Abstract
Gd2Zr2O7 ceramic is considered as a potential candidate for thermal barrier coatings. Here we present hot corrosion behavior of single layer Gd2Zr2O7 (GZO), Gd2Zr2O7 + 50 wt% YbSZ (GZO/YbSZ), YSZ and double-layer YSZ/Gd2Zr2O7 + 50 wt% YbSZ (YSZ + GZO/YbSZ) coatings prepared by air plasma spraying on Inconel 625 substrates. Prior to hot corrosion the fracture toughness of the coatings was assessed by Vickers indentation showing a variation between 0.6 and 2.3 MPa.m1/2 where the GZO/YbSZ coating exhibited the highest fracture toughness. The hot corrosion test was conducted by exposing the coatings to an equimolar mixture of Na2SO4 and V2O5 at 750 °C. After the hot corrosion test, the type of phases, chemical composition, microstructure and crack formation were investigated. Formation of GdVO4 and YVO4 was observed as the corrosion products in the GZO containing coatings and the YSZ coating, respectively. All coatings showed the formation of monoclinic zirconia after the corrosion test. The Gd2Zr2O7 + 50 wt% YbSZ (GZO/YbSZ) coating showed the best hot corrosion resistance due to reduced reactivity and enhanced fracture toughness and represents a new composition with properties promising for TBC applications.