目的 研究温度与保温时间对YSZ热障涂层的高温稳定性,为科学评估YSZ热障涂层的服役性能提供理论支撑。方法 研究采用控制变量法,将EB-PVD工艺制备的YSZ涂层试样在1 200 ℃下分别保温10、20、30、40、50 h,以及在1 250、1 300 ℃下分别保温10 h,分别采用X射线衍射仪、扫描电子显微镜和纳米压痕仪分析温度与保温时间对YSZ涂层的相组成、显微结构、硬度和杨氏模量的影响。结果 在1 200 ℃下,随着保温时间的延长,YSZ涂层中的m相含量基本保持稳定,柱状晶顶部逐渐圆润钝化,柱状晶内的羽状结构逐渐消失,柱间孔隙由于横向拉应力导致烧结颈处开裂从而宽化为纵向裂缝。YSZ涂层的孔隙率下降至~11%,杨氏模量和硬度先分别降低至~38.7 GPa和~4.25 GPa,随后在50 h分别升高至~68.9 GPa和~5.98 GPa。在1 250 ℃及以上温度、保温时间同为10 h的条件下,随着温度的升高,YSZ涂层的m相含量逐渐增加,并在1 300 ℃达到~17.49%（体积分数）,涂层孔隙率随着内部孔隙闭合逐渐降低、杨氏模量和硬度逐渐升高。在1 300 ℃下,YSZ涂层的孔隙率下降至~7.9%,杨氏模量和硬度升高至~67.8 GPa和~7.01 GPa。结论 YSZ热障涂层在1 200 ℃服役50 h内具有良好的相稳定性,随着保温时间的延长与温度的升高,YSZ热障涂层的结构逐渐致密化,孔隙率下降,而硬度和杨氏模量整体呈上升趋势。
Abstract
Thermal barrier coatings (TBCs) are one of the key thermal insulation technologies for high-temperature components in aero-engines and play a critical role in further increasing turbine inlet temperatures. Among various ceramic materials, 8wt.% Y2O3-stabilized ZrO2 (YSZ) has become the most widely used topcoat material due to its low thermal conductivity, excellent phase stability, and favorable thermal cycling resistance. However, under long-term high-temperature service conditions, YSZ coatings inevitably undergo complex temperature-time coupled evolution (i.e., thermal history), during which their phase composition, microstructure, and mechanical properties change significantly, thereby critically affecting the stress state and service lifetime of the coatings.Previous studies have shown that high-temperature exposure can induce tetragonal-to-monoclinic (t→m) phase transformation, sintering-driven densification of columnar structures, and continuous evolution of pore architecture in YSZ coatings. These processes are often accompanied by redistribution of residual stresses and reduction in strain tolerance, ultimately accelerating coating failure. However, most existing studies have focused on isolated thermal conditions, and a systematic understanding of the structure-property evolution under coupled temperature-time effects remains lacking. Therefore, from the perspective of thermal history, establishing the correlation between temperature-time coupling and coating evolution is of great significance for elucidating the high-temperature degradation mechanisms of YSZ coatings.In this work, a series of representative thermal histories were designed with a controlled variable approach: isothermal exposure at 1 200 ℃ for 10, 20, 30, 40, and 50 h, as well as at 1 250 ℃ and 1 300 ℃ for 10 h. X-ray diffraction (XRD), scanning electron microscopy (SEM), and nanoindentation were employed to systematically investigate the effects of thermal history on the phase composition, microstructure, and mechanical properties (hardness and Young's modulus) of YSZ coatings, and to further elucidate the underlying evolution mechanisms. At 1 200 ℃, with the increasing holding time, the monoclinic phase content in the YSZ coatings remained at a low level, indicating good phase stability. Meanwhile, the columnar tops gradually became rounded and blunted, the intra-columnar feathery structures progressively disappeared, and inter-columnar pores evolved into vertical cracks due to the fracture of sintering necks under transverse tensile stress, resulting in an overall porosity reduction to ~11%. Correspondingly, the Youn's modulus and hardness initially decreased to ~38.7 GPa and ~4.25 GPa, respectively, and then increased to ~68.9 GPa and ~5.98 GPa after 50 h. This trend reflected the competition between early-stage pore structure rearrangement and subsequent sintering-induced densification.At a constant holding time of 10 h, increasing temperature led to a significant increase in monoclinic phase content, reaching ~17.49vol.% at 1 300 ℃. Meanwhile, the pores within the coating gradually closed, and no apparent vertical cracks were observed, indicating that higher temperature promoted overall sintering densification. When the temperature increased to 1 300 ℃, the porosity further decreased to ~7.9%, while the Young's modulus and hardness increased to ~67.8 GPa and ~7.01 GPa, respectively. Overall, both increasing temperature and prolonging holding time promoted densification and mechanical property enhancement of YSZ coatings, although their underlying mechanisms differed significantly.In summary, YSZ TBCs exhibit good phase stability during service at 1 200 ℃ for up to 50 h. With intensified thermal history (increasing temperature or holding time), the coatings become progressively densified with reduced porosity, and their hardness and Young's modulus show an overall increasing trend. This work systematically reveals the structure-property evolution of YSZ coatings from the perspective of thermal history, providing theoretical guidance for the design and lifetime prediction of TBC systems under high-temperature service conditions.
关键词
热障涂层 /
YSZ /
高温处理 /
显微结构 /
杨氏模量 /
硬度
Key words
thermal barrier coating /
YSZ /
high-temperature treatment /
microstructure /
Young's modulus /
hardness
{{custom_sec.title}}
{{custom_sec.title}}
{{custom_sec.content}}
参考文献
[1] PADTURE N P.Advanced Structural Ceramics in Aerospace Propulsion[J]. Nature Materials, 2016, 15(8): 804-809.
[2] LI H, YANG S Q, LI X H, et al.Failure Mechanisms and Surface Treatment Processes of Thermal Barrier Coatings: Review[J]. Chinese Journal of Aeronautics, 2024, 37(9): 20-40.
[3] 牟仁德, 陆峰, 何利民, 等. 热障涂层技术在航空发动机上的应用与发展[J]. 热喷涂技术, 2009, 1(1): 53-58.
MU R D, LU F, HE L M, et al.Application and Development of Thermal Barrier Coatings on Aero Engines[J]. Thermal Spray Technology, 2009, 1(1): 53-58.
[4] TOLPYGO V K, CLARKE D R, MURPHY K S.Oxidation-Induced Failure of EB-PVD Thermal Barrier Coatings[J]. Surface and Coatings Technology, 2001, 146: 124-131.
[5] MEHBOOB G, LIU M J, XU T, et al.A Review on Failure Mechanism of Thermal Barrier Coatings and Strategies to Extend Their Lifetime[J]. Ceramics International, 2020, 46(7): 8497-8521.
[6] HERVY T, ALROY R J, BJÖRKLUND S, et al. Evaluation of High-Throughput Columnar YSZ Thermal Barrier Coatings Deposited via Axial Plasma Spraying of Aqueous Solution Precursors[J]. Surface and Coatings Technology, 2025, 509: 132214.
[7] HU X P, LIU Q, XIE Z H, et al.Effect of Bond Coating Surface Roughness on High-Temperature Performance of EB-PVD Thermal Barrier Coatings[J]. Ceramics International, 2025, 51(11): 14307-14318.
[8] 牟仁德, 丁宁, 刘冠熙, 等. 不同电子束流EB-PVD制备YSZ热障涂层的组织结构演变、热循环寿命与失效行为分析[J]. 材料工程, 2024, 52(12): 44-52.
MU R D, DING N, LIU G X, et al.Microstructure Evolution, thermal Cycling Lifetime, and Failure Behavior Analysis of YSZ Thermal Barrier Coatings Prepared by EB-PVD with Different Electron Beam Currents[J]. Journal of Materials Engineering, 2024, 52(12): 44-52.
[9] KWAK E, KIM K, LEE C, et al.Optimization Based on Artificial Intelligence for Thermal Barrier Coating with Shadow Effects Using Electron Beam Physical Vapor Deposition[J]. Aerospace Science and Technology, 2026, 168: 110991.
[10] AZZOPARDI A, MÉVREL R, SAINT-RAMOND B, et al. Influence of Aging on Structure and Thermal Conductivity of Y-PSZ and Y-FSZ EB-PVD Coatings[J]. Surface and Coatings Technology, 2004, 177: 131-139.
[11] XU Z H, WANG Z K, HUANG G H, et al.Morphology, Bond Strength and Thermal Cycling Behavior of (Ni, Pt)Al/YSZ EB-PVD Thermal Barrier Coatings[J]. Journal of Alloys and Compounds, 2015, 651: 445-453.
[12] LIU D L, MU R D, HE L M, et al.Failure Behaviour of EB-PVD YSZ Thermal Barrier Coatings under Simulated Aero-Engine Operating Conditions[J]. Surface and Coatings Technology, 2023, 474: 130027.
[13] SEZAVAR A, SAJJADI S A.A Review on the Performance and Lifetime Improvement of Thermal Barrier Coatings[J]. Journal of the European Ceramic Society, 2025, 45(8): 117274.
[14] 杨子毅, 付永强, 王优强, 等. YSZ基热障涂层研究进展[J]. 表面技术, 2025, 54(5): 27-43.
YANG Z Y, FU Y Q, WANG Y Q, et al.Research Progress on YSZ-Based Thermal Barrier Coatings[J]. Surface Technology, 2025, 54(5): 27-43.
[15] PAKSERESHT A, SHARIFIANJAZI F, ESMAEILKHANIAN A, et al.Failure Mechanisms and Structure Tailoring of YSZ and New Candidates for Thermal Barrier Coatings: A Systematic Review[J]. Materials & Design, 2022, 222: 111044.
[16] WANG J, BAI L Y, MA F, et al.Evaluation of Microstructure Evolution of Thermal Barrier YSZ Coating after Thermal Exposure[J]. Ceramics International, 2022, 48(5): 6681-6690.
[17] GARVIE R C, NICHOLSON P S.Phase Analysis in Zirconia Systems[J]. Journal of the American Ceramic Society, 1972, 55(6): 303-305.
[18] TORAYA H, YOSHIMURA M, SOMIYA S. Calibration Curve for Quantitative Analysis of the Monoclinic- Tetragonal ZrO2 System by X-Ray Diffraction[J]. Journal of the American Ceramic Society, 1984, 67(6): C-119-C-121.
[19] FISCHER-CRIPPS A C, NICHOLSON D W. Nanoindentation. Mechanical Engineering Series[J]. Applied Mechanics Reviews, 2004, 57(2): B12.
[20] SCOTT H G.Phase Relationships in the Zirconia-Yttria System[J]. Journal of Materials Science, 1975, 10(9): 1527-1535.
[21] 牟飞, 徐彤, 李广荣, 等. 烧结硬化行为对双陶瓷层热障涂层服役寿命的影响[J]. 中国材料进展, 2023, 42(12): 993-1000.
MOU F, XU T, LI G R, et al.Effect of Sintering-Induced Hardening on Life Span of Double Ceramic Layer Thermal Barrier Coatings[J]. Materials China, 2023, 42(12): 993-1000.
[22] TANG Y N, YI X L, LUO S L, et al.Ultra-High Temperature T'-YSZ/NiCrAlY Graded Thick TBCS Enabled by Spherical Thin-Walled Hollow-Shell T'-YSZ Powder Engineering[J]. Surface and Coatings Technology, 2025, 514: 132591.
[23] TSENG S, CHAO C, LI D X, et al.Experimental and Simulation Analysis of the Evolution of Residual Stress Due to Expansion via CMAS Infiltration in Thermal Barrier Coatings[J]. Coatings, 2021, 11(10): 1148.
[24] ZHANG Y, GU H, QIAN P X, et al.Synergetic Evolution of the Ordered Nanopores and Stabilizer-Controlled Phase- Separations for the Columnar Structures of 8YSZ Thermal- Barrier Coatings through High-Temperature Aging[J]. Acta Materialia, 2025, 285: 120640.
[25] JANG B K, MATSUBARA H.Microstructure of Nanoporous Yttria-Stabilized Zirconia Films Fabricated by EB- PVD[J]. Journal of the European Ceramic Society, 2006, 26(9): 1585-1590.
[26] 牟仁德, 申造宇, 刘冠熙. EB-PVD制备LaZrCeO/YSZ热障涂层显微组织结构及火焰热冲击失效行为研究[J]. 表面技术, 2026, 55(7): 264-273.
MU R D, SHEN Z Y, LIU G X.Microstructures and Flame Thermal Shock Failure Behaviors of EB-PVD Deposited LaZrCeO/YSZ Thermal Barrier Coatings[J]. Surface Technology, 2026, 55(7): 264-273.
[27] LAUKAITIS G, DUDONIS J, MILČIUS D. Microstructure and Surface Morphology of YSZ Thin Films Deposited by E-Beam Technique[J]. Applied Surface Science, 2008, 254(10): 2980-2987.
[28] GOUVÊA D. Thermodynamic of Solid-State Sintering: Contributions of Grain Boundary Energy[J]. Journal of the European Ceramic Society, 2024, 44(14): 116677.
[29] WAKAI F, BRAKKE K A.Mechanics of Sintering for Coupled Grain Boundary and Surface Diffusion[J]. Acta Materialia, 2011, 59(14): 5379-5387.
[30] EVANS A G, MUMM D R, HUTCHINSON J W, et al.Mechanisms Controlling the Durability of Thermal Barrier Coatings[J]. Progress in Materials Science, 2001, 46(5): 505-553.
[31] HUTCHINSON J W, EVANS A G.On the Delamination of Thermal Barrier Coatings in a Thermal Gradient[J]. Surface and Coatings Technology, 2002, 149(2/3): 179-184.
[32] LUGHI V, TOLPYGO V K, CLARKE D R.Microstructural Aspects of the Sintering of Thermal Barrier Coatings[J]. Materials Science and Engineering: A, 2004, 368(1/2): 212-221.
[33] JANG B K, KIM S H, FISHER C A J, et al. Effect of Isothermal Heat Treatment on Nanoindentation Hardness and Young's Modulus of 4 mol% Y2O3-ZrO2 EB-PVD TBCS[J]. Materials Today Communications, 2022, 31: 103330.
基金
国家自然科学基金（52301089）; 江西省重点研发计划项目（20232BBE50007）
PDF(5935 KB)
渝公网安备 50010702501715号 渝ICP备15012534号-3
