Degradation and lifetime of self-healing thermal barrier coatings containing MoSi2 as self-healing particles in thermo-cycling testing

Yttria-stabilized zirconia (YSZ) is the state-of-the-art top coat material for thermal barrier coatings (TBCs) applied on highly loaded gas turbine parts. During operation at high temperatures, stresses are induced by the thermal expansion coefficient mismatch between the ceramic TBC and the metallic substrate. As a consequence cracks can grow, propagate and finally lead to a spallation of the top coat. Using atmospheric plasma spraying (APS), so-called self-healing MoSi2 particles can be incorporated into the YSZ matrix to mitigate the propagation of cracks leading to a lifetime gain and possibly higher temperature capability of the TBC. In the present work, the healing process is realized by the oxidation of the self-healing particles, which introduces a volume expansion by a formation of reaction products, which can seal the cracks. The self-healing particles were introduced within the first 150 mu m of the YSZ coating matrix immediately on top of the bond coat. The degradation and lifetime of such systems were studied in furnace cycling and in burner rig tests, in which a temperature gradient through the sample was applied. The lifetime of the self-healing coatings was then compared to the lifetime of an YSZ coating without self-healing particles. In burner rig tests a clear lifetime extension of the self-healing TBCs was observed. The origin of this different behavior was investigated by microstructural analysis in scanning electron microscopy. A further insight into the failure mechanisms was gained by the analysis of a self-healing TBC cycled in a furnace cycling test only for about 55% of its expected lifetime.

Automated summary

This study demonstrates the self-healing capability of Yttria-stabilized zirconia (YSZ) thermal barrier coatings (TBCs) through the incorporation of self-healing MoSi2 particles. The self-healing process relies on the oxidation of the particles, which leads to a volume expansion and sealing of cracks. The lifetime of the self-healing coatings is significantly extended compared to YSZ coatings without self-healing particles, as observed in burner rig tests. Microstructural analysis and furnace cycling tests provide insights into the different behavior and failure mechanisms of the self-healing TBCs.