Evaluation of laser-glazed plasma-sprayed thermal barrier coatings under high temperature exposure to molten salts

Thermal Barrier Coating (TBC) systems are frequently used in gas turbine engines to provide thermal insulation to the hot-section metallic components and also to protect them from oxidation, hot corrosion and erosion. Surface sealing treatments, namely laser-glazing, have been showing a high potential for extending in-service lifetimes of these systems by improving chemical and thermo-mechanical resistance. In this investigation, both as-sprayed and laser-glazed TBCs were exposed to hot corrosion in molten salts. The glazed coatings were obtained by scanning the surface of the plasma-sprayed coatings with either a CO2 or a Nd:YAG laser. The hot corrosion investigation was accomplished by subjecting the specimens to an isothermal air furnace testing under V2O5 and/or Na2SO4 at a temperature of 1000 °C for 100 h. Spallation has been observed in coatings in the as-sprayed condition under V2O5 or V2O5 + Na2SO4. Na2SO4 itself had no or minimal effect on the degradation of the laser-glazed or as-sprayed condition coatings, respectively. The degradation in V2O5 was accomplished by destabilization of YSZ as a consequence of depletion of yttria from the solid solution to form YVO4 and therefore led to the disruptive transformation of the metastable tetragonal phase to the monoclinic phase. Moreover, the presence of both corrosive salts induced the formation of large high aspect ratio YVO4 crystals that introduced additional stresses and contributed to the degradation of the coatings. The laser-glazed specimens were not efficient in avoiding the molten salt penetration along the thickness direction due to the presence of cracks on the glazed layer. However due to a reduced specific surface area of the dense glazed layer, the corrosion reaction of the molten salts with the YSZ has been lower than in coatings in the as-sprayed condition.