微结构调控对PS-PVD热障涂层抗CMAS腐蚀性能影响

冯晓龙; 何箐; 李新慧; 李建超

doi:10.16490/j.cnki.issn.1001-3660.2026.03.007

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表面技术 ›› 2026, Vol. 55 ›› Issue (3) : 72-83. DOI: 10.16490/j.cnki.issn.1001-3660.2026.03.007

专题——先进发动机高温防护涂层

微结构调控对PS-PVD热障涂层抗CMAS腐蚀性能影响

冯晓龙^1,2, 何箐^1,2,*, 李新慧^1,2, 李建超^1,2

作者信息 +

Effect of Microstructural Regulation on CMAS Corrosion Resistance of PS-PVD Coatings

FENG Xiaolong^1,2, HE Qing^1,2,*, LI Xinhui^1,2, LI Jianchao^1,2

Author information +

文章历史 +

摘要

目的改善等离子物理气相沉积（PS-PVD）工艺制备类柱状晶涂层的抗环境沉积物（CMAS）腐蚀能力。方法采用氧化钇稳定氧化锆（8YSZ）、镱改性锆酸钆（(Gd_0.9Yb_0.1)₂Zr₂O₇,GYbZ）作为陶瓷层及防护层材料。采用PS-PVD工艺,通过调节喷涂参数实现了表面微结构由疏松类柱状晶向致密结构连续调控,获得了以液相沉积为主的致密表层。系统评价了涂层热震性能以及抗CMAS腐蚀能力,并利用扫描电子显微镜、X射线衍射等手段对涂层显微形貌、物相及元素分布进行了分析。结果结果表明,防护层并不会导致涂层抗水淬热震性能明显下降,热震次数达110次,带有防护层样品涂层剥落处主要在防护层与陶瓷层界面处,避免了陶瓷层的整体剥落。在1 250 ℃、2 h腐蚀时间条件下开展的基于不同地域特征的CMAS腐蚀验证中,防护层对3种成分CMAS的渗透均起到了一定的阻碍作用,带有防护层的样品的平均渗透深度仅为无防护层样品的29.8%。结论致密防护层对涂层准柱状晶间隙、羽毛状枝晶间隙、裂纹孔洞等开放性孔隙具有一定的封孔作用,显著阻碍了CMAS熔体在毛细管力作用下对陶瓷层的渗透,有效提升了涂层抗CMAS腐蚀能力。

Abstract

This study aims to enhance the resistance of columnar-like thermal barrier coatings (TBCs) fabricated by plasma physical vapor deposition (PS-PVD) against Calcium-Magnesium-Alumino-Silicate (CMAS) corrosion, and to elucidate the influence of surface microstructural modification on corrosion resistance and thermal shock lifetime. Yttria-stabilized zirconia (8YSZ) and Yb-modified gadolinium zirconate ((Gd_0.9Yb_0.1)₂Zr₂O₇,GYbZ) are selected as the ceramic coating and protective layer materials in this work. Owing to the high-power and low-pressure characteristics of the PS-PVD process, controlled adjustment of processing parameters allows mixed-phase (solid-liquid-vapor) deposition, enabling microstructural design and optimization of the coating to meet diverse functional and performance requirements. A PS-PVD process dominated by liquid-phase deposition is developed through optimization of spraying parameters, enabling the formation of a dense protective layer. A tri-layered 8YSZ/GYbZ/dense GYbZ TBC system is continuously deposited on the substrate surface. The thermal shock behavior and CMAS corrosion resistance of the coatings are systematically evaluated, and their microstructure, phase composition, and elemental distribution are characterized by scanning electron microscopy (SEM) and X-ray diffraction (XRD). Results indicate that the protective layer exhibits a predominantly lamellar structure containing a small number of partially molten particles, in sharp contrast to the columnar structures of the underlying 8YSZ and GYbZ layers, leading to a significant improvement in coating density. The protective layer is bonded to the ceramic surface without any detectable interfacial cracks or delamination. In addition, it effectively covers the intercolumnar gaps and seals the open pores on the surface of the ceramic layer, thereby improving surface integrity. Furthermore, its incorporation does not markedly reduce the thermal shock resistance, with the coating sustaining up to 110 water-quenching cycles. For the samples without a protective layer, coating spallation primarily occurs at the thermally grown oxide (TGO) and the ceramic layer leads to large-area delamination of the ceramic coating. In contrast, for the samples with a protective layer, spallation mainly takes place at the interface between the protective layer and the ceramic layer. Owing to the relatively low strain tolerance of the protective layer, significant interfacial stresses are generated initiating crack formation. However, lateral cracks at the interface effectively impede the downward propagation of surface vertical cracks, thereby preventing large-scale delamination of the ceramic layer. Three types of region-specific CMAS powders are synthesized according to the compositions of deposits extracted from the surfaces of engine blades operating in different regions, in order to assess the coating's resistance to CMAS corrosion under various environmental contaminant conditions. CMAS corrosion tests conducted at 1 250 ℃ for 2 h using compositions representative of different geographical sources reveal that the protective layer effectively suppresses CMAS infiltration. This improvement is attributed to two synergistic mechanisms: (i) the dense microstructure providing a physical barrier to melt penetration, and (ii) the in-situ formation of high-melting-point apatite and spinel phases during the CMAS-coating interaction, which increase melt viscosity and further retard infiltration. The average CMAS penetration depth in samples with the protective layer is only 29.8% of that in unprotected coatings. Additionally, the dense protective layer effectively seals open pores, including intercolumnar gaps, feather-like dendritic voids, and microcracks, thereby mitigating CMAS infiltration driven by capillary forces and significantly enhancing the coating's overall corrosion resistance.

导出引用

冯晓龙, 何箐, 李新慧, 李建超. 微结构调控对PS-PVD热障涂层抗CMAS腐蚀性能影响[J]. 表面技术. 2026, 55(3): 72-83

FENG Xiaolong, HE Qing, LI Xinhui, LI Jianchao. Effect of Microstructural Regulation on CMAS Corrosion Resistance of PS-PVD Coatings[J]. Surface Technology. 2026, 55(3): 72-83

中图分类号： TG174.4

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