Erosion resistance of CMAS infiltrated sacrificial suspension sprayed alumina top layer on EB-PVD 7YSZ coatings

Research output: Contribution to journalResearch articleContributedpeer-review

Contributors

  • Lars Steinberg - , Chair of Materials Technology, TUD Dresden University of Technology (Author)
  • Christoph Mikulla - , German Aerospace Center (DLR) (Author)
  • Ravisankar Naraparaju - , German Aerospace Center (DLR) (Author)
  • Filofteia Laura Toma - , Fraunhofer Institute for Material and Beam Technology (Author)
  • Holger Großmann - , Anton Paar GmbH (Author)
  • Uwe Schulz - , Chair of Materials Technology, Institute of Materials Science, German Aerospace Center (DLR) (Author)
  • Christoph Leyens - , Chair of Materials Technology, TUD Dresden University of Technology, Fraunhofer Institute for Material and Beam Technology (Author)

Abstract

The development of CMAS (CaO–MgO–Al2O3–SiO2) -resistant thermal barrier coatings is an urgent issue, as the operating temperatures of aero-engines exceed the melting point of the CMAS. Application of alumina as top layer on 7YSZ coatings has shown promising CMAS resistance behavior. It reacts with the CMAS and crystallizes into new stable phases, which seals the CMAS penetration paths in the top layer to save the underlying 7YSZ layer from infiltration. This paper deals with the study of the erosion behavior of porous thermally sprayed Al2O3 sacrificial layer on top of EB-PVD 7YSZ coatings before and after the CMAS infiltration and investigates the combined erosion/corrosion regime. The TBC system has been infiltrated with three different CMAS compositions having a different Ca/Si ratio which resulted in different reaction scenarios and products. The change in the erosion behavior of the coating system as a function of CMAS infiltration depth was investigated and an erosion model has been proposed. The key factors that dictate the erosion resistance of such alumina layers were found to be the thickness and morphology of the reaction layer, the porosity of the non-reacted alumina layer underneath the reaction layer as well as the coating adhesion mechanism between alumina and 7YSZ.

Details

Original languageEnglish
Article number203064
JournalWear
Volume438-439
Publication statusPublished - 15 Nov 2019
Peer-reviewedYes

Keywords

Keywords

  • Alumina, CMAS, Erosion testing, Solid particle erosion, Suspension plasma spraying, TBC