2ZrO2•Y2O3 Thermal Barrier Coatings Resistant to Degradation by Molten CMAS: Part I, Optical Basicity Considerations and Processing

The higher operating temperatures in gas-turbine engines enabled by thermal barrier coatings (TBCs) engender new materials issues, viz silicate particles (sand, volcanic ash, fly ash) ingested by the engine melt on the hot TBC surfaces and form calcium-magnesium-alumino-silicate (CMAS) glass deposits. The molten CMAS glass degrades TBCs, leading to their premature failure. In this context, we have used the concept of optical basicity (OB) to provide a quantitative chemical basis for the screening of CMAS-resistant TBC compositions, which could also be extended to environmental barrier coatings (EBCs). By applying OB difference considerations to various major TBC compositions and two types of important CMASsdesert sand and fly ashthe 2ZrO(2)Y(2)O(3) solid solution (ss) TBC composition, with the potential for high CMAS-resistance, is chosen for this study. Here, we also demonstrate the feasibility of processing of 2ZrO(2)Y(2)O(3)(ss) air-plasma sprayed (APS) TBC using commercially developed powders. The resulting TBCs with typical APS microstructures are found to be single-phase cubic fluorite, having a thermal conductivity <0.9W(mK)(-1) at elevated temperatures. The accompanying Part II paper presents results from experiments and analyses of high-temperature interactions between 2ZrO(2)Y(2)O(3)(ss) APS TBC and the two types of CMASs.