In-situ laser synthesis of rare earth aluminate coatings in the system Ln-Al-O (Ln = Y, Gd)

Laser zone melting (LZM) was employed in this work to prepare Ln-Al-O coatings on polycrystalline Al2O3 substrates, using the corresponding mixtures of powdered rare-earth oxides and Al2O3 as starting materials. In-situ synthesis of the compounds Ln = Y, Gd was performed using a CO2 laser, emitting at 10.6 μm. Microstructure (SEM) and phase nature (XRD) demonstrated in-situ formation of Al2O3/Y3Al5O12(YAG) and Al2O3/GdAlO3(GAP) eutectic systems. The interaction with the substrate resulted in mechanically stable, well integrated 200–500 μm thick composite coatings, as observed in nanoindentation tests. The phase relations found in these materials are consistent with the crystallographic concepts advanced by Vegas (Ramos-Gallardo & Vegas, J. Solid State Chem. 128 (1997) 69), where cation sub-arrays are proposed to play an important role in governing metal oxide structures. These sub-arrays are suggested as the structural drive behind eutectic oxide formation. LZM proves to be a convenient method to investigate the behaviour of complex oxide systems at high temperature, to apply a rational concept towards the understanding of phase relations and to develop design criteria for oxide coatings.

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► Laser zone melting of Lanthanide aluminates is described.
► Eutectic perovskite and garnet Ln-Al-O coatings have been obtained in-situ.
► Structurally driven eutectic formation is proposed and described.