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Corrosion Science 163 (2020) 108224

Contents lists available at ScienceDirect

Corrosion Science
journal homepage: www.elsevier.com/locate/corsci

Effects of gradient transitional layer on thermal cycling life and failure of T


LaZrCeO/YSZ thermal barrier coatings

Zaoyu Shen , Limin He, Rende Mu, Zhenhua Xu, Guanghong Huang
Key Laboratory of Advanced Corrosion and Protection for Aviation Materials, Beijing Institute of Aeronautical Materials, Aero Engine Corporation of China, Beijing
100095, PR China

A R T I C LE I N FO A B S T R A C T

Keywords: The present work focuses on investigation of the effects of gradient transitional layer (GTL) on thermal cycling
A. Ceramic life and failure behavior of LaZrCeO/YSZ thermal barrier coatings. Characterization of microstructure evolution
B. Thermal cycling is implemented using correlative methods, which links together the observations and analysis from X-ray dif-
C. Interfaces fraction, scanning electron microscopy and transmission electron microscopy. The LaZrCeO/YSZ with GTL
C. Oxidation
showed relatively good thermal cycling life and thermal stability. After thermal cycles, Cr element diffuses out
and concentrates in LaZrCeO layer. The crack evolution, diffusion behavior and thermal stability are the key
factors for the good thermal cycling life and failure mechanism of LaZrCeO/YSZ.

1. Introduction the presence of YSZ bottom ceramic layer, the thermal cycling life of
LaZrCeO/YSZ coating is also improved compared with single layer
The thermal barrier coatings (TBCs) as complex systems have been LaZrCeO coating simultaneously [17]. However, the improvement of
widely applied to the hottest part of gas turbine engines in order to thermal cycling life is relativity limited and is similar to the YSZ coating
protect combustion chambers and turbine blades [1–5]. In general, [23,24]. Thus, although the underlying DCL structure TBCs was es-
TBCs material consists of an oxide ceramic coating (CC), a metallic tablished in advanced TBCs more than 10 years ago, it still a challenge
bond coating (BC), and a thin, thermally grown oxide (TGO) layer be- is to translate the concepts to further improve the thermal cycling life of
tween the CC and the BC. Nowadays, the most successful structure of LaZrCeO/YSZ DCL coatings.
TBCs system is composited of a MCrAlY overlay or NiPtAl diffusion BC To further enhance the thermal cycling life of DCL coatings, the
as the oxidation resistant layer and a yttria stabilized zirconia (YSZ) as design and deposition of the gradient transitional layer (GTL) on the
the heat resistant layer [6–9]. Despite YSZ with different advantages in interface of two ceramic coating have been proposed in our research. As
terms of properties and performance under 1100 °C, there is a world- we know, it is generally accepted that the thermal cycling behavior of
wide research under way for ceramic oxides with high-temperature the TGO layer on the interface between CC and BC have a significant
properties and performance that could replace YSZ TBCs [10–15]. influence on the failure mechanism of TBCs [3,4]. Few studies have
Much of this work is presently directed to identify ceramic oxides with been conducted on the DCL structure stability, phase stability and
low thermal conductivity [16–22]. Among them, LaZrCeO with pyro- elements diffusion of new ceramics coatings, especially when little or
chlore structure and/or fluorite structure has been extensively studied nothing is known about the effects of GTL on thermal cycling life and
attributing to its low thermal conductivity and high melting point failure behavior. Thus, a good understanding of the GTL in DCL coating
[5,12]. However, the LaZrCeO TBCs exhibits low thermal cycling life is crucial for potentially the practical application of LaZrCeO/YSZ DCL
than conventional YSZ attributing to its low chemical stability and coating in future.
thermal stability [15–17]. In present study, we report a LaZrCeO/YSZ DCL TBCs with GTL by
Recently, it was reported that double ceramic layers (DCL) coatings electron beam-physical vapor deposition (EB-PVD) method. The ob-
with YSZ bottom ceramic layer can improve the thermal stability and tained LaZrCeO/YSZ DCL TBCs with GTL showed relatively good
chemical stability of LaZrCeO [17], and thus various DCL structures thermal cycling life. The effects of GTL between LaZrCeO and YSZ on
have been designed and investigated in LaZrCeO TBCs [5,22]. Although thermal performances and failure behavior of DCL TBCs have been
the thermal conductivity of LaZrCeO/YSZ coating can be increased in investigated in detail. The evolution of cracks, the phase changes and Cr


Corresponding author.
E-mail address: shenzaoyu@163.com (Z. Shen).

https://doi.org/10.1016/j.corsci.2019.108224
Received 17 July 2019; Received in revised form 11 September 2019; Accepted 12 September 2019
Available online 14 September 2019
0010-938X/ © 2019 Elsevier Ltd. All rights reserved.
Z. Shen, et al. Corrosion Science 163 (2020) 108224

Table 1 (pyrochlore, P) and La2Ce2O7 (fluorite, F). The XRD patterns of the
Preparation parameters of LaZrCeO/YSZ with GTL and without GTL. LaZrCeO ingot shows that the main diffraction peak positions at 28.74°,
Layer Current of Electron Voltage (KV) Rotation Speed Deposition rate 33.28°and 56.60° can be well indexed to La2Zr2O7 with pyrochlore
Beam (A) (rpm) (μm/min) structure. Only one peak of La2Ce2O7 at 77.08° can be detected in the
XRD patterns. For the XRD patterns of the LaZrCeO coating, the peaks
LaZrCeO Gun1# 1.05-1.15 20.0 20 2.0–2.5
of TBCs with GTL are similar to the TBCs without GTL. The peaks at
YSZ Gun3# 1.55-1.65 20.0 20 3.0–3.5
GTL Gun1# 1.05-1.15 20 20 4.0–5.0
56.64°, 33.38° and 28.96° can be indexed as (622), (400) and (222) of
+ Gun3# 1.55- La2Zr2O7 phases, respectively. In contrast, the peaks at 55.84°, 32.92°
1.65 and 28.38° can be indexed as (311), (200) and (111) of La2Ce2O7
phases, respectively. Only one peak of the La2Zr2O7 at 76.42°in TBCs
with GTL is different as compared with TBCs without GTL. It also in-
outward diffusion have a significant effect on thermal cycling life and dicates that the complex structure of pyrochlore and fluorite is pre-
failure mechanism of LaZrCeO/YSZ TBCs. ferred formation in EB-PVD process. Similar crystal structure of
La2Zr2O7 and La2Ce2O7 was also observed in previous literature
2. Experimental section [23,24]. Meanwhile, the preferred growth orientation of pyrochlore
and fluorite structure occurs in the (222) and (111) crystal direction,
The substrate material was the Ni-based superalloy (12.5 Co wt.%, respectively.
6.3 W wt.%, 5.7 Ta wt.%, 6.3 Al wt.%, 2.2 Re wt.%, 5.8 Cr wt.%, 1.3 Mo The LaZrCeO/YSZ DCL TBCs are characterized by XPS in order to
wt.% and Ni as balance). The NiCoCrAlYHf bond coat was prepared by analyze the surface chemical states (Fig. 2). The spectrum of the survey
arc ion-plating physical vapor deposition (AIP-PVD). The composition scan indicates the existence of La, Zr, Ce, and O in the specimens. The
of NiCoCrAlYHf is 10–15 wt.% Co, 18–23 wt.% Cr, 8–12 wt.% Al, XPS data of the TBCs with GTL is similar to the DCL coating without
0.1–0.5 wt.% Y, 0.2–0.6 wt.% Hf, and Ni as balance with the thickness GTL. As shown in Fig. 2b, the core level spectrum of Ce 3d5/2 and Ce
about 50 ± 10 μm. Before the deposition of CC by EB-PVD, the heat 3d3/2 is used to distinguish the chemical valence of Ce element. The
treatment process of specimens was done under 870 ± 10 °C for 3 h. peaks of Ce 3d5/2 at 822.05 eV, 888.85 eV and 897.90 eV can un-
During the deposition of CC by EB-PVD, the specimens’ temperature ambiguously be assigned to Ce4+, confirming the main valence state of
was adjusted to 850 °C. The preparation processes and conditions of the Ce element in surface as Ce4+ [25–27]. Furthermore, the peaks at
LaZrCeO/YSZ with GTL and without GTL are shown in Table 1. 900.70 eV, 907.60 eV and 916.65 eV contributed by Ce 3d3/2 can be
X-ray diffraction (XRD) patterns were acquired on a Rigaku D/max- assigned to the chemical state of Ce4+ [25–27]. According to our pre-
2000 diffractometer equipped with Cu Kα radiation. The X-ray photo- vious work, the chemical valence of Ce4+ plays an important part in the
electron spectroscopy (XPS) was collected on a PHI 5700 ESCA System lifetime and thermal stability [15–17]. From the high-resolution XPS
with an Al Kα chromatic X-ray source (1486.60 eV). The morphology spectra of the Zr 3d, La 3d and O 1s (Fig. 2c–e), we also can conclude
and composition were examined using a scanning electron microscope that the binding energies of La, Zr and O element are close to the re-
(SEM, FEI-Quanta 600) and transmission electron microscopy (TEM, ported value of Zr4+, La3+and O2− [28–30].
JEM-2100 F).
During thermal cycling, the specimens were performed in a furnace 3.2. Morphology and composition
at 1100 °C for 55 min with rapid heating, and fan-assisted laboratory
cooling (5 min). The thermal cycling ended until the broken area excess Fig. 3a–b shows the top surface of LaZrCeO coatings. The gaps on
10% of surface area. column tips can be observed in Fig. 3a. As shown in Fig. 3b, the coating
surface has a pyramidal morphology corresponding to the crystal
structure of pyrochlore phase and fluorite phase [17]. The cross-section
3. Results and discussions morphology of DCL coating with GTL is shown in Fig. 3c–d. The mi-
crostructure of TBCs consists of three layers coatings (top ceramic
3.1. Phase and structure coating, gradient transitional layer and bottom ceramic coating). After
thickness measurement by SEM, the thickness of LaZrCeO is about
The crystal structures of the as-deposited TBCs with GTL, the as- 55–65 μm. The thickness of YSZ is about 50–60 μm. The thickness of
deposited TBCs without GTL and the LaZrCeO ingot are investigated by gradient transitional layer (GTL) is about 5 μm. The thickness ratio of
XRD. As shown in Fig. 1, XRD patterns are compared to La2Zr2O7 LaZrCeO: GTL: YSZ is about 1.0:0.1:1.0. The morphology of three layers
is the typical columnar structure due to the EB-PVD process. The
column gaps and columnar structure would lead to high thermal cycling
life [31,32]. As shown in Fig. 3d, the diameter of columnar is measured
to be about 2.0–2.5 μm. Furthermore, the energy dispersive spectro-
meter (EDS) line scanning reveals the coexistence of La, Zr, Ce and O
four elements and confirms the amounts and different position of La, Zr,
Ce and O (Fig. 3e). The EDS scanning profile of Zr and Ce atom at
different layers confirms the successful formation of three layer struc-
ture. The top ceramic coating is LaZrCeO layer. The bottom ceramic
coating is YSZ layer. The gradient transitional layer is LaZrCeO + YSZ
composite ceramic layer. The gradient reduction of Zr atom is observed
in gradient transitional layer between YSZ layer and LaZrCeO layer. In
addition, the cross-section of TBCs without GTL. The morphology of
TBCs is only composed of top and bottom layer. EDS line scanning
profile of Zr and Ce atom at different layers confirms only two layer
according to the LaZrCeO top layer and YSZ bottom layer.
In the EB-PVD process, due to the vapor phase and combined actions
of surface diffusion, shadowing, and crystallographic growth selection,
Fig. 1. XRD patterns of the as-deposited TBCs and the ingot. inter-columnar structure of the TBCs can be obtained [1–5]. The high

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Z. Shen, et al. Corrosion Science 163 (2020) 108224

Fig. 2. XPS data of (a) whole-range spectrum, (b) Ce 3d, (c) La 3d, (d) Zr 3d and (e) O 1s.

angle annular dark fields (HAADF) detector forms a Z-contrast image 3.3. Thermal cycling life
and TEM image operated in the mode. As shown in Fig. 4a, the intra-
columnar structure consisting of gaps and pores can be clearly seen on To evaluate the thermal cycling life of TBCs, the LaZrCeO/YSZ with
the LaZrCeO layer. The obvious columnar microstructure can provide a GTL, without GTL, LaZrCeO and YSZ were tested under the same
high level of strain tolerance and pseudo-plasticity. In addition, the measurement conditions (55 min heating and 5 min cooling). As shown
disordered structures with intra-columnar pores and gaps play an im- in Fig. 5, the thermal cycling lives of TBCs are the averaged value of five
portant part in thermal performance [1,4,7]. The HAADF is carried out specimens. Interestingly, the LaZrCeO/YSZ with GTL has an average life
on column tips which also reveals that La, Zr, Ce and O four elements of 1535 cycles, which exhibits a significant improvement in thermal
are distributed relatively homogeneously in columnar structure. The cycling life. The thermal cycling life of LaZrCeO/YSZ with GTL is not
high resolution transmission electron microscopy (HRTEM) image is only much higher than LaZrCeO/YSZ without GTL (1132 cycles), but
measured on the LaZrCeO top layer (Fig. 4b). The lattice spacing of also about 50% higher than that of YSZ TBCs. Furthermore, its thermal
LaZrCeO layer is about 0.281 nm and 0.270 nm, corresponding to the cycling life is 15 times higher than that of LaZrCeO single layer (101
(200) plane of pyrochlore La2Zr2O7 and (400) plane of fluorite structure cycles). It has exceeded the most criterion value of thermal cycling life
La2Ce2O7. Furthermore, the corresponding fast fourier transform (FFT) in advanced ceramic material.
pattern detected from the LaZrCeO layer indicates that the LaZrCeO is a Based on the SEM and TEM analysis, the gradient transitional layer,
polycrystalline structure (Fig. 4c). intra-columnar pores and columns gaps are closely related to the im-
provement of thermal cycling life. The columnar structure of LaZrCeO
layer and YSZ layer benefited from the EB-PVD process can provide not

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Z. Shen, et al. Corrosion Science 163 (2020) 108224

Fig. 3. Surface morphology at (a) lower magnification, (b) higher magnification, cross-section morphology at (c) lower magnification, (d) higher magnification, and
(e) EDS line scanning of LaZrCeO/YSZ TBCs with GTL.

Fig. 4. (a) HADDF image, (b) HRTEM and (c) SAED pattern of the LaZrCeO/YSZ TBCs with GTL.

only high strain tolerance but also pseudo-plasticity, which lead to the LaZrCeO/YSZ with GTL, only the vertical cracks occur and extend in the
improvement of thermal cycling life in long-term operation [8]. Fur- LaZrCeO layer and YSZ layer. The GTL layer between LaZrCeO and YSZ
thermore, the introduction of the gradient transitional layer in the remains stable after thermal cycling test. The formation of horizontal
double ceramic layers structure of top coating can avoid the drawbacks cracks between LaZrCeO and YSZ is almost not detected in LaZrCeO/
associated with the instability of the interface between LaZrCeO layer YSZ with GTL by SEM. In contrast, for LaZrCeO/YSZ without GTL, the
and YSZ layer [5]. In a word, the unique gradient transitional layer, the horizontal and vertical cracks occur and extend in the LaZrCeO and YSZ
introduction of intra-columnar pores and columns gaps in ceramic layer layer (Fig. 6b). The horizontal cracks mainly occur in the interface
appear to be relevant with the high thermal cycling life of LaZrCeO/YSZ between LaZrCeO and YSZ layer. The vertical cracks have extended in
TBCs. the interface, LaZrCeO layer and YSZ layer. The massive vertical cracks
and horizontal cracks appear to be relevant with the reduction of the
3.4. Failure mechanism strain tolerance, thus, decreasing the thermal cycling life.
As shown in Fig. 7a and c, EDX line scanning profile of the cross-
To further study the failure mechanism of LaZrCeO/YSZ, the cross- section confirms La, Zr, Ce and O at different position as well as the
section morphology of DCL TBCs with GTL and without GTL after composition of the as LaZrCeO/YSZ with GTL and without GTL. As
thermal cycling test are detected and compared. As shown in Fig. 6a, for shown in Fig. 7b and d, it can be clearly seen that the Cr element in BC

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progress.
According to the above results and discussions, the good thermal
cycling life of LaZrCeO/YSZ can be explained as the following three
reasons. Firstly, the preparation and optimization of DCL coating con-
sisting of feathery microstructure and gradient transitional layer can
provide a high level of strain tolerance, resulting in the high thermal
cycling life. Secondly, the high thermal cycling life of the LaZrCeO/YSZ
with GTL can be attributed to the effective reduction of the thermal
expansion mismatch between LaZrCeO and YSZ coating (YSZ: ca.
11 × 10−6/K, LaZrCeO: ca. 10 × 10−6/K). Thirdly, the formation of
LaZrCeO/YSZ with GTL can bring the thermal gradient condition in
LaZrCeO layer and YSZ layer which also can effectively protect the YSZ
layer. In brief, the gradient transitional layer between ceramic layer
interfaces, the thermal expansion match and thermal gradient condition
Fig. 5. The thermal cycling life of LaZrCeO/YSZ with GTL, without GTL, are believed to be relevant with the good thermal performances of the
LaZrCeO and YSZ. LaZrCeO/YSZ TBCs.

layer diffuses out and extends to the LaZrCeO layer after thermal cycles.
The Cr element diffusion from BC to LaZrCeO layer appear to be re- 4. Conclusions
levant with the presence of LaZrCeO layer. In the case of LaZrCeO/YSZ
DCL coating, LaZrCeO can react with Cr and O2 on the LaZrCeO layer The LaZrCeO/YSZ double ceramic layers thermal barrier coatings
and break the local element balance [23,24]. As a result, Cr would have been deposited and investigated by EB-PVD. The following con-
continuously diffuse from BC into LaZrCeO layer though the grain clusions can be drawn from this work.
boundaries and cracks. Furthermore, it should be noted that the highest
content of Cr element occurs in horizontal cracks and concentrates on (a) The morphology and microstructure of LaZrCeO/YSZ consists of
the interface of two ceramics layer (Fig. 7d). This might be the key LaZrCeO layer, gradient transitional layer and YSZ layer. The
reason for the formation of horizontal cracks on the interface of two LaZrCeO/YSZ TBCs shows obvious feathery microstructure in-
ceramics layer. In addition, when the content of Cr element is reduced cluding intra-columnar pores and gaps.
beneath a certain level, the Cr diffusion might be unbeneficial to the (b) The preparation of the gradient transitional layer on the interface of
selective oxidation of BC, leading to a less stable TGO layer. The ob- LaZrCeO and YSZ coating can improve the thermal cycling life of
vious outward diffusion of Cr element would also be the main reason for TBCs. The thermal cycling life of LaZrCeO/YSZ DCL coating with
the emergence and enlargement of the cracks and micropores in the GTL (1535 cycles) is the highest than that of LaZrCeO single layer,
TBCs as shown in Fig. 6b. As shown in Fig. 8, the migrated Cr element is YSZ and LaZrCeO/YSZ without GTL.
eventually absorbed for the formation of LaCrO3, as substantiated by (c) After thermal cycles, an obvious outward diffusion of Cr from BC
XRD. Evidently these reactions remove Cr from YSZ columnar grain into LaZrCeO layer takes place attributing to the chemical reaction
boundaries, leading to the migration rate of Cr much fast than that of Cr of LaZrCeO and Cr. The initiation of horizontal cracks within the
diffusion in the YSZ layer. In the thermal cycling test, it exists a interface is detected in LaZrCeO/YSZ without GTL leading to the
structure transformation from orthorhombic to rhombohedral, which inferior thermal cycling life.
might introduce a discrete volume change. This might be another
reason for the formation and evolution of vertical cracks in the LaZrCeO
layer. Along with the thermal cycling test, vertical cracks in the Declaration of Competing Interest
LaZrCeO layer grow larger and longer leading to the high residual stress
in YSZ layer. However, an excess increasing of the length and width of The authors declare that they have no known competing financial
vertical cracks in the LaZrCeO layer is increased excess a certain level, interests or personal relationships that could have appeared to influ-
the vertical cracks might occur and extend to the YSZ layer (Fig. 6a and ence the work reported in this paper.
b). This might be the reason for the formation of vertical cracks in the
YSZ layer. To clearly understand the influence of Cr diffusion on the
failure behavior of the LaZrCeO/YSZ TBCs and reduce its detrimental Acknowledgements
effect, the relativity investigations need to be carried out in the future.
Further work of the effects of GTL on thermo-chemical and thermo- The authors are very grateful for my wife Mrs. Z. Liu and my son Mr.
mechanical effects on the interface between LaZrCeO and YSZ are in C. Y. Shen for help and support.

Fig. 6. Cross-section morphology of (a) LaZrCeO/YSZ with GTL and (b) LaZrCeO/YSZ without GTL.

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Fig. 7. (a) EDX line scanning of LaZrCeO/YSZ with GTL, (b) EDX line scanning of Cr element with GTL after thermal cycles after thermal cycles, (c) EDX line scanning
of LaZrCeO/YSZ without GTL, (d) EDX line scanning of Cr element without GTL.

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