Corrosion Behavior of Atmospheric Plasma Spray Thermal Barrier Coatings at 900 °C Beneath NaCl Deposits in Oxygen Flow Carrying Water Vapor

doi:10.11902/1005.4537.2024.412

Journal of Chinese Society for Corrosion and protection

2025, Vol. 45

Issue (5): 1233-1243 DOI: 10.11902/1005.4537.2024.412

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Corrosion Behavior of Atmospheric Plasma Spray Thermal Barrier Coatings at 900 °C Beneath NaCl Deposits in Oxygen Flow Carrying Water Vapor

LI Yanyan¹, LI Shuai²(

), DONG Chao¹, LI Dongqiang¹, BAO Zebin², ZHU Shenglong²

1 National Key Laboratory of Marine Engine Science and Technology, AECC Shenyang Engine Research Institute, Shenyang 110015, China
2 Shi -Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China

Cite this article:

LI Yanyan, LI Shuai, DONG Chao, LI Dongqiang, BAO Zebin, ZHU Shenglong. Corrosion Behavior of Atmospheric Plasma Spray Thermal Barrier Coatings at 900 °C Beneath NaCl Deposits in Oxygen Flow Carrying Water Vapor. Journal of Chinese Society for Corrosion and protection, 2025, 45(5): 1233-1243.

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Abstract

Ceramic top coatings of 8%Y₂O₃-stabilized ZrO₂ (YSZ) were deposited on the surface of NiCoCrAlY bond coat on DZ411 Ni-based high temperature alloy via high-velocity oxygen fuel (HVOF) spraying with tow type of spraying processes, namely Metco 9M and Praxair 7700 spraying techniques, respectively. The corrosion behavior of the two YSZ thermal barrier coatings was evaluated beneath NaCl deposits in oxygen flow carrying water vapor at 900 ℃. As indicated by the results, the air plasma spraying process can optimize the microstructure of the YSZ ceramic top coat through a judicious adjustment of the plasma gas flow rate and spraying current, resulting in a uniformly dense and less porous structure. Due to its dense microstructure and low porosity, the compact YSZ ceramic top coat is capable of hindering the inward migration of chlorine and oxygen to a certain extent, thereby suppressing the oxidation rate of the NiCoCrAlY bond coating. It follows that, the YSZ thermal barrier coating prepared by the Praxair 7700 spraying process exhibited excellent thermal stability and corrosion resistance.

Key words: surface and interface in materials high temperature corrosion thermal barrier coatings simulated marine environment

Received: 26 December 2024 32134.14.1005.4537.2024.412

ZTFLH:

TG174.2

Fund: National Natural Science Foundation of China(52301116);China Postdoctoral Science Foundation(2023M743572);National Key Laboratory of Marine Engine Science and Technology Foundation

Corresponding Authors: LI Shuai, E-mail: sli17s@imr.ac.cn

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	LI Yanyan
	LI Shuai
	DONG Chao
	LI Dongqiang
	BAO Zebin
	ZHU Shenglong

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https://www.jcscp.org/EN/10.11902/1005.4537.2024.412 OR https://www.jcscp.org/EN/Y2025/V45/I5/1233

Table 1 Nominal chemical compositions of DZ411 Ni-based superalloy and NiCoCrAlY powders (mass fraction / %)

Fig.1 Schematic diagram of the high-temperature corrosion testing system

Fig.2 Surface morphologies of the YSZ top coatings deposited by Metco 9M (a, b) and Praxair 7700 (c, d)

Fig.3 Cross-sectional morphologies of TBCs with YSZ top coatings deposited by Metco 9M (a, b) and Praxair 7700 (c, d)

Fig.4 XRD patterns (a) and partially enlarged view (b) of the YSZ top coatings deposited by Metco 9M and Praxair 7700

Fig.5 XRD patterns of TBCs with the YSZ top coatings deposited by Metco 9M (a) and Praxair 7700 (b) after corrosion for 100 and 200 h in the composite environment of water vapor and NaCl at 900 ℃

Fig.6 Cross-sectional morphologies of TBC with the YSZ top coating deposited by Metco 9M after corrosion for 100 h (a, b) and 200 h (c, d)

Fig.7 Cross-sectional morphologies of TBC with the YSZ top coating deposited by Praxair 7700 after corrosion for 100 h (a, b) and 200 h (c, d)

Fig.8 Cross-sectional morphologies of TBC with the YSZ top coating deposited by Metco 9M after corrosion for 300 h (a, b), and EDS elemental mappings in Fig.8b (c-i)

Table 2 EDS results of the marked areas in Fig.8 and Fig.9 (atomic fraction / %)

Fig.9 Cross-sectional morphologies of TBC with the YSZ top coating deposited by Praxair 7700 after corrosion for 300 h (a, b), and EDS elemental mappings in Fig.9b (c-i)

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