Composition, structure and properties of gradient thermal barrier coatings (TBCs) produced by electron beam physical vapor deposition (EB-PVD)

Gradient thermal barrier coatings (TBCs) along with the bond coat were produced by one and the same technological cycle using electron beam physical vapor deposition (EB-PVD) of an MCrAlY ingot, then of an Al-Al2O3-ZrO2(Y2O3) tablet (pressed multicomponent powder mixture) and finally of a ZrO2-7 wt.% Y2O3 ceramic ingot. At the evaporation temperature used, vapor pressures of the tablet components decrease in the direction: AlapproachesAl2O3approachesZrO2(Y2O3). The evaporation of these constituents also proceeds in the same order. As a result, a transition zone [with composition and structure gradients - transition gradient zone (TGZ)] - forms between the bond coat and outer ZrO2-7 wt.% Y2O3 ceramic layer during deposition. The TGZ constitution and structure are primarily determined by the aluminum, Al2O3 and ZrO2 contents of the tablet. As a consequence of liquid aluminum participation in the coating deposition process, a thin layer of β-phase (NiAl), smoothly transitions to an Al2O3 layer and then to ZrO2-7 wt.% Y2O3. (Copyright (c) 1998 Elsevier Science B.V., Amsterdam. All rights reserved.)