Synthesis of Gd2Zr2O7 Coatings Using the Novel Reactive PS-PVD Process

Ceramic topcoats of thermal barrier coatings (TBCs) make it possible to increase the working temperature of the hot sections of jet engines. Yttria-stabilized zirconia oxide (YSZ) is usually used to protect the turbine blades and vanes against high temperature and oxidation. It is necessary to develop new materials which can operate at higher temperatures in a highly oxidizing gas atmosphere. Re2Zr2O7-type pyrochlores are promising YSZ replacements. Usually, they are produced by mixing pure oxides in the calcination process at higher temperatures. In a recent article, the new concept of pyrochlore synthesis during the deposition process was presented. The new technology, called reactive plasma spray physical vapor deposition (reactive PS-PVD), was developed and a Gd2Zr2O7 (GZO) coating was achieved. The reactive PS-PVD process allowed for the use of a mixture of untreated ZrO2 and Gd2O3 powders as reactants, instead of the commercially available gadolinium zirconate powders used in other types of processes. The results of microstructure observations revealed a columnar microstructure in the produced ceramic layer. The phase composition indicated the presence of gadolinium zirconate. Thermal analysis showed a decrease in the thermal conductivity in the range of 700 to 1200 degrees C of the produced layers, as compared to the layer made of the currently used conventional YSZ.

Automated summary

The ceramic topcoats of thermal barrier coatings (TBCs) can increase the working temperature of jet engines, with yttria-stabilized zirconia oxide (YSZ) commonly used for this purpose. The development of Re2Zr2O7-type pyrochlores as YSZ replacements shows promise, with a new synthesis concept and technology called reactive PS-PVD resulting in the successful production of a Gd2Zr2O7 (GZO) coating. The microstructure observations, phase composition, and thermal analysis of the GZO coating revealed improved performance compared to conventional YSZ coatings.