Process-Property Relationship for Air Plasma-Sprayed Gadolinium Zirconate Coatings

The continuous need of elevating operating temperature of gas turbine engines has introduced several challenges with the current state-of-the-art yttria-stabilized zirconia (YSZ)-based thermal barrier coatings (TBCs), requiring examination of new TBC material with high temperature phase stability, lower thermal conductivity, and resistance to environmental ash particles. Gadolinium zirconate (Gd₂Zr₂O₇) (GDZ) has been shown to meet many of these requirements, and has, in fact, been successfully implemented in to engine components. However, several fundamental issues related to the process-ability, toughness, and microstructural differences for GDZ when compared to equivalent YSZ coating. This study seeks to critically address the process-structure-property correlations for plasma-sprayed GDZ coating subjected to controlled parametric exploration. Use of in-flight diagnostics coupled with in situ and ex situ coating property monitoring allows examination and comparison of the process-property interplay and the resultant differences between the two TBC compositions. The results indicate that it is feasible to retain material chemistry and fabricate relevant microstructures of interest with GDZ with concomitant performance advantages such as low conductivity, mechanical compliance, sintering resistance, and suppression of environmentally induced damage from ash particles. This study provides a framework for optimal design and manufacturing of emergent multi-layer and multi-material TBCs.