In-situ laser synthesis of rare earth aluminate coatings in the system Ln-Al-O (Ln = Y, Gd)

Laser zone melting (LZM) was employed in this work to prepare Ln-Al-O coatings on polycrystalline Al2O3 substrates, using the corresponding mixtures of powdered rare-earth oxides and Al2O3 as starting materials. In-situ synthesis of the compounds Ln = Y, Gd was performed using a CO2 laser, emitting at 10.6 mu m. Microstructure (SEM) and phase nature (XRD) demonstrated in-situ formation of Al2O3/Y3Al5O12(YAG) and Al2O3/GdAlO3(GAP) eutectic systems. The interaction with the substrate resulted in mechanically stable, well integrated 200-500 mu m thick composite coatings, as observed in nanoindentation tests. The phase relations found in these materials are consistent with the crystallographic concepts advanced by Vegas (Ramos-Gallardo & Vegas, J. Solid State Chem. 128 (1997) 69), where cation sub-arrays are proposed to play an important role in governing metal oxide structures. These sub-arrays are suggested as the structural drive behind eutectic oxide formation. LZM proves to be a convenient method to investigate the behaviour of complex oxide systems at high temperature, to apply a rational concept towards the understanding of phase relations and to develop design criteria for oxide coatings. (C) 2011 Elsevier Masson SAS. All rights reserved.