Impermeable thin AI2O3 overlay for TBC protection from sulfate and vanadate attack in gas turbines

In order to improve the hot corrosion resistance of conventional YSZ TBC system, a dense and continues overlay of Al{sub 2}O{sub 3} coating of about 0.1-25 {micro}m thick was deposited on the surface of TBC by EB-PVD, high velocity oxy-fuel (HVOF) spray and composite-sol-gel (CSG) techniques. Hot corrosion tests were carried out on the TBC with and without Al{sub 2}O{sub 3} coating in molten salts mixtures (Na{sub 2}SO{sub 4} + 5%V{sub 2}O{sub 5}) at 950 C for 10h. The microstructures of TBC and overlay before and after exposure were examined by means of scanning electron microscopy (SEM), energy-dispersive X-ray spectrometer (EDX), X-ray diffraction (XRD) and secondary ion mass spectrometry (SIMS). In order to investigate the effect of Al{sub 2}O{sub 3} overlay on degradation and spalling of the TBC, indentation test has been employed to study spallation behaviors of YSZ coating with and without Al{sub 2}O{sub 3} overlay. It has been found that TBC will react with V{sub 2}O5 to form YVO{sub 4} in hot corrosion tests. A substantial amount of M-phase of ZrO{sub 2} was formed due to the leaching of Y{sub 2}O{sub 3} from YSZ. During hot corrosion test, there were no significant interactions between overlay Al{sub 2}O{sub 3} coating and molten salts. After exposure, the alumina coating, especially produced by HVOF, was still very dense and cover the surface of YSZ, although they had been translated to {alpha} - Al{sub 2}O{sub 3} from original {gamma} - Al{sub 2}O{sub 3}. As a result, Al{sub 2}O{sub 3} overlay coating decreased the penetration of salts into the YSZ and prevented the YSZ from the attack by molten salts containing vanadium. Accordingly, only a few M-phase was formed in YSZ TBC, compared with TBC without overlay coating. The penetration of salts into alumina coating was thought to be through microcracks formed in overlay Al{sub 2}O{sub 3} coating and at the interface between alumina and zirconia due to the presence of tensile stress in the alumina coating. Al{sub 2}O{sub 3} overlay acted as a barrier against the infiltration of the molten salt into the YSZ coating during exposure, thus significantly reduced the amount of M-phase of ZrO{sub 2} in YSZ coating. However, a thick Al{sub 2}O{sub 3} overlay was harmful for TBC by increasing compressive stress which causes crack and spalling of YSZ coating. As a result, a dense and thin Al{sub 2}O{sub 3} overlay is critical for simultaneously preventing YSZ from hot corrosion and spalling