact area and enhance the interfacial absorption effect. Further, when the wave-absorbing agent was placed in the middle of the composite, its wave-absorbing effect was the best among all the samples, yielding RL min = −27.824 dB and effective absorption bandwidth (EAB) = 8.5453 GHz (effective absorption frequency range 7.9256–16.4709 GHz for a 7.2-mm-thick layer). Crucially, the frequency and bandwidth at which the best absorption occurred could be tuned by adjusting the thickness of the coating. This is because the interfaces in the samples resulted in polarization enhancement and anomalous dispersion, leading to large dielectric losses. Overall, the use of a coaxial measurement technique is highly efficient for EMW absorbing body design and process simulations. [ABSTRACT FROM AUTHOR]

Volcanic ash dispersed in the air adheres to thermal barrier coatings (TBCs) on the hot section components of gas turbines, posing a severe threat to aviation safety. Here, we report a novel strategy inspired by lotus leaf for mitigating the molten volcanic ash adhesion and corrosion. A hierarchical micro-nano structure composed of arrayed micro-conoids and numerous nanoparticles were constructed on the surface of NdYbZr 2 O 7 ceramic pellet by ultrafast laser direct writing technology, whose morphology could be changed by optimizing the processing parameters. The laser-ablated pellet exhibits larger contact angle of molten volcanic ash than the original one, revealing an enhanced resistance repelling volcanic ash. This phenomenon is primarily attributed to the air trapped in the micro-grooves, together with these nanoparticles. Note that the evolution of viscous force and capillary force with time accelerates the transition of molten volcanic ash from the Cassie state to the Wenzel state and reduces its contact angle. Also, this structure effectively inhibits the infiltration of molten volcanic ash by rapidly developing a reaction layer. These findings are an important step toward the design and development of next-generation silicate ash-repellent TBCs. [ABSTRACT FROM AUTHOR]

Yttria-stabilized zirconia hollow spherical powder (YSZ-HOSP) is a widely utilized ceramic material in thermal barrier coatings (TBCs). Within the category of YSZ-HOSP, yttria-stabilized zirconia spherical thin-walled hollow-shell powder (YSZ-STHS) displays immense potential for producing TBCs with minimal inter-lamellar porosity and cracks. Arc plasma torch equipped with flow-shaping nozzle shows promise for preparing YSZ-STHS. However, there is limited research on the impact of the nozzle geometry on plasma flow field characteristics and the resulting effect on the quality of YSZ-HOSP, particularly in terms of spheroidization ratio, hollow-shell powder ratio, and shell thickness. To achieve controllable preparation of YSZ-STHS in arc plasma spheroidization, this paper proposed a novel model for the formation of YSZ-HOSP under different plasma flow characteristics, including high-speed compressing flow field, intermediate-speed critical flow field, and low-speed expanding flow field. These different plasma flow characteristics were achieved by changing the nozzle diameter and investigated by both numerical simulation and experiments in terms of plasma flow characteristics, electro-thermal characteristics, and the quality of the YSZ-HOSP. Results reveal that YSZ-HOSP prepared with high-speed compressing flow field resulted in a low hollow-shell powder ratio, while low-speed expanding flow field led to an over-thick shell. Conversely, the intermediate-speed critical flow field demonstrates relatively high thermal efficiency and enthalpy, along with moderate jet temperature and velocity, resulting in YSZ-STHS with a spheroidization ratio of 96.6 %, a hollow-shell powder ratio of 92.5 %, and a mean shell thickness of 3.49 μm. Therefore, it is evident that manipulating plasma flow characteristics allows for the controlled preparation of YSZ-STHS. [Display omitted] [ABSTRACT FROM AUTHOR]

Notwithstanding the impressive phase stability and low thermal conductivity exhibited by lanthanum zirconate (LZ), its low coefficient of thermal expansion is deemed a paramount limitation. In the present study, (La 1-x Y x) 2 Zr 2 O 7 with x = 0, 0.1, 0.2, 0.3, 0.4, 0.5, as new TBCs, were synthesized by reverse co-precipitation and calcination method. The XRD and Raman analyses elucidated that the substitution of Y3+ ions occurred exclusively at the La3+ positions. In addition, in accordance with FESEM and DTA findings, the incorporation of Y 2 O 3 has induced a reduction in particle size and an enhancement in crystallization resistance. The evaluation of the coefficient of thermal expansion (CTE) demonstrated a notable improvement following the introduction of Y 2 O 3. Specifically, the CTE of LZ increased from 9.34 × 10−6 °C-1 to 10.5 × 10−6 °C-1 in the case of (La 0.5 Y 0.5) 2 Zr 2 O 7 at 1100oC. Investigations of phase stability following a 50 h heat treatment at 1300oC indicated that Y 2 O 3 had no impact on phase stability. All compounds, similar to LZ, exhibited excellent phase stability. Furthermore, the addition of Y 2 O 3 significantly amplified the grain boundary diffusion mechanism during heat treatment, leading to an accelerated grain growth rate. The grain growth rate increased from 1.7 nm/h at LZ to 2.2 nm/h in the case of (La 0.6 Y 0.4) 2 Zr 2 O 7. [ABSTRACT FROM AUTHOR]

Aerosols deposited on the surfaces of alloys and coatings used in high-temperature applications react with the protective thermally grown oxide (TGO) and accelerate component degradation. Understanding how the TGO composition effects these reactions is essential to develop corrosion-resistant materials. This work studies the corrosion of Haynes-214 alloy, which forms a bilayer Ni(Cr,Al)2O4 (spinel) + Al2O3 TGO, exposed to complex oxide and sulfate deposits to understand how the Cr and Ni oxides affect the corrosion mechanisms. The deposit compositions were systematically varied to understand the effect of anion makeup (mixed oxides, oxide-sulfate, and sulfates). The results are compared to a FeCrAlY alloy that forms a simple Al2O3 TGO. On the Haynes-214 alloy, deposits containing mixed oxides (with or without sulfates) have limited corrosive effect. In contrast, a pure CaSO4 deposit reacts aggressively with the TGO to form calcium chromate and aluminate reaction products (RP) that substantially increase the TGO + RP thickness compared to that on the FeCrAlY alloy. Surprisingly, a deposit composed of a mixture of sulfates caused less severe corrosion than the CaSO4 alone since magnesium chromate formation appears to limit aggressive reactions involving Ca. The results are discussed in the context of opportunities for corrosion-resistant alloy design. [ABSTRACT FROM AUTHOR]

Higher operating temperatures for gas turbine engines require highly durable thermal barrier coatings (TBCs) with improved insulation properties. A suspension plasma spray process (SPS) had been developed for the deposition of columnar-structured TBCs. SPS columnar TBCs are normally achieved at a short standoff distance (50.0 mm–75.0 mm), which is not practical when coating complex-shaped engine hardware since the plasma torch may collide with the components being sprayed. Therefore, it is critical to develop SPS columnar TBCs at longer standoff distances. In this work, a commercially available pressure-based suspension delivery system was used to deliver the suspension to the plasma jet, and a high-enthalpy TriplexPro-210 plasma torch was used for the SPS coating deposition. Suspension injection pressure was optimized to maximize the number of droplets injected into the hot plasma core and achieving the best particle-melting states and deposition efficiency. The highest deposition efficiency of 51% was achieved at 0.34 MPa injection pressure with a suspension flow rate of 31.0 g/min. With the optimized process parameters, 1000 μm thick columnar-structured SPS 8 wt% Y2O3-stabilized ZrO2 (8YSZ) TBCs were successfully developed at a standoff distance of 100.0 mm. The SPS TBCs have a columnar width between 100 μm and 300 μm with a porosity of ~22%. Furnace cycling tests at 1125 °C showed the SPS columnar TBCs had an average life of 1012 cycles, which is ~2.5 times that of reference air-plasma-sprayed dense vertically cracked TBCs with the same coating thickness. The superior durability of the SPS columnar TBCs can be attributed to the high-strain-tolerant microstructure. SEM cross-section characterization indicated the failure of the SPS TBCs occurred at the ceramic top coat and thermally grown oxide (TGO) interface. [ABSTRACT FROM AUTHOR]

The concentration of interfacial normal stress at the free edges of thermal barrier coatings (TBCs) can result in coating spallation. Fatigue cracking is one of the main reasons for creating free edges under complex loads. It is crucial to investigate the fatigue cracking of coatings under cyclic loads to assess potential coating failure. To address this issue, a novel model was proposed to predict the fatigue life of the YSZ topcoat under stress parallel to the interface. Firstly, this study conducted uniaxial and tensile-torsional fatigue tests at elevated temperatures on specimens with atmospheric plasma-sprayed TBCs. The test results revealed that fatigue cracks appeared in the topcoat under cyclic loads, but these cracks did not propagate into the bondcoat or substrate immediately. The number of cycles before the topcoat cracked was found to be associated with the magnitude of the cyclic load. Secondly, this study analyzed the test conditions using the finite element method. Simulations indicated that the crack direction in the topcoat under complex loading conditions was aligned with the first principal stress direction. Finally, the fatigue life prediction model of the topcoat was established based on experiments and simulations. The predicted results fell within a fourfold scatter band. [ABSTRACT FROM AUTHOR]

This study uses atmospheric plasma spraying (APS) technology to prepare thermal barrier coatings (TBCs) with yttrium-stabilized zirconia (YSZ) and Yb2O3-Y2O3-co-stabilized ZrO2 (YbYSZ) materials at different spraying powers. It analyzes the differences and changes in the microstructure, thermodynamic properties, and mechanical properties of the TBCs. The CaO-MgO-Al2O3-SiO2 (CMAS) resistance of coatings was tested using thermal cycling-CMAS experiments and isothermal corrosion experiments. Compared to YSZ coatings, YbYSZ coatings have lower thermal conductivity, a higher hardness and elastic modulus, a longer lifetime under thermal cycling-CMAS conditions, and lower penetration and degradation depths. Under thermal cycling-CMAS coupling conditions, the optimal power range for the longest thermal cycling lifetime for both coatings is 39–40 kW. Overall, compared to the YSZ material, the YbYSZ material exhibits superior properties. [ABSTRACT FROM AUTHOR]

Fracture toughness is a key indicator to estimate the anti-peeling performance of thermal barrier coatings (TBCs). A unique superstructure endows Hf 6 Ta 2 O 17 with an outstanding phase stability and mechanical property, which also poses great challenges for studying its intrinsic toughening mechanism. Here, the superstructure Hf 6 Ta 2 O 17 single crystal film was epitaxially grown on YSZ(011) substrate by pulsed laser deposition. An uncommon ripple pattern near the Vickers indentation crack tips was first reported. The pop-in signals in the load-displacement curve indicated it may be relevant to ferroelastic domain transformation, which was further confirmed by spontaneous strain distribution in HRTEM. The transformation path, predicted by DFT, was conducted in b → c ferroelastic domain through in-plane rotation of Hf–O/Ta–O polyhedrons. The corresponding critical stress for domain transformation was up to 5.83 GPa. In addition, an intrinsic ductility was confirmed with a high Pugh ratio B/G of 2.49, much larger than the critical value (1.75) for brittle-ductile transition. These two mechanisms make contribution to the superior fracture toughness of Hf 6 Ta 2 O 17. This work provides a deep insight into the toughening mechanism of ceramics and paves the way to design of next-generation TBCs. [ABSTRACT FROM AUTHOR]

Segmented vertical cracks in high-strain-tolerance thermal barrier coating (TBC) systems provide fast diffusion pathways for oxygen, leading to the accelerated growth of thermally grown oxide (TGO) interfaces. This results in a competition between enhanced strain tolerance and accelerated oxidation. Here, the effects of crack width on oxygen diffusion and TGO growth in TBCs with segmented vertical cracks and underlying mechanism were investigated experimentally and numerically. The findings reveal a critical crack width of approximately 4 μm, underscoring the importance of selecting an appropriate segmented vertical crack width to design TBCs with superior strain tolerance and sufficient oxidation resistance. [Display omitted] [ABSTRACT FROM AUTHOR]

High‐temperature oxidation (1050°C) of Sr.9(Zr.9Yb.05Y.05)O2.85 (SZYY) thermal barrier coatings (TBCs) by suspension plasma spraying (SPS) and growth behavior of thermally grown oxide (TGO) were investigated. When the TBCs were exposed to high temperature for a period of time (∼5 h), the BC oxidized and TGO inevitably formed between the bond coating (BC) and the ceramic top coating (TC). The high‐temperature oxidation behavior of the BC is generally manifested as the growth of TGO, which has four specific stages as follows: (1) formative oxidation stage (0‒10 h), (2) rapid oxidation stage (10‒50 h), (3) stable oxidation stage (50‒100 h), and (4) complex oxidation stage (100‒200 h). The main component of early TGO is α‐Al2O3. It has a very low oxygen ion diffusivity and provides an excellent diffusion barrier, which has a positive effect on preventing further BC oxidation. However, as the heat treatment time increased, the Al consumption and the formation of a CNS layer (NiO, Co3O4, and spinel) in the BC eventually led to coating failure. The working life of TBCs can be improved by improving the ceramic TC structure and the Al content of BC. SZYY‐TBCs have certain potential application value. [ABSTRACT FROM AUTHOR]

In this study, the CMAS corrosion behavior of two high-yttria-stabilized zirconia thermal barrier coatings (38YSZ and 55YSZ) deposited by air plasma spraying is investigated and compared with a typical 8YSZ coating at 1250 °C to unravel the underlying corrosion mechanism. The 8YSZ coating undergoes severe CMAS attack driven by dissolution-reprecipitation and intergranular corrosion. However, the 38YSZ and 55YSZ coatings can react with CMAS melt vigorously to form a dense reaction layer with CMAS-resistant apatite phase at the CMAS/coating interface, thereby resisting the CMAS infiltration. The apatite phase can be formed only when the yttria content in c-ZrO 2 precipitated from CMAS attains the critical value (∼20 at%). Moreover, compared to the 38YSZ coating, apart from the high yttria content, the low zirconia content in the 55YSZ coating also allows higher free Y3+ available to form apatite phase via inhibiting the formation of c-ZrO 2 , thus facilitating the formation of more apatite phase. [ABSTRACT FROM AUTHOR]

In this study, the garnet-type Yb 3 Al 5 O 12 coating was fabricated by atmospheric plasma spraying and its properties were systematically investigated. Results show the as-sprayed coating consists of crystalline Yb 3 Al 5 O 12 with amorphous phase, recrystallization occurs at 918.5 °C accompanied by a 0.32% volume shrinkage. Yb 3 Al 5 O 12 coating demonstrates low thermal conductivity (2.1 W/(m∙K) at 1000 °C) coupled with a moderate thermal expansion coefficient (8.87 × 10−6 K−1 from 200 °C to 1400 °C). Additionally, Yb 3 Al 5 O 12 coating displays remarkable structure stability and sintering resistance at elevated temperatures. Its robust corrosion resistance can be demonstrated by rapidly generating dense anorthite layers during CMAS corrosion and the lack of a discernible corrosion layer in water vapor corrosion. Yb 3 Al 5 O 12 /YSZ TBC undertakes a thermal cycling lifetime of 970 cycles, superior to YSZ of 764 cycles. This improvement is primarily ascribed to lower oxygen permeability of garnet layer. These preliminary results indicate that Yb 3 Al 5 O 12 coating might be suitable for advanced TBC applications. [ABSTRACT FROM AUTHOR]

Hot corrosion caused by molten salt attack has been one of the main factors leading to the thermal barrier coating (TBC) degradation and premature failure. In this work, the molten salt corrosion behaviours of EB-PVD TBCs exposed to V 2 O 5 + Na 2 SO 4 at 1050 ℃ were and characterized. Hot corrosion mechanisms, microstructures evolution, and failure behaviours of TBCs under hot corrosion were investigated. The molten salt would react with the stabilizer Y 2 O 3 , which caused the depletion of Y 2 O 3 phase in the ceramic coating, promoting the destabilization of metastable zirconia (t′ -ZrO 2) into monoclinic zirconia (m -ZrO 2), resulting in obvious volume expansion of ceramic coating. The corrosion and formation of new products would densify the ceramic coating and generate high level stress in the TBCs, leading to the formation of micro cracks and pores in the ceramic layer. In addition, the growth behaviour and elemental composition of thermally grown oxide (TGO) under molten salt corrosion were determined. Hot corrosion significantly accelerated the growth of TGO, as the thickness of TGO layer under corrosion was about five times that after isothermal oxidation. Hot corrosion also destroyed the integrity of TGO layer, and the loose and porous TGO layer formed during corrosion would lead to cracking at the interface between the ceramic layer and bonding layer. The formation of cracks and pores under corrosion finally resulted in the premature failure of TBCs. [ABSTRACT FROM AUTHOR]

The article presents a new concept of A 2 B 2 O 7 pyrochlore materials design dedicated to thermal barrier coating based on the simultaneous use of several structural mechanisms responsible for phonon wave scattering. The basis for these analyses is the La 2 O 3 -Gd 2 O 3 -ZrO 2 ternary system, in which a smaller Gd3+ gadolinium atom was introduced into the La 2 Zr 2 O 7 compound in the substitution position A, with the simultaneous introduction of an excess B atom (Zr4+) and its partial localisation in position A. This resulted in the cumulative effect of the difference in mass and radius of rare earth elements cations, with the simultaneous formation of a non-stoichiometric type of lattice and the rattling effect. Initially, this effect was achieved using substitution atoms with a much smaller radius, such as Tm3+ or Yb3+, but without creating non-stoichiometric structures. Such systems were also characterised by a strong tendency to decompose into pyrochlore and fluorite phases. Using a new approach, a phase-stable material with ultra-low thermal conductivity was obtained, with a two-phase structure, which, however, was not formed as a result of the compound's decomposition but is the result of the presence of excess Zr4+ and a shift in the ternary system to the two-phase region. As a result, a material with extremely low thermal conductivity and a course independent of temperature increase was obtained, which suggests the maximum level of crystal lattice defect. In addition, thermal conductivity was effectively reduced by using relatively cheap rare earth oxides, reducing their amount compared to pyrochlore compounds based on lanthanum with ytterbium or thulium. [ABSTRACT FROM AUTHOR]

The effect of critical plasma spraying parameters (CPSPs) on phase composition, microstructure and mechanical property of (La 0.2 Nd 0.2 Sm 0.2 Eu 0.2 Gd 0.2) 2 Zr 2 O 7 thick coatings was investigated. After coating deposition, the phase structure of (La 0.2 Nd 0.2 Sm 0.2 Eu 0.2 Gd 0.2) 2 Zr 2 O 7 was transformed from pyrochlore to fluorite in the coating. When the CPSP value increased from 0.83kW/Lpm to 1.17kW/Lpm, the porosity of as-deposited coating was decreased from (16.46 ± 0.65)% to (6.94 ± 0.44)%. As a result, the elastic modulus of the coating was improved from (59.34 ± 2.39) GPa to (79.19 ± 4.78) GPa, and the corresponding micro-hardness was also increased from (2.59 ± 0.30) GPa to (3.39 ± 0.37) GPa. Consequently, the fracture toughness of as-deposited coating was decreased with the increasing CPSP value, while the corresponding residual stress was obtained to be compressive stress and it increased from -(43.00 ± 1.96) MPa to -(70.42 ± 3.89) MPa, indicating that the lower CPSP value was beneficial to reducing the residual compressive stress, which might be in favor of enhancing thermal shock resistance of coating. [ABSTRACT FROM AUTHOR]

Plasma spray–physical vapour deposition uses finely agglomerated spherical powders as raw materials; these powders undergo a complex process of dispersing–melting–evaporation–condensation in high-temperature and high-speed plasma jets to attain the desired physical phase and high-performance columnar-like structure thermal barrier coatings. Currently, the interactions between the powders and the jets have not been fully disclosed. The article examines the crushing strength of powders with various particle sizes and properties. To further elaborate the crushing process, discrete element simulation was used. Additionally, powder spray deposition experiments were conducted to disclose the association between powder properties and the efficiency of coating deposition. The findings indicate that the stiffness of the powder and the size of the internal particles have an impact on the crushing strength of the powder. The stronger the bond strength caused by greater powder stiffness, the more effective the dispersion effect becomes. Furthermore, the smaller the particle size, the higher the compressive and collapse strength. Therefore, the greater the crushing strength of the powder, the higher the rate of powder deposition. [ABSTRACT FROM AUTHOR]

Yttria‐stabilized zirconia (YSZ) powder is widely used in battery and thermal barrier coatings. This article reports a method of preparing YSZ powder using plasma in air atmosphere at room temperature in 0.34 M ZrO(NO3)2–0.06 M Y(NO3)3 solution. Diverse characterization techniques are utilized to examine the morphology and composition of synthesized powders. Electrolytic green powder consists mainly of hydroxide, which is annealed to form a well‐crystallized YSZ oxide powder with coexisting tetragonal and cubic phases. The green powder is composed of micrometer‐sized particles, with a particle size distribution (D50) of 51.90 μm. The molar ratio of Y to Zr is 2.84:1. The YSZ powder is finer (D50 is 5.80 μm) with irregular nanoparticles aggregating together, and the molar ratio of Y to Zr is 2.57:1. Hydroxyl radicals (OH·) and hydrogen radicals (H·) are found in the flame during discharge electrolysis, and the main formation reactions of the powders by this process are H2O + 2e− → H2↑ + 2OH−; Zr4+ + 4OH− + nH2O → Zr(OH)4·nH2O↓; and Y3+ + 3OH− + nH2O → Y(OH)3·nH2O↓. The conductivity of electrolyte sintered by YSZ powders increases with rising temperature, reaching 0.038S cm−1 at 1000 °C. [ABSTRACT FROM AUTHOR]

This paper is the first to look at the structural, electronic, mechanical, optical, and thermodynamic properties of the ANiX (ASc, Ti, Y, Zr, Hf; XBi, Sn) half‐Heusler (HH) using DFT based first principles method. The lattice parameters that we have calculated are very similar to those obtained in prior investigations with theoretical and experimental data. The positive phonon dispersion curve confirm the dynamical stability of ANiX (ASc, Ti, Y, Zr, Hf; XBi, Sn). The electronic band structure and DOS confirmed that the studied materials ANiX (ASc, Ti, Y, Zr, Hf; XBi, Sn) are direct band gap semiconductors. The investigation also determined significant constants, including dielectric function, absorption, conductivity, reflectivity, refractive index, and loss function. These optical observations unveiled our compounds potential utilization in various electronic and optoelectronic device applications. The elastic constants were used to fulfill the Born criteria, confirming the mechanical stability and ductility of the solids ANiX (ASc, Ti, Y, Zr, Hf; XBi, Sn). The calculated elastic modulus revealed that our studied compounds are elastically anisotropic. Moreover, ANiX (ASc, Ti, Y, Zr, Hf; XBi, Sn) has a very low minimum thermal conductivity (Kmin), and a low Debye temperature (θD), which indicating their appropriateness for utilization in thermal barrier coating (TBC) applications. The Helmholtz free energy (F), internal energy (E), entropy (S), and specific heat capacity (Cv) are determined by calculations derived from the phonon density of states. [ABSTRACT FROM AUTHOR]

AbstractThe enhancement of turbine blade performance within turbo jet engines is crucial for prolonged engine life. Amidst various cooling strategies for turbine blades, thermal barrier coatings (TBCs) emerge as a highly effective method. Just as the choice of material for the turbine blade holds importance, so too do the materials comprising TBCs. The current research work aims to pursue finite element-based analyses of turbine blades with TBCs, an almost real complex-shaped geometric model comprising the blade body with a rabbet is essential, the stress generated during TGO growth which is crucial for analysis, to select the substrate from both a thermo-structural and cost perspective. In this research endeavor, TBCs were structured with a substrate, a bond coat (NiCoCrAlY), and a top coat of lanthanum cerate (La2Ce2O7) ceramic layers. A thermally grown oxide (TGO), namely α-Al2O3, forms between the bond coat and the top coat due to the elevated temperatures experienced. Two distinct substrates, Inconel 625 and Titanium-T6 alloy, were meticulously chosen as turbine blade materials. Commencing with NACA 4412 airfoil data, the turbine blade was meticulously designed using CATIA, followed by simulations conducted on ANSYS software through a static thermal structural model. The simulation aimed to determine the optimal top coat/thermally grown oxide (TC/TGO) and TGO/bond coat (TGO/BC) layer thicknesses to achieve minimal equivalent stress and total deformation in the turbine blade. The simulated results revealed that a combination of 400 µm TC/10 µm TGO and 10 µm TGO/100 µm BC provided the lowest equivalent stress and total deformation, thereby offering valuable insights for the current research. [ABSTRACT FROM AUTHOR]

To prolong the service life and structural stability of CoCrNiAlY–yttria stabilized zirconia–LaMgAl11O19 (LaMA) dual ceramic coating during high temperature exposure, an AlY plating layer was deposited on top LaMA. Results revealed that this coating without AlY plating layer showed a rapid mass increase from 6.62 mg/cm2 at 20 h to 10.63 mg/cm2 at 80 h, but also suffered from a fast TGO growth and severe elemental diffusion, resulting in an exacerbating interface fracture of the coating. However, AlY plating layer was first oxidized, and Y2O3 induced the formation of a dense α‐Al2O3 reaction layer on the top LaMA layer, which greatly prevented the internal penetration of O2. This coating with AlY plating layer showed a relatively stable structure, a very slow TGO growth, and a slight mass increase trend from 8.19 mg/cm2 at 20 h to 8.73 mg/cm2 at 80 h. Potential oxidation damage mechanisms of the coatings with or without AlY plating layer were comprehensively clarified. [ABSTRACT FROM AUTHOR]

Thermal barrier coatings to protect and extend the life of hot-end parts of gas turbine engine have come a long way from their introduction almost half a century ago, having been the subject of constant innovations determined to push their capabilities. The need for even more efficient next generation of gas turbines will require higher operating temperatures that results in an increased near-infrared radiative output. Unfortunately, the state-of-the-art yttria-stabilized zirconia is transparent to near-infrared leading to direct radiative heating of the substrate, significantly reducing its life. This opens up the requirement for advanced thermal barrier coatings that can optically reflect the incident radiation reducing overall thermal transport to the underlying super-alloy. The present review gives a thorough overview of the current state of research into the approaches employed to achieve thermal radiative barrier coatings for reflection of near-infrared radiation; either by modification of existing infrastructure or via completely novel approaches. Moreover, to complement the experimental research in this up-and-coming domain, an emphasis is laid on the modeling approaches to expedite further advancements. [ABSTRACT FROM AUTHOR]

Cerate is regarded as a promising material for the next-generation of thermal barrier coating due to its high coefficient of thermal expansion (CTE) and low thermal conductivity. However, its thermal contraction within the temperature range of 473-673 K poses a significant challenge to its widespread application. The aim of this work is to improve the thermal contraction by regulating the configurational entropy of cerate ceramics. Six kinds of rare earth doped cerate ceramics with different configurational entropy were prepared. The results indicated that the phases of the as-prepared ceramics are all fluorite structures. With the increase of configurational entropy, the problem of thermal contraction is improved continuously. More importantly, the as-prepared (La 1/8 Sm 1/8 Yb 1/8 Y 1/8 Er 1/8 Eu 1/8 Nd 1/8 Gd 1/8) 2 Ce 2 O 7 (8RC) high entropy cerate ceramic demonstrates a near elimination of thermal contraction in the 473-673 K temperature range, and accompanied by high CTE, low thermal conductivity and good thermal stability, suggesting its potential application in the field of thermal barrier coating material. [ABSTRACT FROM AUTHOR]

The effect of doping with rare earth elements of different ionic radii on the ablation resistance of C/C–ZrC–SiC composites was investigated and the ablative behavior and ablation resistance of C/C–ZrC–SiC composites with the addition of different rare earth elements was tested. Although rare-earth doped stabilized zirconia has been used for a long time in the field of thermal barrier coatings, the existing techniques are usually coating modifications with rare-earth oxide or boride additions, it is difficult to prepare coatings that can be used on the surface of carbon matrix materials due to the large difference in the coefficients of thermal expansion. Therefore, this study attempts to introduce rare earth components into the interior of C/C–ZrC–SiC composites for matrix modification. The results show that the addition of rare earth elements enhances the ablation performance of the composites, but the mechanism of enhancement is different: rare earth ions with a smaller radius difference from Zr4+ ions stabilize the crystal structure of ZrO 2 by forming replacement solid solutions and stabilize the surface oxide film structure by preventing the homogeneous multiphase transformation of the oxide to achieve higher ablation performance; whereas rare earth ions with a larger radius difference from Zr4+ ions cannot stabilize ZrO 2 by replacement solid solutions, but instead form high viscosity, low volatility liquid phase oxides to heal the surface defects of the oxide film and reduce liquid phase dissipation to enhance ablation performance. [ABSTRACT FROM AUTHOR]

To address global research in energy technologies, a UK–US collaboration was setup to look at implications in the use of alternative gas turbine liquid/gaseous fuels and first-generation IGCC-derived syngas. The development of predictive models for deposition, corrosion and component living in gas turbines operating on such novel fuel gases is now being developed. Linked to this, the non-destructive inspection of hot gas path components needs to be refined and the life prediction models utilising thermal barrier coatings need to be validated to enable the on-going assessment of the remnant lives of components during their use. Thermal barrier coatings (TBCs) have been critical to the operation of gas turbines in aircraft and land-based applications. As the engine demands increase with respect to operational temperature and efficiency, so has the requirement for TBCs, both from the perspective of their performance (thermal conductivity, durability) as well as their reliability. Because TBCs play critical role in protecting the underlying super alloy, their failure (spallation) cause accelerated component damage leading to unplanned outage. Therefore, it is important to inspect and monitor the TBC condition to assure its quality and reliability. Non-destructive evaluation (NDE) methods would allow for direct determination of TBC thermal conductivity on coated components and, therefore, they can be used to inspect the quality of as processed components and monitor TBC degradation during service. This paper presents a new method, the pulsed thermal imaging–multilayer analysis (PTI–MLA) method, which can measure the coating thermal conductivity and heat capacity distributions for coatings on different substrates and thickness. NDE methods were also evaluated based on preliminary experimental results for TBC samples that were thermal cycled to various lifetimes to monitor TBC degradation and predict TBC life. Initial insight into the TBC response with painted and unpainted surfaces is also discussed to demonstrate next steps. [ABSTRACT FROM AUTHOR]