Corrosion of Thermal Barrier Coatings in Atmospheric Environment

doi:10.19894/j.issn.1000-0518.240427

Chinese Journal of Applied Chemistry ›› 2025, Vol. 42 ›› Issue (7): 930-944.DOI: 10.19894/j.issn.1000-0518.240427

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Corrosion of Thermal Barrier Coatings in Atmospheric Environment

Xue-Qiang CAO¹(), Jia-Min ZENG², Yao SHI², Ying-Jing YUAN², Xiang FANG², Guang DU¹, Long-Hui DENG¹, Jia-Ning JIANG¹

^1.State Key Laboratory of Silicate Materials for Architectures，Wuhan University of Technology，Wuhan 430070，China
^2.Hunan Aviation Powerplant Research Institute，Aero Engine Corporation of China，Zhuzhou 412000，China

Received:2024-12-15 Accepted:2025-06-17 Published:2025-07-01 Online:2025-07-23
Contact: Xue-Qiang CAO
About author:xcao@whut.edu.cn
Supported by:
the National Natural Science Foundation of China(92060201)

Abstract

Abstract:

Thermal barrier coatings （TBCs） have been widely used for the protection of high-temperature metallic components of aero， space and land-based gas turbine engines， and other weapons， etc. The structure of TBCs basically consists of metallic substrate， metallic bond coat （BC） and ceramic top coat. The substrate material is Ni-based super alloy MCrAlY （M=Ni， Co）， usually some trace elements are added， such as Re， W， Ta， Si and so on. The metallic bond coat also consists of MCrAlY with much more Cr and Al for better anti-oxidation. The ceramic top coating is usually yttria stabilized zirconia （YSZ）. After deposition of TBCs and being stored in natural environment for longer than half a month， some corrosion spots could be observed. The corrosion phenomenon is more obvious in May to July with hot， rainy and humid environment. By means of Laser ablation-inductively coupled plasma-mass spectroscopy （LA-ICP-MS）， distribution of Ni， Co， Cr， Al， Zr and Y in the TBCs depth was analyzed， and the formation of corrosion spots is revealed to be a result of outward diffusion of corrosion products. BC has more Al than the substrate， leading to the Galvanic corrosion of BC. Acidic air pollutants or acidic impurities in TBCs pore sealer are electrolytes of Galvanic corrosion. Reducing acidic impurities and drying TBCs before the pore sealer spraying are effective methods to stop the BC corrosion.

Key words: Thermal barrier coatings, Bond coat, Corrosion spots

CLC Number:

O646.6

Xue-Qiang CAO, Jia-Min ZENG, Yao SHI, Ying-Jing YUAN, Xiang FANG, Guang DU, Long-Hui DENG, Jia-Ning JIANG. Corrosion of Thermal Barrier Coatings in Atmospheric Environment[J]. Chinese Journal of Applied Chemistry, 2025, 42(7): 930-944.

Figures/Tables 18

Fig.1 Corrosion spots of TBCs

Fig.2 Sampling and analysis methods

Fig.3 Analysis of the fluorocarbon coating on TBCs

Fig.4 Corrosion spots on TBCs

Fig.5 LA-ICP-MS analysis of corrosion spots on HYT1 （A） and the enlarged picture of 3 spots in （A） with the dashed line for cutting （B）

Fig.6 LA-ICP-MS analysis results of corrosion spots on HYT1 （laser pulse 500 times）

Fig.7 LA-ICP-MS analysis results of corrosion spots on HYT1 （laser pulse 5000 times）

Fig.8 LA-ICP-MS analysis results （A） and the inner-micrograph （B） of B-5000-1 on HYT1

Fig.9 SEM （A）， EDS （B-H） and SEM images of the BC/YSZ interface （I） of B-5000-1 hole after LA-ICP-MS analysis

Fig.10 SEM （A）， EDS （B-G） and LA-ICP-MS （H） of the hole B-500-2

Fig.11 SEM （A） and EDS （B-H） of TBCs with fluorocarbon coating

Fig.12 SEM （A-C） and EDS （D-F） of the fluorocarbon coating pieces after being soaked in acetone

Fig.13 XRD of the white powders in the fluorocarbon coating pieces after TBCs being soaked in acetone

Fig.14 Comparison of the front and backside of TBCs on the burner

Fig.15 Surface change of HYT0 after being heated at 80 ℃ for 10 days in moisture

Fig.16 SEM of TBCs after being soaked composition a （A）， composition b （B） and composition （C） for 10 days in the three compositions of fluorocarbon coating

Fig.17 The acidic composition in air of the industrialized cities of China （2014-2022）［19］

Fig.18 Potentiodynamic polarization curves of HY3 and DZ125 in：（A） 5×10-4~1 mol/L H2SO4；（B） Natural rain water

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Corrosion of Thermal Barrier Coatings in Atmospheric Environment

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