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Article(id=1320090153813655736, tenantId=1146029695717560320, journalId=1263187385517883426, issueId=1320090116236882876, articleNumber=null, orderNo=null, doi=10.14062/j.issn.0454-5648.20240684, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1730131200000, receivedDateStr=2024-10-29, revisedDate=1734105600000, revisedDateStr=2024-12-14, acceptedDate=null, acceptedDateStr=null, onlineDate=1792663618757, onlineDateStr=2026-10-22, pubDate=1745078400000, pubDateStr=2025-04-20, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1792663618757, onlineIssueDateStr=2026-10-22, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1792663618757, creator=13701087609, updateTime=1792663618757, updator=13701087609, issue=Issue{id=1320090116236882876, tenantId=1146029695717560320, journalId=1263187385517883426, year='2025', volume='53', issue='4', pageStart='733', pageEnd='1030', issueExtLink='null', onlineDate='null', pubDate='1745078400000', pubDateStr='2025-04-20', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1792663609799, creator='13701087609', updateTime=1792663788359, updator='13701087609', preIssue=null, nextIssue=null, articleTotal=null, ext={EN=IssueExt(id=1320090865276670951, tenantId=1146029695717560320, journalId=1263187385517883426, issueId=1320090116236882876, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1320090865276670952, tenantId=1146029695717560320, journalId=1263187385517883426, issueId=1320090116236882876, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null, downloadFileDto=null}, startPage=985, endPage=997, ext={EN=ArticleExt(id=1320090154010788025, articleId=1320090153813655736, tenantId=1146029695717560320, journalId=1263187385517883426, language=EN, title=Thermal Shock Cycling Behavior and Failure Mechanism of GdYb-YSZ/8YSZ Double Ceramic Layer Thermal Barrier Coatings with Different Thickness Ratios, columnId=1319726165087077079, journalTitle=Journal of the Chinese Ceramic Society, columnName=Research Article, runingTitle=null, highlight=null, articleAbstract=
Introduction

With the development of aero-engine towards large thrust, high thrust-to-weight ratio, high thermal efficiency, low fuel consumption and long life, the turbine inlet temperature is bound to continuously increase. Thermal barrier coating (TBC) with high thermal insulation and long life becomes popular. Multi-rare-earth doped zirconia (especially Gd2O3-Yb2O3-Y2O3 co-doped ZrO2, GdYb-YSZ) as one of the most potential candidate materials for ultra-high temperature TBCs has a better high-temperature phase stability and a lower thermal conductivity rather than YSZ. It is easy to generate thermal stress during thermal cycling due to GdYb-YSZ with a low fracture toughness, resulting in a poor thermal cycling performance of GdYb-YSZ/NiCrAlY TBC. The design of double ceramic layer (DCL) TBC can alleviate the thermal stress mismatch and effectively solve this problem. In the DLC TBCs system, the thickness ratio between ceramic layers can seriously affect the thermal insulation effect and thermal cycle life of the coating. However, little work on the effect of thickness ratio of GdYb-YSZ/8YSZ ceramic layers on the mechanical properties and thermal cycle life of GdYb-YSZ/8YSZ DLC TBCs system has been reported yet.

In this paper, four kinds of GdYb-YSZ/8YSZ DLC TBCs systems with different ceramic layer thickness ratios were prepared. The microstructure, mechanical properties and water quenching-thermal shock cycle properties of GdYb-YSZ/8YSZ DLC TBCs systems with different ceramic layers thickness ratios were investigated. The failure behavior and failure mechanism of GdYb-YSZ/8YSZ DLC TBCs at 1150 ℃ were also discussed.

Methods

GdYb-YSZ/8YSZ DLC TBCs systems with different ceramic layer thickness ratios (i.e., GdYb-YSZ∶8YSZ=5∶1, 2∶1, 1∶1, and 1∶2) were prepared with GH4169 nickel-based superalloy as a matrix, NiCoCrAlY as a bond coating, 8YSZ as the first ceramic layer, and GdYb-YSZ as the second ceramic layer., and then four TBC systems on the surface of GH4169 nickel-based superalloy were prepared by a model UniCoatProTM atmospheric plasma spraying system (Oerlikon Metco Inc., USA). Subsequently, the microstructure and phase composition of four kinds of GdYb-YSZ/8YSZ DLC TBCs systems were characterized. The bonding strength and water quenching-thermal shock cycle behavior at 1150 ℃ were tested, and the failure mechanism was analyzed. To analyze the water quenching-thermal shock cycle behavior at 1150 ℃, the coated sample was kept in a high-temperature furnace at 1150 ℃ for 5 min and then quickly cooled in distilled water to room temperature. After drying, the sample surface was recorded as a cycle experiment. Repeating the steps above until the cracking or peeling area of the coating surface of greater than 5% was considered as the TBC failure.

Results and discussion

Most of the GdYb-YSZ and 8YSZ spraying powders were melted in a high-temperature plasma flame flow, and interacted with the matrix to form the smooth structures via high speed jetting. A small number of unmelted and partially melted particles can form a rough microstructure during deposition, accompanied by micro-cracks and pores. The interfaces of each layer are closely bonded and clearly demarcated in GdYb-YSZ/8YSZ/NiCoCrAlY/substrate TBC system. The average bonding strength of the four GdYb-YSZ/8YSZ thermal barrier coating systems all is greater than 40 MPa. The macro-image of fracture after tensile test shows that most of the fracture occurs at the interface between 8YSZ and NiCoCrAlY. The average porosity of GdYb-YSZ/8YSZ TBC systems with different ceramic layer thickness ratios (i.e., 5∶1, 2∶1, 1∶1, and 1∶2) calculated by a software named Image J is 3.39%, 2.65%, 4.0%, and 2.64%, respectively. The GdYb-YSZ ceramic layer is composed of 98% (mole fraction) c-ZrO2 phase and 2% m-ZrO2 phase, which is basically the same as the phase composition in the spraying powder.

Four kinds of TBCs with different thickness ratios are intact after 80 quenching-thermal shock cycles at 1150 ℃. GdYb-YSZ/8YSZ TBC systems with four ceramic layer thickness ratios (5∶1, 2∶1, 1∶1, and 1∶2) begin to peel off at the edge of the coating after 85, 165, 120, and 195 water quenching-thermal shock cycles, respectively. The water quench-thermal shock cycle resistance of the GdYb-YSZ/8YSZ TBC system becomes better as the thickness of the GdYb-YSZ ceramic layer decreases and the thickness of the 8YSZ ceramic layer increases at a constant total thickness of the ceramic layer. The GdYb-YSZ/8YSZ TBC systems with different ceramic layer thickness ratios (i.e., 5∶1, 2∶1, 1∶1, and 1∶2) have a quenching-thermal shock cycle life of 125, 195, 200, and 205 times at 1150 ℃, respectively. The GdYb-YSZ/8YSZ TBC systems with different ceramic layer thickness ratios are mainly characterized via the peeling of ceramic layer during the water-quenching-thermal shock cycle at 1150 ℃. The thermal stress is one of the main factors leading to the failure of TBCs. The residual stress of 8YSZ ceramic layer with different layer thickness ratios of 5∶1, 2∶1, 1∶1 and 1∶2 is 0.01, 0.08, 0.12 GPa and 0.15 GPa, respectively, after the water quenching-thermal shock cycle failure at 1150 ℃. The stress increases gradually with the increase of the thickness of the ceramic interlayer 8YSZ. The residual stress (i.e., compressive stress) in the TGO layer in the coating system with different layer thickness ratios is 0.51, 0.29, 0.72 GPa and 0.62 GPa, respectively. The compressive stress of the TGO layer will cause the 8YSZ/TGO interface to buckle, and the tensile stress will be generated at the crest of the wave, thus promoting the generation of cracks. In the process of water quenching-thermal shock cycle of GdYb-YSZ/8YSZ TBCs, some micro-cracks are easy to form on one side of the 8YSZ ceramic layer near the 8YSZ/TGO interface under the combined action of residual stress in the ceramic layer and TGO layer. The microcracks can further spread into TGO layer as the TGO layer increases, seriously weakening the interface bonding force between ceramic layer and adhesive layer, and finally leading to the failure of coating spalling.

Conclusions

GdYb-YSZ/8YSZ double ceramic layer thermal barrier coatings (i.e., DCL TBC) with different layer thickness ratios (i.e., GdYb-YSZ/8YSZ = 5∶1, 2∶1, 1∶1, and 1∶2) were prepared by an atmospheric plasma spraying technology. GdYb-YSZ ceramic top coated with four coatings were composed of c-ZrO2 phase and a small amount of m-ZrO2. The bonding strength of the four coatings was greater than 40 MPa, and the average bonding strength of the coatings was the maximum when the thickness of GdYb-YSZ/8YSZ was 5∶1. The thermal shock cycle resistance of GdYb-YSZ/8YSZ TBC system became better as the thickness of the GdYb-YSZ ceramic coat decreased and the thickness of the 8YSZ ceramic coat increased. At the thickness ratio of GdYb-YSZ/8YSZ of 1∶2, the water quenching-thermal shock of the TBC was up to 205 cycles at 1150 ℃, having the optimum thermal shock resistance. In addition, GdYb-YSZ/8YSZ TBCs with different ceramic layer thickness ratios did not undergo a phase transformation under the water-quenching-thermal shock cycle at 1150 ℃. The failure mechanism of GdYb-YSZ/8YSZ TBCs with different ceramic layer thickness ratios under the quench-thermal shock cycle at 1150 ℃ was as follows, i.e., in the process of water quenching-thermal shock cycle at 1150 ℃, the residual stress in 8YSZ coating increased with the increase of the thickness of 8YSZ ceramic layer, and micro-cracks were easy to form on one side of 8YSZ ceramic layer at near 8YSZ/TGO interface. In addition, the formation of TGO in the process of thermal cycling was accompanied by the generation of compressive stress. TGO further increased, and the micro-cracks in the coating expanded into TGO with the increase of the number of thermal cycles, reducing the binding force of the coating, and eventually causing the coating to flake and fail.

, authors=Jiao MEI1, Zhaolu XUE1, Yue ZHENG1, Haiyuan YU2, Guanghua LIU3, Xiufang GONG4, Jian SUN3, Zhenya ZHANG1, Shihong ZHANG1, authorsList=Jiao MEI, Zhaolu XUE, Yue ZHENG, Haiyuan YU, Guanghua LIU, Xiufang GONG, Jian SUN, Zhenya ZHANG, Shihong ZHANG, authorCompany=null, correspAuthors=Zhaolu XUE, Shihong ZHANG, authorNote=

MEI Jiao (2000-), female, Master candidate. E-mail:

, correspAuthorsNote=
XUE Zhaolu (1984-), male, Ph.D., Lecturer. E-mail: ;
ZHANG Shihong (1981-), male, Ph.D., Professor.
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多元稀土掺杂氧化锆是超高温热障涂层的理想候选材料之一，并且双陶瓷层热障涂层由于具有优良的综合性能而受到了广泛关注。通过设计4种不同陶瓷层厚度比［Gd2O3-Yb2O3-Y2O3共掺杂ZrO2（GdYb-YSZ）：质量分数为6%~8%的Y2O3部分稳定ZrO2（8YSZ）为5∶1，2∶1，1∶1，1∶2］的GdYb-YSZ/8YSZ双陶瓷层热障涂层，随后采用大气等离子喷涂技术制备了4种GdYb-YSZ/8YSZ双陶瓷层热障涂层，研究了GdYb-YSZ/8YSZ陶瓷层厚度比对热障涂层微观组织、结合强度和水淬-热震循环性能的影响，探讨了4种热障涂层在1150 ℃水淬-热震循环下的失效机理。结果显示：绝大部分GdYb-YSZ和8YSZ喷涂粉末材料都已熔化，有少部分粉末未熔或半熔化状态，导致涂层的表面由光滑组织和粗糙组织构成。GdYb-YSZ陶瓷顶层均是由c-ZrO2相和少量m-ZrO2相组成，GdYb-YSZ/8YSZ厚度比为5：1时的涂层的平均结合强度最大。在陶瓷层总厚度约300 μm不变的情况下，随着GdYb-YSZ陶瓷层的厚度减小，GdYb-YSZ/8YSZ涂层体系在1150 ℃的抗热震循环性能越来越好，当GdYb-YSZ/8YSZ厚度比为1：2时，水淬-热震循环达到了205次，抗热震性能最好。在1150 ℃的水淬-热震循环过程中，随着8YSZ陶瓷层厚度的增加，8YSZ涂层内的残余应力越大，微裂纹容易在8YSZ/TGO（热生长氧化物层）界面处靠近8YSZ一侧形成；加上热循环过程中TGO形成并伴随有压应力的产生，随着热循环次数的增加，TGO不断增长，涂层中的微裂纹也会进一步扩展至TGO内，降低涂层的结合力，最终导致涂层发生剥落失效。

, authors=梅娇1, 薛召露1, 郑越1, 于海原2, 刘广华3, 巩秀芳4, 孙健3, 张振亚1, 张世宏1, authorsList=梅娇, 薛召露, 郑越, 于海原, 刘广华, 巩秀芳, 孙健, 张振亚, 张世宏, authorCompany=null, correspAuthors=薛召露, 张世宏, authorNote=

梅娇（2000—），女，硕士研究生。

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薛召露（1984—），男，博士，讲师；
张世宏（1981—），男，博士，教授。
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不同厚度比GdYb-YSZ/8YSZ双陶瓷层热障涂层的水淬-热震循环行为及失效机理
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梅娇 1 , 薛召露 1 , 郑越 1 , 于海原 2 , 刘广华 3 , 巩秀芳 4 , 孙健 3 , 张振亚 1 , 张世宏 1
硅酸盐学报 | 研究论文 2025,53(4): 985-997
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硅酸盐学报 |研究论文 2025 , 53 (4) : 985 -997
不同厚度比GdYb-YSZ/8YSZ双陶瓷层热障涂层的水淬-热震循环行为及失效机理
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梅娇1 , 薛召露1 , 郑越1, 于海原2, 刘广华3, 巩秀芳4, 孙健3, 张振亚1, 张世宏1
作者信息
  • 1．安徽工业大学先进金属材料绿色制备与表面技术教育部重点实验室，安徽 马鞍山 243002
  • 2．北京北冶功能材料有限公司，北京 100192
  • 3．中国联合重型燃气轮机有限公司，北京 100015
  • 4．东方电气集团东方汽轮机有限公司，四川 德阳 618000
通讯作者:
薛召露（1984—），男，博士，讲师；
张世宏（1981—），男，博士，教授。
作者简介:

梅娇（2000—），女，硕士研究生。

Thermal Shock Cycling Behavior and Failure Mechanism of GdYb-YSZ/8YSZ Double Ceramic Layer Thermal Barrier Coatings with Different Thickness Ratios
Jiao MEI1 , Zhaolu XUE1 , Yue ZHENG1, Haiyuan YU2, Guanghua LIU3, Xiufang GONG4, Jian SUN3, Zhenya ZHANG1, Shihong ZHANG1
Affiliations
  • 1.Key Laboratory of Green Fabrication and Surface Technology of Advanced Metal Materials, Anhui University of Technology, Maanshan 243002, Anhui, China
  • 2.Beijing Beiye Functional Materials Co., Ltd., Beijing 100192, China
  • 3.China United Gas Turbine Technology Co., Ltd., Beijing 100015, China
  • 4.Dongfang Electric Corporation Dongfang Turbine Co., LTD, Deyang 618000, Sichuan, China
    • Corresponding Author:
    XUE Zhaolu (1984-), male, Ph.D., Lecturer. E-mail: ;
    ZHANG Shihong (1981-), male, Ph.D., Professor.

    MEI Jiao (2000-), female, Master candidate. E-mail:

出版时间: 2025-04-20 doi: 10.14062/j.issn.0454-5648.20240684
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摘要
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多元稀土掺杂氧化锆是超高温热障涂层的理想候选材料之一，并且双陶瓷层热障涂层由于具有优良的综合性能而受到了广泛关注。通过设计4种不同陶瓷层厚度比［Gd2O3-Yb2O3-Y2O3共掺杂ZrO2（GdYb-YSZ）：质量分数为6%~8%的Y2O3部分稳定ZrO2（8YSZ）为5∶1，2∶1，1∶1，1∶2］的GdYb-YSZ/8YSZ双陶瓷层热障涂层，随后采用大气等离子喷涂技术制备了4种GdYb-YSZ/8YSZ双陶瓷层热障涂层，研究了GdYb-YSZ/8YSZ陶瓷层厚度比对热障涂层微观组织、结合强度和水淬-热震循环性能的影响，探讨了4种热障涂层在1150 ℃水淬-热震循环下的失效机理。结果显示：绝大部分GdYb-YSZ和8YSZ喷涂粉末材料都已熔化，有少部分粉末未熔或半熔化状态，导致涂层的表面由光滑组织和粗糙组织构成。GdYb-YSZ陶瓷顶层均是由c-ZrO2相和少量m-ZrO2相组成，GdYb-YSZ/8YSZ厚度比为5：1时的涂层的平均结合强度最大。在陶瓷层总厚度约300 μm不变的情况下，随着GdYb-YSZ陶瓷层的厚度减小，GdYb-YSZ/8YSZ涂层体系在1150 ℃的抗热震循环性能越来越好，当GdYb-YSZ/8YSZ厚度比为1：2时，水淬-热震循环达到了205次，抗热震性能最好。在1150 ℃的水淬-热震循环过程中，随着8YSZ陶瓷层厚度的增加，8YSZ涂层内的残余应力越大，微裂纹容易在8YSZ/TGO（热生长氧化物层）界面处靠近8YSZ一侧形成；加上热循环过程中TGO形成并伴随有压应力的产生，随着热循环次数的增加，TGO不断增长，涂层中的微裂纹也会进一步扩展至TGO内，降低涂层的结合力，最终导致涂层发生剥落失效。

热障涂层  /  大气等离子喷涂技术  /  氧化钆-氧化镱-氧化钇共掺杂氧化锆  /  热循环失效机理
Introduction

With the development of aero-engine towards large thrust, high thrust-to-weight ratio, high thermal efficiency, low fuel consumption and long life, the turbine inlet temperature is bound to continuously increase. Thermal barrier coating (TBC) with high thermal insulation and long life becomes popular. Multi-rare-earth doped zirconia (especially Gd2O3-Yb2O3-Y2O3 co-doped ZrO2, GdYb-YSZ) as one of the most potential candidate materials for ultra-high temperature TBCs has a better high-temperature phase stability and a lower thermal conductivity rather than YSZ. It is easy to generate thermal stress during thermal cycling due to GdYb-YSZ with a low fracture toughness, resulting in a poor thermal cycling performance of GdYb-YSZ/NiCrAlY TBC. The design of double ceramic layer (DCL) TBC can alleviate the thermal stress mismatch and effectively solve this problem. In the DLC TBCs system, the thickness ratio between ceramic layers can seriously affect the thermal insulation effect and thermal cycle life of the coating. However, little work on the effect of thickness ratio of GdYb-YSZ/8YSZ ceramic layers on the mechanical properties and thermal cycle life of GdYb-YSZ/8YSZ DLC TBCs system has been reported yet.

In this paper, four kinds of GdYb-YSZ/8YSZ DLC TBCs systems with different ceramic layer thickness ratios were prepared. The microstructure, mechanical properties and water quenching-thermal shock cycle properties of GdYb-YSZ/8YSZ DLC TBCs systems with different ceramic layers thickness ratios were investigated. The failure behavior and failure mechanism of GdYb-YSZ/8YSZ DLC TBCs at 1150 ℃ were also discussed.

Methods

GdYb-YSZ/8YSZ DLC TBCs systems with different ceramic layer thickness ratios (i.e., GdYb-YSZ∶8YSZ=5∶1, 2∶1, 1∶1, and 1∶2) were prepared with GH4169 nickel-based superalloy as a matrix, NiCoCrAlY as a bond coating, 8YSZ as the first ceramic layer, and GdYb-YSZ as the second ceramic layer., and then four TBC systems on the surface of GH4169 nickel-based superalloy were prepared by a model UniCoatProTM atmospheric plasma spraying system (Oerlikon Metco Inc., USA). Subsequently, the microstructure and phase composition of four kinds of GdYb-YSZ/8YSZ DLC TBCs systems were characterized. The bonding strength and water quenching-thermal shock cycle behavior at 1150 ℃ were tested, and the failure mechanism was analyzed. To analyze the water quenching-thermal shock cycle behavior at 1150 ℃, the coated sample was kept in a high-temperature furnace at 1150 ℃ for 5 min and then quickly cooled in distilled water to room temperature. After drying, the sample surface was recorded as a cycle experiment. Repeating the steps above until the cracking or peeling area of the coating surface of greater than 5% was considered as the TBC failure.

Results and discussion

Most of the GdYb-YSZ and 8YSZ spraying powders were melted in a high-temperature plasma flame flow, and interacted with the matrix to form the smooth structures via high speed jetting. A small number of unmelted and partially melted particles can form a rough microstructure during deposition, accompanied by micro-cracks and pores. The interfaces of each layer are closely bonded and clearly demarcated in GdYb-YSZ/8YSZ/NiCoCrAlY/substrate TBC system. The average bonding strength of the four GdYb-YSZ/8YSZ thermal barrier coating systems all is greater than 40 MPa. The macro-image of fracture after tensile test shows that most of the fracture occurs at the interface between 8YSZ and NiCoCrAlY. The average porosity of GdYb-YSZ/8YSZ TBC systems with different ceramic layer thickness ratios (i.e., 5∶1, 2∶1, 1∶1, and 1∶2) calculated by a software named Image J is 3.39%, 2.65%, 4.0%, and 2.64%, respectively. The GdYb-YSZ ceramic layer is composed of 98% (mole fraction) c-ZrO2 phase and 2% m-ZrO2 phase, which is basically the same as the phase composition in the spraying powder.

Four kinds of TBCs with different thickness ratios are intact after 80 quenching-thermal shock cycles at 1150 ℃. GdYb-YSZ/8YSZ TBC systems with four ceramic layer thickness ratios (5∶1, 2∶1, 1∶1, and 1∶2) begin to peel off at the edge of the coating after 85, 165, 120, and 195 water quenching-thermal shock cycles, respectively. The water quench-thermal shock cycle resistance of the GdYb-YSZ/8YSZ TBC system becomes better as the thickness of the GdYb-YSZ ceramic layer decreases and the thickness of the 8YSZ ceramic layer increases at a constant total thickness of the ceramic layer. The GdYb-YSZ/8YSZ TBC systems with different ceramic layer thickness ratios (i.e., 5∶1, 2∶1, 1∶1, and 1∶2) have a quenching-thermal shock cycle life of 125, 195, 200, and 205 times at 1150 ℃, respectively. The GdYb-YSZ/8YSZ TBC systems with different ceramic layer thickness ratios are mainly characterized via the peeling of ceramic layer during the water-quenching-thermal shock cycle at 1150 ℃. The thermal stress is one of the main factors leading to the failure of TBCs. The residual stress of 8YSZ ceramic layer with different layer thickness ratios of 5∶1, 2∶1, 1∶1 and 1∶2 is 0.01, 0.08, 0.12 GPa and 0.15 GPa, respectively, after the water quenching-thermal shock cycle failure at 1150 ℃. The stress increases gradually with the increase of the thickness of the ceramic interlayer 8YSZ. The residual stress (i.e., compressive stress) in the TGO layer in the coating system with different layer thickness ratios is 0.51, 0.29, 0.72 GPa and 0.62 GPa, respectively. The compressive stress of the TGO layer will cause the 8YSZ/TGO interface to buckle, and the tensile stress will be generated at the crest of the wave, thus promoting the generation of cracks. In the process of water quenching-thermal shock cycle of GdYb-YSZ/8YSZ TBCs, some micro-cracks are easy to form on one side of the 8YSZ ceramic layer near the 8YSZ/TGO interface under the combined action of residual stress in the ceramic layer and TGO layer. The microcracks can further spread into TGO layer as the TGO layer increases, seriously weakening the interface bonding force between ceramic layer and adhesive layer, and finally leading to the failure of coating spalling.

Conclusions

GdYb-YSZ/8YSZ double ceramic layer thermal barrier coatings (i.e., DCL TBC) with different layer thickness ratios (i.e., GdYb-YSZ/8YSZ = 5∶1, 2∶1, 1∶1, and 1∶2) were prepared by an atmospheric plasma spraying technology. GdYb-YSZ ceramic top coated with four coatings were composed of c-ZrO2 phase and a small amount of m-ZrO2. The bonding strength of the four coatings was greater than 40 MPa, and the average bonding strength of the coatings was the maximum when the thickness of GdYb-YSZ/8YSZ was 5∶1. The thermal shock cycle resistance of GdYb-YSZ/8YSZ TBC system became better as the thickness of the GdYb-YSZ ceramic coat decreased and the thickness of the 8YSZ ceramic coat increased. At the thickness ratio of GdYb-YSZ/8YSZ of 1∶2, the water quenching-thermal shock of the TBC was up to 205 cycles at 1150 ℃, having the optimum thermal shock resistance. In addition, GdYb-YSZ/8YSZ TBCs with different ceramic layer thickness ratios did not undergo a phase transformation under the water-quenching-thermal shock cycle at 1150 ℃. The failure mechanism of GdYb-YSZ/8YSZ TBCs with different ceramic layer thickness ratios under the quench-thermal shock cycle at 1150 ℃ was as follows, i.e., in the process of water quenching-thermal shock cycle at 1150 ℃, the residual stress in 8YSZ coating increased with the increase of the thickness of 8YSZ ceramic layer, and micro-cracks were easy to form on one side of 8YSZ ceramic layer at near 8YSZ/TGO interface. In addition, the formation of TGO in the process of thermal cycling was accompanied by the generation of compressive stress. TGO further increased, and the micro-cracks in the coating expanded into TGO with the increase of the number of thermal cycles, reducing the binding force of the coating, and eventually causing the coating to flake and fail.

thermal barrier coating  /  atmospheric plasma spraying technology  /  gadolinium oxide-ytterbium oxide-yttrium oxide co-doped zirconia  /  thermal cycle failure mechanism
梅娇, 薛召露, 郑越, 于海原, 刘广华, 巩秀芳, 孙健, 张振亚, 张世宏. 不同厚度比GdYb-YSZ/8YSZ双陶瓷层热障涂层的水淬-热震循环行为及失效机理. 硅酸盐学报, 2025 , 53 (4) : 985 -997 . DOI: 10.14062/j.issn.0454-5648.20240684
Jiao MEI, Zhaolu XUE, Yue ZHENG, Haiyuan YU, Guanghua LIU, Xiufang GONG, Jian SUN, Zhenya ZHANG, Shihong ZHANG. Thermal Shock Cycling Behavior and Failure Mechanism of GdYb-YSZ/8YSZ Double Ceramic Layer Thermal Barrier Coatings with Different Thickness Ratios[J]. Journal of the Chinese Ceramic Society, 2025 , 53 (4) : 985 -997 . DOI: 10.14062/j.issn.0454-5648.20240684
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  • 安徽省高校自然科学重点项目(KJ2021A0389)
  • 国家重点研发计划(2019YFE0107500)
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doi: 10.14062/j.issn.0454-5648.20240684
  • 接收时间：2024-10-29
  • 首发时间：2026-10-22
  • 出版时间：2025-04-20
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  • 收稿日期：2024-10-29
  • 修回日期：2024-12-14
基金
安徽省高校自然科学重点项目(KJ2021A0389)
国家重点研发计划(2019YFE0107500)
作者信息
    1．安徽工业大学先进金属材料绿色制备与表面技术教育部重点实验室，安徽 马鞍山 243002
    2．北京北冶功能材料有限公司，北京 100192
    3．中国联合重型燃气轮机有限公司，北京 100015
    4．东方电气集团东方汽轮机有限公司，四川 德阳 618000

通讯作者:

薛召露（1984—），男，博士，讲师；
张世宏（1981—），男，博士，教授。
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