Journal of the European Ceramic Society 24 (2004) 110 www.elsevier.

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Ceramic materials for thermal barrier coatings

Key Laboratory of Rare Earth Chemistry and Physics, Changchun Institute of Applied Chemistry, Chinese Academy of Sciences, Changchun 130022, Jilin, China b IWV-1, Forschungszentrum Juelich GmbH, D-52425, Germany Received 30 June 2002; received in revised form 20 February 2003; accepted 7 March 2003

Abstract This paper summarizes the basic properties of ceramic materials for thermal barrier coatings. Ceramics, in contrast to metals, are often more resistant to oxidation, corrosion and wear, as well as being better thermal insulators. Except yttria stabilized zirconia, other materials such as lanthanum zirconate and rare earth oxides are also promising materials for thermal barrier coatings. # 2003 Elsevier Ltd. All rights reserved.
Keywords: Coatings; Mechanical properties; Thermal barrier coatings; Thermal properties

1. Introduction During the past decade, research eorts were devoted to the development and manufacturing of ceramic thermal barrier coatings (TBCs) on turbine parts because the traditional turbine material have reached the limits of their temperature capabilities. TBCs are deposited on transition pieces, combustion lines, rst-stage blades and vanes and other hot-path components of gas turbines either to increase the inlet temperature with a consequent improvement of the eciency or to reduce the requirements for the cooling system.13 The earliest ceramic coatings for aerospace applications were frit enamels developed by the National Advisory Committee for Aeronautics (NACA) and the coating of calcia stabilized zirconia on the exhaust nozzle of the X-15 manned rocket plane in 1960s is believed to be the rst use of TBCs in manned ight.4 The working parts of aircraft jet engines are subjected to serve mechanical, chemical and thermal stresses. Several ceramic coatings such as Al2O3, TiO2, mullite, CaO/ MgO+ZrO2, YSZ, CeO2+YSZ, zircon and La2Zr2O7, etc. have been evaluated as TBC materials. The selection of TBC materials is restricted by some basic requirements: (1) high melting point, (2) no phase transformation between room temperature and operation temperature, (3) low thermal conductivity, (4) chemical
* Corresponding author. E-mail address: [email protected] (X.Q. Cao). 0955-2219/03/$ - see front matter # 2003 Elsevier Ltd. All rights reserved. doi:10.1016/S0955-2219(03)00129-8

inertness, (5) thermal expansion match with the metallic substrate, (6) good adherence to the metallic substrate and (7) low sintering rate of the porous microstructure.1,5 The number of materials that can be used as TBCs is very limited. So far, only a few materials have been found to basically satisfy these requirements. This paper is believed to be the rst review about the ceramic TBC materials and is helpful to the selection of TBC materials. In Ref. 6 the development of new TBC systems is described. The following are TBC materials under investigation. Properties of some ceramics that can be used in TBC system are summarized in Table 1. Among those properties, thermal expansion coecient and thermal conductivity seem to be the most important. These data are collected from dierent references and hence may not be complete. Metal substrate and bond coats are also included for comparison. The number before yttria stabilized zirconia (YSZ) represents the weight percentage of Y2O3 in ZrO2. The advantages and disadvantages of other TBC materials are compared with YSZ and listed in Table 2. The improvement techniques of YSZ coatings are also summarized in this table.

2. Materials for TBCs 2.1. YSZ 7-8YSZ is the most widely studied and used TBC material because it provides the best performance in

2 Table 1 Properties of TBC materials Materials ZrO2

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Properties Tm=2973 K7 Dth=0.43106 m2 s1 (1273 K)8 l=2.17 W m1 K1 (1273 K)9 E=21 GPa (1373 K)10 =15.3106 K1 (1273 K)11 =0.2510 Tm=2973 K12 Dth=0.58106 m2 s1 (1273 K)5 l=2.12 W m1 K1 (1273 K)5 Cp=0.64 J g1 K1 (1273 K)5 =11.5106 K1 (2931273 K)5 E=40 GPa (293 K)13 =10.7106 K1 (2931273 K)13 =0.2213 =10.53106 K1 (1273 K)8 Tsoftening=2558 K7 E=149.3 GPa (293 K)7 =9.91106 K1 (1273 K)8 =0.287 Tm=2123 K14 l=3.3 W m1 K1 (1400 K)10 E=30 GPa (293 K)15 =5.3106 K1 (2931273 K)16 =0.2510 Tm=2323 K9 Dth=0.47106 m2 s1 (1273 K)8 l=5.8 W m1 K1 (1400 K)10 E=30 GPa (293 K)10 =9.6106 K1 (1273 K, this work) =0.2610 E=360 GPa (293 K)13 =8106 K1 (2931273 K)13 =0.2213 Dth=0.65106 m2 s1 (1273 K)8 =5.56106 K1 (1073 K)8 Tm=2873 K9 Dth=0.86106 m2 s1 (1273 K)5 Cp=0.47 J g1 K1 (1273 K)5 l=2.77 W m1 K1 (1273 K)5 E=172 GPa (293 K)10 =13106 K1 (2931500K)10 =0.270.3110

Materials La2Zr2O7

Properties Tm=2573 K12 Dth=0.54106 m2 s1 (1273 K)5 Cp=0.49 J g1 K1 (1273 K)5 l=1.56 W m1 K1 (1273 K)5 E=175 GPa (293 K)17 =9.1106 K1 (2931273 K)5 Tm=2963 K12 Dth=1.25106 m2 s1 (1273 K)5 Cp=0.45 J g1 K1 (1273 K)5 l=3.42 W m1 K1 (1273 K)5 E=181 GPa (293 K)17 =8.1106 K1 (2931273 K)5 Tm=2098 K18 Dth=0.52106 m2 s1 (1073 K)8 l=3.3 W m1 K1 (1400 K)10 E=283 GPa (293 K)10 =9.4106 K1 (2931500 K)10 =0.2810 Tm=2243 K19 =9.1106 K119 l=3.0 W m1 K1 (1273 K)19

3YSZ

BaZrO3

8YSZ (plasma-sprayed)

TiO2

18YSZ 5 wt.% CaO+ZrO2

Mullite

Garnet (Y3Al5O12)

Lanthanum aluminate (LaMgAl11O19)

Al2O3

l=1.7 W m1 K1 (1273 K)20 =10.1106 K1 (2981473 K)21 Cp=0.86 J g1 K1 (1273 K)20 Tm=2343 K22 l=1.8 W m1 K1 (973 K)22  =10.5106 K1 (1273 K)23 E=133 Gpa (293 K)23 =0.28 (293 K)23 E=86 GPa (293 K)13 =17.5106 K1 (2931273 K)13 =0.313

LaPO4

Al2O3 (TGO)

Al2O3+TiO2

NiCoCrAlY (bond coat of TBC)

CeO2

IN737 supperalloy (Substrate of TBC)

E=197 GPa (293 K)13 =16106 K1 (2931273 K)13 =0.313

Symbols in Table 1 have the following meanings: Dth, thermal diusivity; ESymbols , Youngs , thermal expansion coecient; thermaldiuconinmodulus; Table 1 have the following meanings: Dthl , ,thermal oxide on bond ductivity; Cp, heat capacity; , Poissons number; Tm, melting point; TGO, thermally sivity; E,grown Youngs modulus; ,coat. thermal expansion coecient; l, ther-

high-temperature applications such as diesel engines and gas turbines,27,29,33,3540 and reports about this material are numerous. YSZ coating has been proved to be more resistant against the corrosion of Na2SO4 and V2O5 than the ZrO2 coating stabilized by CaO or MgO.36 18-20YSZ coatings has also been studied.24,41 A

major disadvantage of YSZ is the limited operation temperature ( < 1473 K) for long-term application. At higher temperatures, phase transformations from the t0 tetragonal to tetragonal and cubic (t+c) and then to monoclinic (m) occur, giving rise to the formation of cracks in the coating.5,42 A practical upper-use tem-

X.Q. Cao et al. / Journal of the European Ceramic Society 24 (2004) 110 Table 2 TBC materials and their characteristics Materials 7-8 YSZ Advantages (1) high thermal expansion coecient (2) low thermal conductivity (3) high thermal shock resistance Disadvantages (1) sintering above 1473 K (2) phase transformation (1443 K) (3) corrosion (4) oxygen-transparent (1) crystallization (1023-1273 K) (2) very low thermal expansion coecient

Mullite

(1) high corrosion-resistance (2) low thermal conductivity (3) good thermal-shock resistance below 1273 K (4) not oxygen-transparent (1) high corrosion-resistance (2) high hardness (3) not oxygen-transparent (1) high thermal expansion coecient (2) low thermal conductivity (3) high corrosion-resistance (4) less phase transformation between m and t than YSZ (5) high thermal-shock resistance (1) very high thermal stability (2) low thermal conductivity (3) low sintering (4) not oxygen-transparent (1) Cheap, readily available (2) high corrosion-resistance

Alumina

(1) phase transformation (1273 K) (2) high thermal conductivity (3) very low thermal expansion coecient (1) increased sintering rate (2) CeO2 precipitation ( > 1373 K) (3) CeO2-loss during spraying

YSZ+CeO2

La2Zr2O7

(1) relatively low thermal expansion coecient

Silicates

(1) decomposition into ZrO2 and SiO2 during thermal spraying (2) very low thermal expansion coecient

Improvement of YSZ TBCs: (1) post-deposition of the coating with sealants24,25 or laser irradiation of the coating surface26 for better corrosion resistance; (2) gradient,6,27,28 or multilayered,6,2932 coatings with other materials; (3) thick TBC for better thermal insulation.33,34

perature of 1223 K in gas turbine for the ZrO2 coating stabilized by CaO and MgO was reported.4 On the other hand, these coatings, possess a high concentration of oxygen ion vacancies, which at high temperature assist oxygen transport and the oxidation of the bond coat at the ceramicbond coat interface, namely the formation of thermally grown oxide (TGO) on the bondcoat surface. This leads to spallation of the ceramic and such a mode of failure of the TBC is predominant when the coatings are thin as in gas turbines. This problem has been overcome to a large extent by providing oxidation resistant bond coats such as alumina and mullite.43 A model of life prediction of TBCs has been developed, in which the coating failure was attributed to stresses arising from the formation of TGO,13 and in Fig. 1 is shown the relationship between the thermal cycling life of TBCs and the substrate temperature.6 The silica impurity (even as low as 1 wt.%) in YSZ coating has a strong detrimental eect on the thermal cycling life.44,45 In bulk zirconia-based ceramics, silica segregates to grain boundaries with excessive amounts collecting at triple points. Silica at the grain boundaries leads to changes in the size and shape of grains and it may dissolve Y2O3 from the YSZ grain boundary regions leading to localized destabiliza-

tion.45 Silica can also cause ZrO2 polycrystal superplasticity, dramatic increases in sintering rates, and decreases in electrical conductivity. It may also lead to increased creep rates, as has been observed with siliconbase ceramics.45 However, silicates have much lower

Fig. 1. Thermal cycling lives of TBCs as a function of the substrate temperature. (After Ref. 6. Reprinted with permission of the American Ceramic Society, copyright 2002. All rights reserved.).

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oxygen conductivity than YSZ, and a thin layer of silicates on the top of the bond coat as oxygen barrier might improve the oxidation resistance of the bond coat.46 2.2. Mullite

TBC candidate, its addition to YSZ can increase the hardness of the coating and improve the oxidation resistance of the substrate. A gradient coating of 8YSZ Al2O3 has a much longer thermal cycling life than that of 8YSZ coating.28 2.4. CeO2+YSZ

Mullite is an important ceramic material because of its low density, high thermal stability, stability in severe chemical environments, low thermal conductivity and favorable strength and creep behavior.47 It is a compound of SiO2 and Al2O3 with composition 3Al2O3. 2SiO2. Compared with YSZ, mullite has a much lower thermal expansion coecient and higher thermal conductivity, and is much more oxygen-resistant than YSZ. For the applications such as diesel engines where the surface temperatures are lower than those encountered in gas turbines and where the temperature variations across the coating are large, mullite is an excellent alternative to zirconia as a TBC material. Engine tests performed with both materials show that the life of the mullite coating in the engine is signicantly longer than that of zirconia.15,48 Above 1273 K, the thermal cycling life of mullite coating is much shorter than that of YSZ.43 mullite coating crystallizes at 10231273 K, accompanied by a volume contraction, causing cracking and de-bonding.43 Mullite is the most promising coating material for the SiC substrate because their thermal expansion coecients are similar.16 2.3. Al2O3 a-Al2O3 is the only stable phase among all aluminum oxides. It has very high hardness and chemical inertness. The erosion behavior of vacuum plasma sprayed and air plasma sprayed alumina coatings has been studied and compared with that of bulk material.49 The addition of a certain amount of alumina into YSZ coatings can improve the hardness and bond strength without substantial modication of Youngs modulus and toughness.5052 The hardness of the coating can also be achieved by spraying an outer coat of alumina onto YSZ coatings.52 However, the plasma sprayed coating of alumina contains mainly unstable phases such as g and d-Al2O3. These unstable phases will transform into a-Al2O3 during thermal cycling, accompanied by a signicant volume change (g!a,  15%) which results in microcrack formation in the coating.53,54 The doping of transition metal oxides such as Cr2O3, Fe2O3 and TiO2 into alumina can only partially stabilize the a phase. On the other hand, alumina has relatively high thermal conductivity and low thermal expansion coecient compared with YSZ.5 The mechanical properties of alumina coating can be signicantly improved by the incorporation of silicon carbide bers.55 Even though alumina alone is not a good

CeO2 has higher thermal expansion coecient and lower thermal conductivity than YSZ, and the addition of CeO2 into YSZ coating is supposed to be eective for the improvement of thermal cycling life. Remarkable improvement of thermal shock tolerability was attained by the addition of CeO2 into YSZ.5658 The ceria-doped coating has a better thermal shock resistance because mainly:59 (1) there is little phase transformation between the monoclinic and tetragonal phase in the CeO2+YSZ coating; (2) stress generated by bond coat oxidation is smaller in the CeO2+YSZ coating due to better thermal insulation; (3) the thermal expansion coecient is larger in the CeO2+YSZ coating. However, the addition of CeO2 has some negative eects, such as the decrease of hardness and stoichiometry change of the coating due to the vaporization of CeO2,56 reduction of CeO2 into Ce2O3 and accelerated sintering rate of the coating.60,61 2.5. La2Zr2O7 La2Zr2O7 (LZ) was recently proposed as a promising TBC material.5,6,12,17,30,62,63 It has a cubic pyrochlore structure which has been discussed in detail by Subramanian et al.64 The crystal structure consists of the corner-shared ZrO6 octahedra forming the back bone of the network and La3+ ions ll the holes which are formed by 6 ZrO6 octahedra. It can largely tolerate vacancies at the La3+, Zr4+ and O2-sites without phase transformation. Both La3+ and Zr4+-sites can be substituted by a lot of other elements with similar ionic radii in case the electrical neutrality is satised, giving rise to the possibility of its thermal properties to be tailored. It is one of the few oxides with pyrochlore structure (such as La2Zr2O7, La2Hf2O7, Pr2Hf2O7, Ce2Zr2O7 and Sm2Ti2O7) that are phase-stable up to their melting points (Fig. 2) and this is a major reason that it is believed to have potential as TBC material. On the other hand, La2Zr2O7 has even lower thermal conductivity than YSZ. However, the coating of this material did not give a longer thermal cycling life than YSZ coating which might be explained by its relatively low thermal expansion coecient and poor toughness.63 By the substitution of CeO2 for ZrO2 (LC), the thermal expansion coecient of the coating can be increased and its thermal cycling life is largely improved (Fig. 3), comparable with or even better than the standard coating material 8YSZ.6

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spraying, zircon dissociates and consequently coatings are composed of a mixture of crystalline ZrO2 and amorphous SiO2. When using zircon as TBC for diesel engines, the decomposed SiO2 in the coating may cause problems due to the evaporation of SiO and Si(OH)2.69 The barrier eect is supposed to be due to the ZrO2 phase in the coating.67 Quite a few other silicates are relatively cheap and readily available and have potential as TBC materials, such as garnet almandine Fe3Al2(SiO4)3, garnet pyrope Mg3Al2(SiO4)3, garnet andradite-grossular Ca3Al2(SiO4)3, basalt (glass).66 The coating of composite oxides 2CaO.SiO2-10 to 30 wt.% CaO.ZrO2 shows excellent thermal shock resistance and hot corrosion.26 2.7. Rare earth oxides The mixture of rare earth oxides is readily available and very cheap. The coatings of rare earth oxides (La2O3, CeO2, Pr2O3 and Nb2O5 as main phases) have lower thermal diusivity and higher thermal expansion coecient than ZrO2, and they have the potential as thermal barrier coatings.70 No further reports about this material are available. Most of the rare earth oxides are polymorphic at elevated temperatures,71 and the phase instability will certainly to some extent aect the thermal shock resistance of their coatings. 2.8. Metalglass composite From the whole wide group of silicates, only the spraying of zircon (ZrSiO4)66 or natural zircon sand67 is occasionally reported. Zircon has a low thermal expansion coecient (4.99106 K1, 3001700 K) and high thermal conductivity (3.46 W m1 K1, 3651810 K).7 It is chemically very stable, particularly at lower temperatures. With the exception of concentrated hydrouoric acid, zircon is not generally attacked by acids but by basic materials at elevated temperatures. Zircon has no true melting point as it dissociates before melting. The thermal decomposition of zircon occurs at 1949 K or even as low as 1558 K depending on the purity.68 During plasma This is totally a new TBC system.72,73 The powder mixture of metal and normal glass can be plasmasprayed in vacuum. For a suitable composition this TBC material has similar thermal expansion coecient with metal substrate and its thermal conductivity is about a factor of 2 larger than that of YSZ. There are basically three reasons for the long thermal cycling life of metal-glass TBC, namely high thermal expansion coecient (12.3106 K1), good adherence to the bond-coat and the absence of open porosity. Such a coating does not have open pores, preventing the oxidation of bond-coat

Fig. 2. Phase diagram of La2O3ZrO2 system. (After Ref. 65. Reprinted with permission of the American Ceramic Society, copyright 2002. All rights reserved.)

2.6. Silicates

Fig. 3. Coatings after thermal cycling: (3a) LZ, Tsurf.1200  C/Tsub.960  C, 775 cycles; (3b) LC, Tsurf.1225  C/Tsub.965  C, 3238 cycles.

X.Q. Cao et al. / Journal of the European Ceramic Society 24 (2004) 110

from corrosive gases. Fig. 4 shows the microstructure of such a coating after thermal treatment. 2.9. Y3AlxFe5xO12 Garnet ceramics with compositions of Y3AlxFe5xO12 (x=0, 0.7, 1.4 and 5) have been proposed as TBC materials.19 YAG (Y3Al5O12), in particular, has superior high-temperature mechanical properties, excellent phase/thermal stability up to the melting point (2243 K) and low thermal conductivity. The oxygen diusivity in YAG is about 10 orders of magnitude lower than that in zirconia, implying that it is more oxygen-resistant than the latter and can give a better protection to the bond coat. However, the relatively low thermal expansion coecient (9.1106/K) and low melting point of this material seem to be the major problem. 2.10. SrZrO3 and BaZrO3 So far, only two materials with perovskite structure have been studied, i.e. SrZrO3 and BaZrO3.17 They have very high melting points (3073 and 2963 K, respectively), their thermal expansion coecients (10.9106 K1 and 7.9106 K1, respectively, 3031273 K) are comparatively lower than that of YSZ. A former work about the TBC of BaZrO3 proved that this coating did not show better thermal-shock resistance than YSZ. SrZrO3 shows a phase instability, which is expected to be detrimental to its thermal shock resistance. 2.11. Lanthanum aluminates A newly developed alumina-based ceramic coating consisting of La2O3, Al2O3 and MgO (MMeAl11O19,

M=La, Nd; Me=alkaline earth elements, magnetoplumbite structure) that possesses long term structural and thermochemical stability up to 1673 K is presented in Refs. 6,20,74. This coating has signicantly lower sintering rate than zirconia-based TBCs. The low thermal conductivity of LHA is caused by its microstructure, i.e. a random arrangement of LHA platelets that build up a microporous coating and the insulating properties of the material with its crystallographic feature itself. A study describing the development of an optimized procedure for the processing, manufacturing and application of LHA as TBCs is reported in Ref. 20. 2.12. (Ca1xMgx)Zr4(PO4)6 It is reported that this material has lower thermal conductivity than zirconia and the thermal expansion coecient is near zero.75 On the other hand, this material is less dense than ZrO2 with theoretical density 3.2 g/cm3 vs. 5.8 g/cm3. Furthermore, no strength-loss after air quenching from temperatures up to 1773 K was observed, showing a good thermal shock resistance. It is not clear if this material can really be used for thermal barrier coatings because of its low thermal expansion coecient. No further results about this coating are reported. 2.13. LaPO4 Lathanum phosphate is monoclinic with four formula units of LaPO4 in the P21/n unit cell.23 It is considered as a potential material for thermal insulation coating on Ni-based superalloys owing to its high-temperature stability (melting point 2345 20 K), its high thermal expansion and low thermal conductivity (comparable with properties of dense zirconia).22 In addition, lanthanum phosphate is expected to have good corrosion resistance in environments containing sulfur and vanadium salts. It does not react with alumina, which is a positive attribute, but bonds poorly to it, which is a limitation for the application. On the other hand, LaPO4 is a line compound that melts congruently but small deviations from stoichiometry change its solidus temperature from 2343 to 1853 K on the La-rich side or to 1323 K on the P-rich side. From this point of view, it is very hard to make coating of this material by plasma spraying, and it is expected that the coating made from this material can hardly be used for high temperature applications. No thermal cycling tests about this coating are reported.

Fig. 4. Plasma-sprayed metalglass thermal barrier coating after annealing at 1000  C for 300 h without cracks and spalling. White and gray strips are metal and glass, and the black spots are pores. (After Ref. 73. Reprinted with permission of Wiley-VCH, STM-Copyright & Licenses.)

3. Summary In the periodical table of elements, the elements whose oxides nd applications in TBCs are mainly dis-

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Fig. 5. Double-ceramic-coating system. [After Ref. 77 (6a) and Ref. 78 (6b). Reprinted with permission of Wiley-VCH, STM-Copyright & Licenses.].

tributed in IIIB (rare earth elements), IVB (Ti, Zr and Hf), IIIA (Al) and IVA (Si). The IIA elements (Mg and Ca) can only be used as stabilizers of zirconia. Rare earth oxides are promising materials for TBCs because of their low thermal conductivity, high thermal expansion coecients chemical inertness. By the doping of certain elements, the thermal expansion coecient of La2Zr2O7 can be increased. When its thermal expansion coecient is increased to a value similar to that of YSZ, the La2Zr2O7 coating can be hopefully used in high temperature applications. On the other hand, as the dual layer MCrAlY/YSZ system seems to reach their optimum performance, the development of TBCs must shift towards dierent materials combinations and deposition processes. It seems that the concept of multilayer is eective for the improvement of the thermal shock life of TBCs29,76 because no single material satises all requirements for TBCs. The multilayer includes an erosion resistant layer as the outer layer, a thermal barrier layer, a corrosion-oxidation resistant layer, a thermal stress control layer and a diusion resistant layer. Based on the multiplayer system, a double-ceramic-coating system is newly developed as shown in Fig. 5. On the top of 8YSZ coating, another coating whose thermal conductivity is lower than that of 8YSZ is formed. The top ceramic layer acts as thermal insulator to protect the 8YSZ layer. As reported by the authors, the thermal cycling performance of La2Zr2O7/ 8YSZ coating is excellent,77 and the CeO2/8YSZ coating showed a good thermal shock resistance.78 Taken in total, several decades of TBC development indicate that when all of the necessary properties for successful TBCs considered, YSZ remains dicult to be replaced.

about LZ and LC coatings were nished in and nancially supported by Forschungszentrum Juelich GmbH with the help of Dr. R. Vassen and Professor D. Stoever.

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