Oxidation resistance of YSZ-alumina composites compared to normal YSZ TBC coatings at 1100 °C

In the present work oxidation behavior of plasma sprayed YSZ-alumina composite TBC coatings on Ni-base (IN-738LC) super alloy substrate was studied and compared to normal YSZ. Cyclic oxidation process in 4 h intervals was performed in an air electrical furnace at 1100 °C and the specimens were cooled in the furnace during each cycle. Preliminary checking was done with naked eye and further investigation was achieved using scanning electron microscopy. If there were any cracks or spallation in the coating's edge, the tests were stopped, the time was recorded and coating microstructure was studied. YSZ-alumina composites were made by applying alumina layer at the top of YSZ or mixed with YSZ as a TBC layer on the bond coat. Composite coatings of YSZ-alumina having alumina as a top coat and the mixed YSZ-alumina layer, showed better resistance than normal YSZ in oxidation test. It was observed that alumina overlay on YSZ has promoted the oxidation resistance of the coatings for longer times by preventing infiltration of oxygen through YSZ layer.

► This work aims to study the oxidation behavior of plasma sprayed YSZ-alumina composites coatings.
► The composites TBC coatings of YSZ-alumina showed better oxidation resistance than normal YSZ.
► The durability of composite coating with alumina is a novel method and has not been reported before.