Foreign object damage behavior and failure mechanism of Al2O3-modified TBCs prepared by PS-PVD

作者：Zifan Wang, J. J. Fan, K. Kang, Jian Wu, Min Liu, Kesong Zhou, Qian Zhang, Zhibo Zhang, Xiaoqiang Li, Xiao-feng ZHANG · 发表于：Transactions of Nonferrous Metals Society of China · 年份：2024 · DOI：10.1016/s1003-6326(24)66541-6 · 被引用次数：9 · 研究领域：High-Temperature Coating Behaviors、Advanced materials and composites、Metal and Thin Film Mechanics

Particle erosion induced by foreign object damage (FOD) is an important factor that restricts the working life of thermal barrier coatings (TBCs). A dense α-Al2O3 overlay was prepared by magnetron sputtering and vacuum treatment on the surface of 7YSZ TBCs sprayed by plasma spray-physical vapor deposition (PS-PVD) to improve the erosion resistance of the TBCs. The FOD behavior of the TBCs was systematically studied and the interface of α-Al2O3/c-ZrO2 was investigated by first principles calculations. The experimental results show that the erosion rates of the PS-PVD, atmospheric plasma spraying (APS), and electron beam-physical vapor deposition (EB-PVD) TBCs were 324, 248, and 139 μg/g, respectively, while the erosion rate of the Al2O3-modified PS-PVD TBCs was reduced to 199 μg/g. In addition, the highest interface adhesive energy of 3.88 J/m2 observed in the top configuration model of Al2O3/ZrO2−O is much higher than that of ZrO2/Ni (2.011 J/m 2), which results in improved interface bonding performance.